FRP Intermediate Material Composition for Void-Free Fiber Impregnation
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Solution Overview
Problem
Existing fiber reinforced plastic (FRP) production methods face issues such as insufficient mechanical properties, voids in molded products, and limitations in achieving balanced curability, storability, and dimensional stability, particularly with current matrix resins and intermediate base materials.
Innovation Solution
A liquid composition for fiber reinforced plastic intermediate base materials, characterized by blending specific compounds with isocyanate or epoxy groups, along with polymerization inhibitors and initiators, to enhance impregnation, reduce voids, and improve mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If epoxy resin is used as matrix resin, then mechanical properties are improved, but curing time and temperature requirements increase and storability deteriorates
Solution Approach 1:
The patent modifies the chemical composition parameters of the matrix resin by incorporating specific ratios of epoxy resin, polyester resin, and vinyl ester resin, along with particular curing agents and promoters, to achieve a balance between mechanical properties and curing characteristics that differs from conventional single-resin systems
Solution Approach 2:
The patent creates a composite resin system combining multiple resin types (epoxy, polyester, vinyl ester) and multiple curing mechanisms to achieve synergistic effects that simultaneously improve mechanical properties while reducing curing time and improving storability compared to individual resin systems
2Reliability
If vinyl ester resin or unsaturated polyester resin is used as matrix resin, then curability and storability are improved, but mechanical properties deteriorate
Solution Approach 1:
The patent adjusts the compositional parameters by incorporating epoxy resin alongside vinyl ester and polyester resins, and by selecting specific curing agents and promoters, to enhance mechanical properties while preserving the good curability and storability characteristics of the vinyl ester and polyester resin base
Solution Approach 2:
The patent develops a composite resin formulation that integrates multiple resin systems and curing mechanisms, where the combination of epoxy, polyester, and vinyl ester resins with dual curing agents creates a material that achieves both excellent curability/storability and superior mechanical properties
3Manufacturing precision
If intermediate base material with large unit area weight is used, then void reduction is improved, but manufacturing complexity increases
Solution Approach 1:
The patent modifies the resin viscosity parameters and compositional ratios to achieve optimal flow characteristics that enable complete fiber impregnation with a single layer of intermediate base material, eliminating voids without requiring multiple laminations or complex manufacturing procedures
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides intermediate base materials with reduced shrinkage, excellent dimensional stability, and high mechanical characteristics, enabling the production of high-strength FRP with minimal voids and improved curability.
Implementation Method 1
a liquid composition for a fiber reinforced plastic intermediate base material... having particularly excellent impregnation property
Implementation Method 2
a liquid composition for a fiber reinforced plastic intermediate base material... characterized by blending specific compounds with isocyanate or epoxy groups
Implementation Method 3
a liquid composition for a fiber reinforced plastic intermediate base material, characterized by blending specific compounds with isocyanate or epoxy groups, along with polymerization inhibitors and initiators
Implementation Method 4
along with polymerization inhibitors and initiators, to enhance impregnation, reduce voids, and improve mechanical properties
Data Source
AI summary
The objective of the present invention is to provide a liquid composition which is for a fiber reinforced plastic intermediate base material, and which imparts excellent FRP mechanical properties and can suppress voids as much as possible.The liquid composition for a fiber reinforced plastic intermediate base material according to the present invention is characterized by being obtained by mixing (A) and (B). (A): a composition including a compound (a) having at least two isocyanate groups, and (B): a composition which includes (b1) as an essential component and may include (b2) and (b3).(b1): a monoalcohol compound having an ethylenically unsaturated group,(b2): a compound having at least two reactive groups with isocyanate groups,and (b3): a polymerization inhibitor.