FRP Precursor Lamination With Pre-Coating for Filler Dispersion

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Solution Overview

Problem

Existing methods using resin films to impregnate glass cloths result in localized filler agglomeration, leading to high viscosity and poor moldability due to insufficient impregnation of resin into voids, affecting thermal conductivity and insulation properties of FRP precursors.

Innovation Solution

A method involving pre-coating a resin varnish with low filler content on a sheet-shaped aggregate, followed by melt-pasting thermosetting resin films with high filler content on both surfaces, under controlled pressure and heating conditions, to ensure uniform impregnation and prevent filler agglomeration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If resin films with high filler content are directly laminated on aggregate, then thermal conductivity is improved, but filler agglomeration occurs on yarn surfaces leading to high viscosity and poor moldability

Engineering Contradiction:

Improvethermal conductivityVSAvoidmoldability

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The patent applies a low filler-content resin varnish to the aggregate surface before laminating the high filler-content resin film. This preliminary coating creates a resin-rich layer that prevents filler particles from agglomerating on the yarn surfaces during subsequent lamination, thereby maintaining moldability while achieving high thermal conductivity in the final composite.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent creates different resin compositions at different locations: a low filler-content resin varnish layer at the aggregate interface and a high filler-content resin film in the bulk. This local differentiation allows the interface region to maintain good wetting and moldability while the bulk region achieves high thermal conductivity.

Inventive Principle:

Principle #3Local quality

2Temperature

If filler content in resin is increased to improve thermal conductivity, then heat dissipation performance is enhanced, but resin impregnability into aggregate deteriorates

Engineering Contradiction:

Improvethermal conductivityVSAvoidresin impregnability

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The low filler-content resin varnish is applied to the aggregate surface beforehand to ensure complete impregnation of the aggregate structure. This preliminary resin layer fills all voids and spaces in the aggregate, ensuring reliable resin impregnability before the high filler-content film is laminated.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The low filler-content resin varnish acts as an intermediary layer between the aggregate and the high filler-content resin film. It facilitates complete resin impregnation into the aggregate structure while preventing filler agglomeration, thereby enabling both high thermal conductivity and reliable impregnability.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of operation

If resin varnish with low filler content is used, then liquidity and impregnability are maintained, but thermal conductivity enhancement is insufficient

Engineering Contradiction:

ImproveliquidityVSAvoidthermal conductivity

Core Design Contradiction:

Ease of operationVSTemperature

Solution Approach 1:

The patent divides the resin system into two segments: a low filler-content resin varnish for initial impregnation and a high filler-content resin film for thermal conductivity enhancement. This segmentation allows each component to perform its specialized function optimally without compromise.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent creates a composite resin system combining two resin compositions with different filler contents. The low filler-content varnish provides liquidity and impregnability, while the high filler-content film provides thermal conductivity, achieving a synergistic effect greater than either component alone.

Inventive Principle:

Principle #40Composite materials

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

This approach enhances thermal conductivity while maintaining moldability by ensuring even resin distribution, preventing filler agglomeration, and preserving insulation properties in the FRP precursor.

Implementation Method 1

an undercoat in which a resin varnish having a filler content of 5 vol % or less in a solid content thereof is pre-coated

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 2

a resin film having a filler content of 30 vol % or more is melt-pasted to both surfaces

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS12466946B2Method for producing FRP precursor

Publication Date: 2025.11.11 RESONAC CORP

AI summary

Provided is a production method of an FRP precursor. The method includes: a pre-coating step of applying a resin varnish having a filler content of 5 vol % or less in a solid content thereof, to a sheet-shaped aggregate, and a melt-pasting step of melt-pasting a pair of resin films, each having a filler content of 30 vol % or more, to both surfaces of the aggregate, after the pre-coating step.