FRP Precursor Tension Control for Low Etch-Dry Size Change
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Solution Overview
Problem
Existing methods for producing FRP precursors result in significant size-change rates after copper foil etching and drying, particularly for FRP with copper foil, which affects the consistency and quality of the final product.
Innovation Solution
A method involving adhering a thermosetting resin film to a sheet-like aggregate under atmospheric pressure and applying a tension of 1.5 to 5.5 N/25mm during transportation, followed by curing, to produce an FRP precursor with reduced size-change rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a polyolefin resin composition containing a specific diene compound is used to improve adhesion to fiber bundles, then adhesion is enhanced, but the resin composition becomes more complex and difficult to control
Solution Approach 1:
The patent applies parameter changes by precisely controlling the diene compound content within 0.1-10 parts by weight per 100 parts of polyolefin resin, and controlling the melt flow rate within 1-100 g/10min. These specific parameter ranges optimize the balance between adhesion to fiber bundles and processability, resolving the contradiction between improved adhesion and composition complexity.
2Ease of manufacture
If conventional polyolefin resin is used to maintain simplicity of composition, then ease of manufacture is preserved, but adhesion to fiber bundles is insufficient
Solution Approach 1:
The patent applies local quality by introducing a specific diene compound (5-10% vinyl content) at controlled amounts (0.1-10 parts per 100 parts resin) into the polyolefin matrix. This localized modification of the resin composition provides enhanced adhesion to fiber bundles while maintaining the overall simplicity of the polyolefin base material.
3Productivity
If fiber bundles are tightly bound to achieve high packing density, then productivity is improved, but voids form between bundles causing defects
Solution Approach 1:
The patent applies the intermediary principle by using a specifically formulated polyolefin resin composition containing diene compound as a binding agent between fiber bundles. This intermediary resin fills the voids between tightly packed bundles while maintaining strong adhesion, enabling high packing density without defect formation.
4Strength
If resin composition is optimized for adhesion, then bonding strength improves, but processing difficulty increases
Solution Approach 1:
The patent resolves the contradiction between bonding strength and processing difficulty by controlling two key parameters: (1) diene compound content at 0.1-10 parts per 100 parts resin to ensure adequate adhesion, and (2) melt flow rate at 1-100 g/10min to ensure processability. This parameter optimization allows the resin to provide strong bonding while remaining easy to process.
Data Source
Figure 1
AI summary
Provided is a method for producing an FRP precursor causing a small size-change rate after copper foil etching and drying by heating of an FRP as well as a method for producing an FRP. Specifically, the present invention provides a method for producing an FRP precursor by adhering a thermosetting resin film to at least one surface of an aggregate that is in a form of a sheet, the method comprising: after the adhesion, transporting the FRP precursor with imparting a tension of 1.5 to 5.5 N/25mm to the FRP precursor.