Fiber-Reinforced Plastic Substrate Production via Dual Resin Impregnation
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Solution Overview
Problem
Existing methods for producing fiber-reinforced plastic substrates face challenges in achieving simultaneous handleability, productivity, joinability, and mechanical characteristics, particularly due to issues with fiber fluff generation, thermosetting resin stickiness, and the inability to produce complex shapes in a single molding step.
Innovation Solution
A method involving continuous and sequential drawing, first and second impregnating steps, and a take-up step to produce a fiber-reinforced plastic substrate with thermoplastic and thermosetting resins impregnated into reinforcing fibers, ensuring effective distribution and curing of the resins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a thermosetting resin is used as matrix resin to achieve excellent mechanical characteristics and heat resistance, then strength and rigidity are improved, but fiber fluff is generated and process stability deteriorates due to stickiness
Solution Approach 1:
The patent divides the matrix resin into two distinct components: a thermosetting resin (epoxy resin) providing mechanical strength and heat resistance, and a thermoplastic resin (polyester resin) providing processability and reducing fiber fluff. This segmentation allows each resin type to perform its specialized function without the harmful effects of using either alone.
Solution Approach 2:
The patent creates a composite matrix resin system combining thermosetting and thermoplastic resins. The epoxy polyester composite resin leverages the advantages of both resin types: the thermosetting component provides structural integrity while the thermoplastic component improves handling characteristics and reduces fiber fluff generation during processing.
2Reliability
If a thermosetting resin is used to achieve excellent heat resistance and chemical resistance, then resistance to high temperature and chemicals is improved, but the resin cannot be integrated with other thermoplastic resin members
Solution Approach 1:
The patent segments the resin system into thermosetting and thermoplastic components, where the thermoplastic polyester resin layer on the fiber surface enables welding integration with other thermoplastic members, while the bulk epoxy resin maintains heat and chemical resistance. This segmentation allows simultaneous achievement of both integrability and resistance properties.
Solution Approach 2:
The patent applies different resin types to different regions of the composite structure: thermoplastic resin is concentrated at the fiber surface and in the resin rich layer to provide weldability and integrability, while thermosetting resin forms the bulk matrix to provide heat and chemical resistance. This local differentiation resolves the contradiction between integrability and resistance.
3Adaptability or versatility
If all matrix resins are thermoplastic resins to enable weld joining, then joinability with other thermoplastic members is improved, but physical properties deteriorate due to fiber disturbance during melting
Solution Approach 1:
The patent segments the resin system so that only the thermoplastic component is present at the fiber surface and in thin layers where welding occurs, while the bulk thermosetting resin maintains structural integrity. This limited presence of thermoplastic resin enables weld joining without causing extensive fiber disturbance throughout the entire structure.
Solution Approach 2:
Instead of using thermoplastic resin throughout the entire structure (excessive action), the patent applies thermoplastic resin partially only where needed for welding and integration (fiber surface and resin rich layers). This partial application provides sufficient joinability while minimizing fiber disturbance and maintaining physical properties.
4Productivity
If continuous production is implemented to improve productivity, then production efficiency is improved, but process stability becomes more difficult to maintain
Solution Approach 1:
The patent enables continuous production through the continuous impregnation process where the fiber-reinforced plastic substrate is continuously fed through the resin application system. The thermoplastic resin's lower viscosity allows for continuous coating without interruption, maintaining both productivity and process stability simultaneously.
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 method enables the production of fiber-reinforced plastic substrates that excel in handleability, productivity, joinability, and mechanical characteristics, overcoming previous limitations and improving economic efficiency.
Implementation Method 1
a method involving continuous and sequential drawing, first and second impregnating steps, and a take-up step to produce a fiber-reinforced plastic substrate with thermoplastic and thermosetting resins impregnated into reinforcing fibers
Data Source
AI summary
A method is described for producing a fiber-reinforced plastic substrate that simultaneously satisfies three points of joinability, mechanical characteristics, and productivity, the method including the following components [A], [B], and [C], wherein at least the following drawing step, first impregnating step, second impregnating step, and take-up step are continuously and sequentially performed while the component [A] is caused to run:[A] a reinforcing fiber[B] a thermoplastic resin[C] a thermosetting resin 2<drawing step> step of drawing a continuous reinforcing fiber sheet containing the component [A];<first impregnating step> step of impregnating either the component [B] or the component [C] from one surface of the continuous reinforcing fiber sheet to obtain a fiber-reinforced plastic intermediate in which either the component [B] or the component [C] is disposed on a first surface;<second impregnating step> step of impregnating the other of the component [B] or the component [C] from a second surface opposite to the first surface to obtain a fiber-reinforced plastic substrate; and<take-up step> step of taking up the fiber-reinforced plastic substrate.