Surface-Treated Glass Wool Composite Molding Material
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Solution Overview
Problem
Existing composite molding materials face challenges in uniformly dispersing glass fibers into thermoplastic resins, leading to issues like warpage, surface roughness, and increased manufacturing costs, particularly when attempting to achieve high glass fiber content, which affects the reinforcing effect and mechanical properties.
Innovation Solution
Heating glass wool to a temperature within a specific range relative to the thermoplastic resin and surface-treating it with calixarene and optionally a silane coupling agent to improve dispersion and prevent cutting during kneading, allowing for a higher glass wool content with maintained fiber length and improved reinforcing effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If glass fibers with diameter of 10 to 18 μm are kneaded into thermoplastic resin, then the manufacturing process is simplified, but the uniform dispersibility deteriorates and surface smoothness becomes poor when fiber content is 20 to 50%
Solution Approach 1:
The patent changes the fiber diameter parameter from conventional 10-18 μm to 3-6 μm, and applies surface treatment with silane coupling agent and film-forming agent. These parameter changes enable high fiber content (50% or higher) while maintaining uniform dispersibility and surface smoothness in thin-walled injection-molded parts.
Solution Approach 2:
The patent uses glass wool as a composite reinforcing material with specific properties (fiber diameter 3-6 μm, length 300-1000 μm) combined with thermoplastic resin. This composite material system achieves both ease of manufacture and high manufacturing precision through the specific combination and properties of the components.
2Strength
If the proportion of chopped strands in composite molding material is increased to enhance reinforcing effect, then the viscosity during kneading increases and load on roller or injection nozzle increases
Solution Approach 1:
The patent changes the fiber diameter parameter to 3-6 μm (smaller than conventional fibers), which reduces the viscosity increase during kneading even at high fiber content. This allows achieving high reinforcing effect without excessive load on processing equipment.
Solution Approach 2:
The patent introduces silane coupling agent and film-forming agent as intermediary substances that improve the interface between glass wool and resin, reducing friction and viscosity during kneading while maintaining high fiber content for reinforcing effect.
3Ease of manufacture
If conventional glass wool is kneaded into thermoplastic resin without heating, then the process is simple, but the glass wool is cut during kneading and fiber length is reduced
Solution Approach 1:
The patent applies surface treatment to the glass wool before kneading, and heats the glass wool to a specific temperature range. These preliminary actions prevent fiber cutting during kneading, maintaining fiber length while still keeping the process relatively simple.
Solution Approach 2:
The patent changes the temperature parameter by heating glass wool to a specific temperature range before kneading. This parameter change prevents fiber cutting during the kneading process, preserving the fiber length necessary for reinforcing effect.
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 composite molding materials with enhanced reinforcing effects, flexibility, fire-retardant properties, and thermal stability, allowing for higher glass wool content without fiber cutting, thus improving mechanical properties and dimensional stability.
Implementation Method 1
Heating glass wool to a temperature within a specific range relative to the thermoplastic resin
Implementation Method 2
surface-treating it with calixarene and optionally a silane coupling agent
Data Source
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AI summary
A composite molding material formed by kneading at least glass wool into a thermoplastic resin has such a feature that the glass wool in the composite molding material has a fiber diameter of 1 to 7 mum, an average fiber length of 30 to 300 mum, and an aspect ratio of not less than 10.