Glass Wool Thermoplastic Composite for Uniform Thin-Wall Dispersion
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Solution Overview
Problem
Existing fiber-reinforced thermoplastic resin composites face challenges in achieving even fiber dispersion and sufficient reinforcing effect due to limitations in fiber diameter and length, leading to issues like warping and increased production costs, especially when producing thin-walled molded products.
Innovation Solution
The use of high-strength glass wool produced by a centrifugal process with controlled fiber cooling using compressed air, combined with a silane coupling agent, to create a thermoplastic resin composite with glass fibers having a specific diameter and length range, enhancing the aspect ratio and adhesion with the resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the fiber diameter of glass fiber is reduced to a few μm to improve fiber dispersion in thin-walled molded products, then fiber dispersion and appearance smoothness are improved, but production cost increases significantly due to reduced productivity
Solution Approach 1:
The invention changes the physical parameters of glass fiber by producing glass wool with controlled fiber diameter (3-6 μm) and length (300-1000 μm) through centrifugal process, achieving optimal dispersion in thin-walled products while maintaining production efficiency. This parameter optimization resolves the contradiction between fine fiber requirements and manufacturing productivity.
2Strength
If the fiber length of glass fiber is increased to improve reinforcing effect, then tensile strength and rigidity are improved, but fiber dispersion becomes difficult and warping increases
Solution Approach 1:
The invention optimizes fiber dimensions by controlling glass wool to have length of 300-1000 μm and diameter of 3-6 μm, achieving aspect ratio of 50-300. This specific parameter range balances reinforcing effect with dispersion capability, preventing warping while maintaining strength.
Solution Approach 2:
The invention performs preliminary cutting of glass wool to controlled lengths before injection molding. This pre-processing ensures uniform fiber length distribution, improving dispersion in thin-walled products while maintaining adequate length for reinforcement.
3Strength
If conventional glass fiber is used for structural materials to achieve high strength, then tensile strength is improved, but weight reduction is limited compared to plastic-only materials
Solution Approach 1:
The invention creates fiber-reinforced plastic composite materials by combining thermoplastic resin with glass wool fibers. This composite structure provides high tensile strength through fiber reinforcement while maintaining the light weight advantage of plastics, achieving optimal strength-to-weight ratio for structural applications.
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 resulting composite exhibits improved tensile, flexural, and impact strengths, allowing it to be used as a structural material while maintaining smoothness and stability, suitable for thin-walled electrical and electronic parts.
Implementation Method 1
by effectively using compressed air during glass wool production by centrifugal process to rapidly cool the glass fibers
Implementation Method 2
glass wool production by centrifugal process
Data Source
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AI summary
The purpose of the present invention is to provide a glass wool sheet using high-strength glass wool, a thermoplastic resin composite material containing glass fiber and having higher rigidity than that of the conventional glass fiber, and a method for manufacturing the thermoplastic resin composite material. The thermoplastic resin composite material contains a thermoplastic resin and glass fibers. The glass fibers have an average fiber diameter of 1µm to 8µm inclusive,have an average fiber length of 300µm to 600µm inclusive in the thermoplastic resin composite material, and have an aspect ratiso of 50 or more.