Heat-Resistant Resin Composite with High Tg Fibers
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Solution Overview
Problem
Existing heat-resistant resin composites, such as those using polyphenylene sulfide, nylon 6, and polypropylene fibers, are limited by their glass transition temperatures below 100°C, restricting their use in high-temperature applications due to significant changes in physical properties and thermal degradation of binders at elevated temperatures.
Innovation Solution
A heat-resistant resin composite is developed using a non-woven fabric comprising heat-resistant thermoplastic fibers with a glass transition temperature of 100°C or higher, combined with reinforcing fibers and a polyester-based binder fiber, which are thermo-formed at temperatures above the flow starting temperature of the thermoplastic fibers to maintain mechanical properties and enhance heat resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermoplastic fibers with glass transition temperature below 100°C (such as polyphenylene sulfide, nylon 6, and polypropylene fibers) are used to produce heat-resistant resin composites, then the composites can be manufactured with good processability and mechanical properties at room temperature, but the composites exhibit significant changes in physical properties and thermal degradation when exposed to temperatures of 100°C or higher
Solution Approach 1:
The invention changes the key parameter of glass transition temperature from below 100°C to 100°C or higher by selecting specific heat-resistant thermoplastic polymers (polyetherimide, semi-aromatic polyamide, polyether ether ketone, or polycarbonate). This parameter change enables the composite to maintain mechanical properties at high temperatures while still allowing processable manufacturing through thermo-forming at elevated temperatures.
Solution Approach 2:
The invention creates a composite material system consisting of heat-resistant thermoplastic fibers (with Tg ≥ 100°C) combined with reinforcing fibers (carbon or glass fibers) in a weight ratio of 20:80 to 80:20. This composite structure combines the heat resistance of the thermoplastic matrix with the mechanical strength of the reinforcing fibers, achieving both processability and high-temperature performance.
2Strength
If continuous reinforcing fibers are incorporated to enhance mechanical properties, then the composite achieves high specific strength and stiffness, but the shaping capability deteriorates and manufacturing of complicated shapes becomes difficult
Solution Approach 1:
The invention segments the fiber reinforcement into discontinuous fibers (1-50 mm in length) rather than using continuous fibers. This segmentation allows the fibers to be randomly distributed and embedded in the thermoplastic matrix, enabling excellent shaping capability and easy manufacturing of complicated shapes while still providing sufficient mechanical reinforcement through the high strength of individual fiber segments.
3Temperature
If thermoplastic fibers with glass transition temperature of 100°C or higher are used to maintain heat resistance, then the composite exhibits excellent heat resistance and mechanical properties at elevated temperatures, but the manufacturing process requires higher temperatures that may cause thermal degradation of binder fibers
Solution Approach 1:
The invention changes the binder fiber material from conventional low-temperature binders to heat-resistant polyester-based binder fibers that can withstand the higher thermo-forming temperatures (above the flow starting temperature of the thermoplastic fibers) without degrading. This parameter change in binder material enables the manufacturing process to proceed at the required high temperatures while maintaining the integrity of the binder and preventing thermal degradation.
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 excellent mechanical properties and heat resistance, allowing for use in high-temperature environments without requiring specialized molding processes, and can be produced at reduced costs, making it suitable for various industrial and electronic applications.
Implementation Method 1
heat-resistant thermoplastic fibers having a glass transition temperature of 100°C or higher
Implementation Method 2
thermo-formed at temperatures above the flow starting temperature of the thermoplastic fibers
Implementation Method 3
a polyester-based binder fiber to bind other fibers
Implementation Method 4
thermo-compressing the one or more non-woven fabrics
Data Source
AI summary
Provided is a heat-resistant resin composite excellent in heat resistance and bending properties. This heat-resistant resin composite is constituted of a matrix resin and reinforcing fibers dispersed in the matrix resin. The matrix resin is constituted of a heat-resistant thermoplastic polymer having a glass transition temperature of 100°C or higher, and a polyester-based polymer comprising a terephthalic acid unit (A) and an isophthalic acid unit (B) at a copolymerization proportion (molar ratio) of (A)/(B) = 100/0 to 40/60. The proportion of the heat-resistant thermoplastic polymer in the composite is 30 to 80 wt%.