High Melt Flow Index Resin Composite Automotive Parts
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Solution Overview
Problem
Existing composite articles for automotive and construction materials face challenges in meeting stringent performance specifications due to limitations in the properties of traditional high melt flow index resins, particularly in terms of density, porosity, and mechanical properties.
Innovation Solution
The development of thermoplastic composite articles featuring a fiber-reinforced thermoplastic polymer core layer with high melt flow index resins, such as polypropylene, and surface layers, which provide enhanced mechanical properties and reduced basis weight while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional high melt flow index resins are used in composite articles, then processing ease is improved, but mechanical properties and structural integrity deteriorate
Solution Approach 1:
The patent applies composite materials by combining high melt flow index resin with reinforcing fibers (glass, carbon, or other strengthening materials) to create a fiber-reinforced thermoplastic composite. This composite structure allows the material to achieve both easy processing (from the high MFI resin) and improved mechanical properties (from the reinforcing fibers), resolving the contradiction between processing ease and strength.
2Weight of moving object
If higher melt flow index resins are used to reduce basis weight, then weight reduction is achieved, but structural integrity may be compromised
Solution Approach 1:
The patent utilizes parameter changes by selecting resins with specific melt flow index ranges (greater than 325 g/10 min) and adjusting processing parameters (temperature, pressure, time) to optimize both weight reduction and structural integrity. The high MFI resin enables lower basis weight while controlled processing conditions maintain structural integrity through proper fiber-matrix bonding.
Solution Approach 2:
By creating fiber-reinforced composites, the patent achieves weight reduction through the use of high MFI resins while maintaining structural integrity through the reinforcing fiber network. The composite structure distributes loads effectively, compensating for the lighter weight material properties.
3Strength
If fiber reinforcement is added to improve mechanical properties, then strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies local quality by incorporating reinforcing fibers at specific locations and orientations within the composite structure based on stress analysis. Fibers are strategically placed to reinforce areas subject to highest stresses, improving mechanical properties while minimizing the amount of reinforcement material and manufacturing complexity required.
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 solution enables the creation of lightweight composite articles with improved flexural modulus, peak load, and slope, allowing for reduced material usage while maintaining or exceeding the physical properties of heavier articles, thus enhancing efficiency and performance in automotive and construction applications.
Implementation Method 1
a melt flow resin having a melt flow index of greater than 325 g/10 minutes
Data Source
AI summary
Certain embodiments described herein are directed to composite materials comprising one or more high melt flow index resins. In some examples, the composites can be used to provide automotive parts such as, for example, vehicle interior parts and vehicle exterior parts. In some configurations, the composite comprises a fiber reinforced polymer core comprising reinforcing fibers and a resin comprising a high melt flow index of greater than 325 g/10 min. as measured by ASTM D1238, condition L.