Incised Unidirectional Prepreg for 3D Fiber-Reinforced Plastic Molding
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Solution Overview
Problem
Fiber reinforced plastic materials face challenges in shaping complex forms due to difficulties in flowability and uniformity, particularly when molding into three-dimensional shapes with convex/concave portions, leading to defective moldings and compromised mechanical properties.
Innovation Solution
A laminated base material comprising layers of incised prepreg with unidirectionally oriented reinforcement fibers and additional base plies with varying fiber lengths and orientations, optimized for fiber volume fraction and incision patterns to enhance flowability and shape conformity in both in-plane and out-of-plane directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If continuous fiber prepregs are used to maintain high mechanical properties, then strength is improved, but difficulty in shaping into three-dimensional or complicated shapes increases
Solution Approach 1:
The continuous reinforcement fibers are divided into discontinuous segments through incisions made at specific angles (1° to 45°) relative to the fiber direction. This segmentation allows the fiber bundles to flow and conform to three-dimensional shapes while maintaining sufficient length (10mm to 300mm) to preserve mechanical reinforcement. The incised prepreg structure enables both complex shaping and adequate mechanical properties by creating controlled fiber discontinuity.
2Shape
If incisions are made in prepregs to enable three-dimensional shaping, then shape conformity is improved, but incision enlargement during extension occurs leading to deteriorated mechanical properties and surface quality
Solution Approach 1:
The incision angle parameter is precisely controlled within 1° to 45° relative to the fiber direction to prevent excessive incision enlargement during extension. The fiber length after incision is optimized to 10mm to 300mm to balance flowability and mechanical reinforcement. These parameter optimizations ensure that incisions do not enlarge excessively during molding, preventing resin pooling and maintaining surface quality while enabling three-dimensional shaping.
3Adaptability or versatility
If lamination base materials are used for complex shapes with convex/concave portions, then shape diversity is improved, but flowability is hindered near rising faces leading to defective moldings
Solution Approach 1:
The lamination base material is segmented into multiple layers with different fiber orientations and properties. The first lamination base material contains incised prepregs optimized for flowability, while the second contains materials optimized for mechanical properties. This layered segmentation allows different regions of the complex mold to be filled appropriately, with flowable materials reaching convex/concave portions and rising faces.
Solution Approach 2:
Different regions of the lamination base material are assigned different properties: the first lamination base material (with incised prepregs) provides enhanced flowability for difficult-to-reach areas, while the second lamination base material provides structural reinforcement. This local quality differentiation ensures optimal performance in both flowable and structurally critical regions.
4Manufacturing precision
If multiple lamination base materials are stacked to achieve good moldings in complex shapes, then molding quality is improved, but production complexity increases
Solution Approach 1:
The production process is segmented into distinct steps: preparing incised prepregs with specific fiber orientations, stacking them in predetermined sequences with other lamination base materials, and molding the composite stack. This segmentation of the production process into standardized, repeatable steps manages complexity while achieving high molding quality through controlled material architecture.
Data Source
AI summary
A substantially flat-plate-shaped laminated base material has at least a layer-shaped body α and a layer-shaped body β are layered or disposed side by side, the layer-shaped body α having one or more cut prepregs A in which reinforcing fibers oriented in one direction are impregnated with a resin composition, the volume fraction of fiber is 45-65%, and at least a portion of the reinforcing fibers are segmented into a fiber length of 10-300 mm by a plurality of cuts, and the layer-shaped body β having one or more base materials B in which reinforcing fibers having a fiber length in the range of 10-300 mm are impregnated with a resin composition.