Laminated Sheets Resolving Fiber Surface Harshness
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Solution Overview
Problem
Fiber mats impregnated with thermoplastic resins for increased flexure strength have glass fibers exposed on the outer surfaces, making them harsh to the touch and prone to peeling issues, which also affects molded parts.
Innovation Solution
A method involving a needled nonwoven fiber mat with a thermoplastic resin sheet and a surface sheet of non-woven cloth, where the thermoplastic resin has a lower softening temperature than the fibers, allowing for a heating and pressure treatment to form a fully impregnated laminated sheet with improved adhesive strength and porosity control, enabling the production of flexurally rigid molded parts with enhanced surface attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glass fiber mats are impregnated with thermoplastic resins to increase flexure strength, then the flexure strength is improved, but the outer surfaces become harsh to the touch and the surface sheets become easy to peel off
Solution Approach 1:
A nonwoven cloth surface sheet is introduced as an intermediary layer between the glass fiber mat and the external environment. This surface sheet is bonded to the glass fiber mat through a thermoplastic resin layer, mediating the interaction between the harsh glass fibers and the user's touch while preventing direct contact and peeling issues
Solution Approach 2:
The invention creates a composite structure consisting of multiple layers: glass fiber mat, thermoplastic resin, and nonwoven cloth surface sheet. This composite material combines the high strength of glass fibers with the smooth touch and durability of nonwoven cloth, resolving the contradiction between strength and surface quality
2Object-affected harmful factors
If a nonwoven cloth is applied on the outer side of fiber mats to achieve smooth feel and nice appearance, then the surface quality is improved, but the applied nonwoven cloth becomes easy to peel off
Solution Approach 1:
The nonwoven cloth surface sheet is merged with the glass fiber mat through a thermoplastic resin layer, creating a unified composite structure. The resin acts as a bonding agent that merges the two layers into a single reliable unit, preventing peeling while maintaining surface quality
Solution Approach 2:
The invention controls the adhesive strength parameter by selecting appropriate thermoplastic resin and processing conditions. The resin's bonding properties are optimized to ensure the surface sheet remains firmly attached to the glass fiber mat, transforming the peeling issue into a reliable bond
3Ease of manufacture
If the thermoplastic resin softening temperature is kept lower than fiber softening temperatures for proper impregnation, then the impregnation process is simplified, but the processing temperature range becomes constrained
Solution Approach 1:
The invention carefully selects and controls the thermoplastic resin's softening temperature parameter, setting it lower than the fiber softening temperatures. This parameter optimization enables easy impregnation while maintaining structural integrity, resolving the contradiction between processability and temperature flexibility
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 results in laminated sheets and molded parts with improved adhesive strength, a smooth surface feel, and increased sound absorbency, while maintaining mechanical stability and structural integrity.
Implementation Method 1
subjecting said multilayered sheet to a heating and pressure treatment, thereby melting said thermoplastic resin sheet so as to form a fully impregnated laminated sheet
Implementation Method 2
subjecting said fully impregnated laminated sheet to a cooling and pressure treatment, thereby solidifying said melted thermoplastic resin, so as to form a consolidated laminated sheet with a porosity not exceeding 5% by volume
Implementation Method 3
subjecting said nonwoven fiber mat to a needling process, thereby obtaining a needled nonwoven fiber mat
Data Source
Figure 1a~1b
Figure 2a~3b
Figure 4a~5f
AI summary
A method for producing a flexurally rigid molded part, comprises stacking a needled nonwoven mat (7) of reinforcing fibers, at least one thermoplastic resin sheet and at least one surface sheet ( 9 ) formed of a non-woven cloth comprising cloth fibers. The multilayered sheet obtained in this manner is subjected to a heating and pressure treatment followed by a cooling and pressure treatment, thereby forming a semi - finished product consisting of a consolidated laminated sheet with a porosity not exceeding 5% by volume. Upon reheating, the main body increases in thickness, thereby forming a porous laminated sheet that is formed to a compact in a hot molding process.