Layered Thermoplastic Composite for Fiber Melt Fluidity
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Solution Overview
Problem
Existing long fiber reinforced thermoplastic composite materials fail to meet the demands of high mechanical performance, functionalization, and processing requirements for large-size complicated parts and high-precision electronic components, particularly in terms of fluidity, ease of molding, dimensional stability, and surface quality.
Innovation Solution
A thermoplastic composite material is designed with a core layer of continuous fiber bundles impregnated with a first thermoplastic resin and a first auxiliary agent, wrapped by an outer layer of a second thermoplastic resin and optional auxiliary agent, allowing for performance synergism and improved fiber melt fluidity, enhancing surface quality and application range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-layer thermoplastic composite material is used, then the manufacturing process is simple, but the surface quality and mechanical performance are insufficient for high-precision applications
Solution Approach 1:
The composite material is divided into multiple functional layers: a core layer containing fiber bundles for mechanical strength, and outer resin layers for surface quality. This segmentation allows each layer to be optimized independently for its specific function while maintaining overall manufacturing feasibility.
Solution Approach 2:
The invention uses a composite structure combining different materials in specific layers: fiber bundles (glass fiber, carbon fiber, or basalt fiber) in the core layer for mechanical properties, and thermoplastic resins (polypropylene, polyamide, or polyethylene terephthalate) in outer layers for surface quality and functional performance.
2Strength
If fiber bundles are tightly bound to maintain structural integrity, then mechanical strength is improved, but fluidity of fibers in resin melt deteriorates
Solution Approach 1:
The fiber bundles are arranged with controlled spacing and orientation in the core layer, creating local variations in density and arrangement. This allows sufficient tight binding for mechanical strength while maintaining adequate fluidity for molding operations, as the resin can flow through the spaced fiber structure.
3Strength
If the composite material is designed for high mechanical performance, then strength and modulus are improved, but adaptability to different application requirements deteriorates
Solution Approach 1:
The invention allows adjustment of multiple parameters including fiber type (glass, carbon, basalt), fiber orientation, resin composition (polypropylene, polyamide, polyethylene terephthalate), and layer thickness ratios. These parameter changes enable the same basic multi-layer structure to be adapted for different mechanical performance requirements and application scenarios.
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 composite material achieves improved mechanical properties, surface quality, and expanded application range by optimizing the resin layers and fiber orientation, addressing the limitations of existing materials.
Implementation Method 1
a first component comprising a first thermoplastic resin and a first auxiliary agent is used to impregnate continuous fiber bundles so as to form a core layer
Data Source
AI summary
A thermoplastic composite material has an inner layer material and at least one layer of outer layer material. The inner layer material is a core layer that contains fiber bundles, a first thermoplastic resin and a first auxiliary agent; and the at least one layer of outer layer material wraps the core layer and is a resin layer comprising a second thermoplastic resin and an optional second auxiliary agent. The fiber bundles extend continuously from one end of the core layer to the opposite end thereof. The inner layer-outer layer composite structure improves the processing performance of the thermoplastic composite material and the lubricity between fibers and resin matrixes during injection molding, and improves the fluidity of the fibers in a resin matrix melt.