Liquid Crystal Polyester Composition with Sized Carbon Fibers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing liquid crystal polyester resin compositions fail to provide sufficient mechanical strength for molded bodies, particularly in applications like automobile frames and suspensions, despite their potential for reducing weight and improving fuel efficiency.
Innovation Solution
A liquid crystal polyester resin composition incorporating sizing-agent-coated carbon fibers, with specific ratios and adhesion amounts, is formulated to enhance strength, where the carbon fibers are arranged parallel to the resin's longitudinal direction and hardened within a defined temperature range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If liquid crystal polyester resin is used alone or with conventional fillers, then weight reduction is achieved, but mechanical strength becomes insufficient
Solution Approach 1:
The patent applies composite materials by combining liquid crystal polyester resin with specifically treated carbon fibers. The carbon fibers are coated with a sizing agent that has controlled adhesion characteristics, creating a composite material that achieves both weight reduction and enhanced mechanical strength. The composite structure allows the resin matrix to bind the reinforcement fibers effectively, solving the strength deficiency of using resin alone while maintaining the lightweight advantage.
Solution Approach 2:
The patent applies local quality by treating only the surface of the carbon fibers with a sizing agent rather than modifying the entire fiber structure or resin composition uniformly. The sizing agent coating creates a localized interface modification on the fiber surface that enhances adhesion to the resin, while the bulk properties of both fiber and resin remain unchanged. This localized treatment optimizes the fiber-matrix interface for strength without compromising the lightweight characteristics.
2Strength
If fiber fillers are simply mixed with liquid crystal polyester, then some strength improvement is achieved, but required strength levels are not met
Solution Approach 1:
The patent applies the intermediary principle by introducing a sizing agent as a mediating substance between the carbon fibers and the liquid crystal polyester resin. This sizing agent acts as an adhesive intermediary that chemically or physically bonds to both the fiber surface and the resin matrix, creating a strong interface. The sizing agent resolves the adhesion problem by providing a compatible bonding layer that ensures reliable stress transfer from the resin to the reinforcement fibers.
Solution Approach 2:
The patent applies parameter changes by precisely controlling the adhesion amount of the sizing agent within a specific range (0.1-1.2 parts by mass per 100 parts of carbon fibers) and the fiber content (5-120 parts per 100 parts of resin). These parameter optimizations ensure that the interface adhesion is sufficient for strength while preventing excessive adhesion that could cause brittleness or processing difficulties. The controlled parameters achieve the required reliability without compromising other properties.
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 composition significantly enhances the strength of molded bodies, addressing the mechanical weakness of conventional resin compositions while maintaining lightweight properties.
Implementation Method 1
when the sizing-agent-coated carbon fibers are heated in air from 25° C. to 400° C. at a temperature-increase rate of 50° C./min, the mass loss rate thereof within the range of 300° C. to 400° C. is less than 0.8% by mass
Implementation Method 2
A liquid crystal polyester resin composition incorporating sizing-agent-coated carbon fibers, with specific ratios and adhesion amounts, is formulated to enhance strength
Data Source
AI summary
The present invention relates to: a liquid crystal polyester resin composition which contains a liquid crystal polyester resin and carbon fibers with a sizing agent; and a method for producing this liquid crystal polyester resin composition. The content of the carbon fibers with a sizing-agent is from 5 parts by mass to 120 parts by mass relative to 100 parts by mass of the liquid crystal polyester resin. With respect to the carbon fibers with a sizing-agent, the adhesion amount of the sizing agent with respect to the carbon fibers is from 0.1 parts by mass to 1.2 parts by mass relative to 100 parts by mass of the carbon fibers. If the carbon fibers with a sizing agent are heated from 25° C. to 400° C. in the air at a heating rate of 50° C./min, the mass loss rate within the range from 300° C. to 400° C. is less than 0.8% by mass.