Composite sheet

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Solution Overview

Problem

Existing composite sheets face challenges in achieving a balance of high strength, flexibility, and light weight due to limitations in fiber selection, specific gravity, and flexibility, as well as difficulties in thinning and durability.

Innovation Solution

A composite sheet comprising a woven fabric of liquid crystal polyester fibers coated with a thermoplastic resin on one or both sides, with a tensile strength of 300 N/cm or more and a resin-to-fiber mass ratio of 5 to 25%, providing enhanced tensile strength, flexibility, and bending resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If glass fibers are used to achieve high tear strength and dimensional stability, then the composite sheet exhibits high specific gravity and insufficient flexibility

Engineering Contradiction:

Improvetear strengthVSAvoidspecific gravity

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent changes the fiber material parameter from glass fiber to liquid crystal polyester fiber, which has lower specific gravity while maintaining high strength properties. This parameter substitution resolves the contradiction by achieving high tear strength without the penalty of high specific gravity associated with glass fibers.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite structure combining liquid crystal polyester fiber fabric with thermoplastic resin coating. This composite material approach allows the fiber component to provide tear strength while the resin component provides flexibility, and the overall composite has lower specific gravity than glass fiber composites.

Inventive Principle:

Principle #40Composite materials

2Strength

If glass fibers are used to achieve high tear strength and dimensional stability, then the composite sheet exhibits insufficient flexibility

Engineering Contradiction:

Improvetear strengthVSAvoidflexibility

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent creates a composite structure combining liquid crystal polyester fiber fabric with thermoplastic resin coating. This composite material approach allows the fiber component to provide tear strength while the resin component provides flexibility, resolving the contradiction between strength and ease of operation.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the fiber material from glass fiber to liquid crystal polyester fiber, which inherently provides better flexibility. Combined with the thermoplastic resin coating that adds柔韧性, this parameter change resolves the contradiction between tear strength and flexibility.

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If conventional fibers (polyester, nylon, polypropylene) are used for the woven fabric sheet, then the composite sheet exhibits high flexibility and durability, but the strength of the fiber itself is low and the strength of the composite sheet is insufficient

Engineering Contradiction:

ImproveflexibilityVSAvoidtensile strength

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The patent changes the fiber material parameter from conventional fibers (polyester, nylon, polypropylene) to liquid crystal polyester fiber, which has inherently higher tensile strength while maintaining flexibility. This parameter substitution resolves the contradiction by achieving both high flexibility and high tensile strength.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite structure combining liquid crystal polyester fiber fabric with thermoplastic resin coating. The fiber component provides high strength while the resin component provides flexibility and durability, resolving the contradiction between fiber strength and composite flexibility.

Inventive Principle:

Principle #40Composite materials

4Strength

If the composite sheet is produced by laminating a thermoplastic polyurethane sheet on a cloth consisting of glass fibers, then the composite sheet exhibits high tear strength and dimensional stability, but there is a limit to thinning the composite sheet

Engineering Contradiction:

Improvetear strengthVSAvoidthickness

Core Design Contradiction:

StrengthVSLength of moving object

Solution Approach 1:

The patent changes the base fabric material from glass fiber cloth to liquid crystal polyester fiber fabric, which has higher strength-to-weight ratio and allows for thinner construction. This parameter change enables the composite sheet to be thinned while maintaining tear strength.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20210348327A1Composite sheet

Publication Date: 2021.11.11 KURARAY CO LTD

AI summary

The present invention relates to a composite sheet comprising a woven fabric consisting of liquid crystal polyester fiber in which one side or both sides of the woven fabric is coated with a coating material comprising a thermoplastic resin, wherein a tensile strength of the composite sheet in a warp direction of the woven fabric is 300 N/cm or more, and wherein a ratio of a mass of the thermoplastic resin to a mass of the woven fabric is 5 to 25% by mass.