Metal-CFRTP Composite Corrosion Prevention via Resin Layer
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Solution Overview
Problem
The challenge is to prevent contact corrosion between dissimilar materials, particularly between ferrous materials or ferrous alloys and carbon fiber reinforced plastics (CFRTP), which occurs due to the contact of carbon fibers with metal members, leading to corrosion issues when using thermosetting resins as the matrix resin.
Innovation Solution
A metal-carbon fiber reinforced plastic composite is developed with a thermoplastic resin layer having a higher melting point than the matrix resin, preventing carbon fiber penetration and contact with the metal member, thereby suppressing corrosion. This composite includes a ferrous material or ferrous alloy with a thermoplastic resin layer and carbon fiber reinforced plastic, where the melting point of the resin layer is higher than that of the CFRTP, and the thickness of the resin layer is 5 μm or more.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a thermosetting resin is used as the matrix resin in CFRP, then tensile strength and workability are improved, but brittle fracture occurs easily and compressive strength is insufficient
Solution Approach 1:
The invention changes the fundamental parameter of the matrix resin from thermosetting to thermoplastic. This parameter change transforms the material's mechanical behavior, providing both high tensile strength and improved toughness to prevent brittle fracture, while maintaining compressive strength through the metal-CFRTP composite structure.
Solution Approach 2:
The invention creates a hybrid composite material system combining metal and CFRTP (carbon fiber reinforced thermoplastic). This composite structure leverages the high tensile strength of carbon fibers and the toughness of thermoplastic resin, while the metal component provides compressive strength, achieving balanced mechanical properties.
2Reliability
If the resin layer thickness is increased to prevent carbon fiber penetration, then contact corrosion is suppressed, but manufacturing complexity and material usage increase
Solution Approach 1:
The invention changes the melting point parameter of the resin layer to be higher than that of the CFRTP matrix resin. This parameter change allows the resin layer to maintain its structural integrity and prevent carbon fiber penetration at hot press bonding temperatures, providing effective corrosion protection with a thin layer (5 μm or more) rather than requiring a thick barrier.
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 solution effectively suppresses contact corrosion between dissimilar materials, enhancing the corrosion resistance of the metal-carbon fiber reinforced plastic composite, even when using ferrous materials, by maintaining the resin layer's hardness during hot press bonding and preventing carbon fiber penetration.
Implementation Method 1
a melting point Tm1 of the resin layer being higher than a melting point Tm2 of the carbon fiber reinforced plastic
Implementation Method 2
an AC impedance at a frequency 1 Hz when immersing the metal-carbon fiber reinforced plastic composite in an aqueous solution containing sodium chloride in 5 mass % is 1×10^7Ω or more
Data Source
AI summary
A metal-carbon fiber reinforced plastic composite comprising a metal member of a ferrous material or ferrous alloy, a resin layer provided on at least one surface of the metal member and including a thermoplastic resin, and carbon fiber reinforced plastic provided on a surface of the resin layer and including a carbon fiber material and a matrix resin having thermoplasticity, a glass transition point Tg1 or melting point Tm1 of the resin layer being higher than a glass transition point Tg2 or melting point Tm2 of the carbon fiber reinforced plastic, in which metal-carbon fiber reinforced plastic composite, an AC impedance at a frequency 1 Hz when immersing the metal-carbon fiber reinforced plastic composite in an aqueous solution containing sodium chloride in 5 mass % is 1×107Ω or more.