Molded article comprising thermoplastic continuous fiber reinforced woven composite, and method for manufacturing same
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Solution Overview
Problem
Thermoplastic resin-based materials used in automotive parts, such as continuous fiber-reinforced woven fabrics, suffer from deterioration in flame retardancy, impact resistance, stiffness, and poor appearance characteristics when applied to lower protective plates of battery modules for electric vehicles, necessitating improved properties in lightweightness, flame retardancy, impact resistance, and appearance.
Innovation Solution
A molded article comprising a woven fabric sheet made of stacked thermoplastic continuous fiber-reinforced woven fabrics, with a non-woven fabric applied to one surface, using a glass fiber composite material containing glass fibers, polypropylene resin, piperazine pyrophosphate, phosphazene compound, and zeolite, and a manufacturing method involving heating and pressing to enhance properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If thermoplastic resin is applied to continuous fiber-reinforced woven fabric for weight reduction, then lightweightness is improved, but flame retardancy deteriorates
Solution Approach 1:
The patent applies composite materials by combining thermoplastic resin (polypropylene) with flame retardant additives (piperazine pyrophosphate and phosphazene compound) to create a composite material that simultaneously achieves weight reduction and flame retardancy. The specific formulation uses 35-72 parts polypropylene resin, 12-35 parts piperazine pyrophosphate, and 1-20 parts phosphazene compound per 100 parts glass fiber, creating a balanced composite that meets both lightweight and fire safety requirements for EV battery protective plates.
2Weight of moving object
If thermoplastic resin is applied to continuous fiber-reinforced woven fabric for weight reduction, then lightweightness is improved, but impact resistance deteriorates
Solution Approach 1:
The patent uses composite materials formulation where thermoplastic resin is combined with glass fiber reinforcement and flame retardant additives. The glass fiber provides structural strength and impact resistance, while the resin matrix binds the fibers together. The specific composition (35-72 parts polypropylene resin per 100 parts glass fiber) creates a composite that maintains impact resistance while achieving weight reduction compared to metal alternatives.
3Weight of moving object
If thermoplastic resin is applied to continuous fiber-reinforced woven fabric for weight reduction, then lightweightness is improved, but stiffness deteriorates
Solution Approach 1:
The patent applies composite materials principle by using glass fiber-reinforced thermoplastic resin structure. The glass fibers provide stiffness and structural integrity, while the thermoplastic resin matrix provides lightweight properties and binds the fibers. The woven fabric structure further enhances stiffness by creating a rigid architecture. This composite approach maintains stiffness requirements for EV battery protective plates while achieving weight reduction.
4Weight of moving object
If thermoplastic resin is applied alone for lightweightness, then weight is reduced, but appearance characteristics deteriorate due to fiber protrusion
Solution Approach 1:
The patent applies composite materials by formulating a resin system with polypropylene resin, piperazine pyrophosphate, and phosphazene compound that provides adequate melt flow and binding properties. This composite resin formulation effectively binds the glass fibers during molding, preventing fiber protrusion and achieving good surface appearance while maintaining the lightweight advantage of thermoplastic materials.
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 molded article achieves good properties in lightweightness, flame retardancy, impact resistance, stiffness, and appearance characteristics, with a density of 1.40 g/cm³ to 1.55 g/cm³, peak force of 3.5 kN to 6.0 kN, energy absorption of 30 J to 50 J, and self-extinguishing capability, suitable for battery module protective plates.
Implementation Method 1
a non-woven fabric heated and pressed on at least one surface of the woven fabric sheet to be stacked thereon
Implementation Method 2
about 12 parts by weight to about 35 parts by weight of piperazine pyrophosphate; about 1 part by weight to about 20 parts by weight of a phosphazene compound
Data Source
Figure 1
AI summary
A molded article of the present invention comprises: a woven composite sheet formed from two or more stacked sheets of thermoplastic continuous fiber reinforced woven composites; and a nonwoven fabric heated and compressed to be stacked on at least one surface of the woven composite sheet, wherein the thermoplastic continuous fiber reinforced woven composites are woven using, as warp and weft, a glass fiber composite comprising approximately 100 parts by weight of glass fiber, approximately 35-72 parts by weight of a polypropylene resin, approximately 12-35 parts by weight of piperazine pyrophosphate, approximately 1-20 parts by weight of a phosphazene compound and approximately 1-20 parts by weight of zeolite. The glass fiber composite has excellent lightweightness, flame retardancy, impact resistance, stiffness, exterior characteristics and the like.