Fiber-Reinforced Molding Base with Resin Barrier for Heat Insulation
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Solution Overview
Problem
Existing methods for enhancing thermal resistance and heat insulation in fiber-reinforced resin molded products, such as using high-thermal-resistance resins or polyimide fiber paper, face issues like increased weight, complexity, and loss of insulation due to resin permeation during molding.
Innovation Solution
A molding base material comprising a fiber-reinforced resin prepreg layer, a fiber paper layer, and a partition layer interposed between them, which prevents resin intrusion into the fiber paper layer, maintaining air gaps and ensuring high heat insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If polyimide fiber paper is applied to improve thermal resistance and heat insulation, then thermal resistance and heat insulation are improved, but resin permeates into the fiber paper during molding, filling gaps and impairing heat insulation
Solution Approach 1:
The invention divides the fiber paper into multiple layers (first fiber paper layer, second fiber paper layer) separated by a resin non-permeable layer. This segmentation prevents resin from permeating through the entire fiber paper structure, maintaining the air gaps necessary for heat insulation while allowing the fiber paper to provide thermal resistance.
Solution Approach 2:
A resin non-permeable layer is introduced as an intermediary between the first and second fiber paper layers. This intermediate layer acts as a barrier that prevents resin permeation into the fiber paper gaps during molding, thereby preserving the heat insulation performance while allowing the fiber paper to maintain its thermal resistance properties.
2Temperature
If fiber paper is joined to molded product by post-processing, then thermal resistance and heat insulation are improved, but joining takes time and effort, adhesives are required, and peeling risk exists
Solution Approach 1:
The invention merges the fiber paper layers with the resin-molded product by integrally molding them together in a single process. The fiber paper layers are positioned within the molding apparatus and molded simultaneously with the resin, eliminating the need for separate post-processing joining steps and avoiding adhesive requirements.
Solution Approach 2:
The fiber paper layers are prepared and positioned in advance within the molding apparatus before resin injection. This preliminary positioning ensures that the fiber paper is correctly placed and will be integrally molded with the resin in the desired location, eliminating the need for subsequent joining operations.
3Weight of moving object
If fiber paper is made thin to improve space efficiency and weight reduction, then space efficiency and weight are improved, but heat insulation performance may be compromised
Solution Approach 1:
The invention segments the fiber paper structure into multiple thin layers separated by a resin non-permeable layer. This allows the use of thinner individual fiber paper layers that reduce weight and improve space efficiency, while the cumulative effect of multiple layers maintained by the non-permeable barrier preserves the overall heat insulation performance.
Solution Approach 2:
The invention uses thin fiber paper layers that can be flexibly positioned and molded into complex shapes. These thin layers provide sufficient heat insulation when combined in a multi-layer structure with the resin non-permeable layer, achieving both weight reduction and maintained thermal performance.
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 allows for high thermal resistance and heat insulation while reducing weight and improving space efficiency, enabling the production of molded products with desired shapes and improved strength and rigidity.
Implementation Method 1
it can exhibit a high heat insulation because it has gaps (air layer between fibers) inside
Implementation Method 2
the resin of the prepreg permeates into the polyimide fiber paper, gaps in the fiber paper are filled (the air layer is eliminated or greatly reduced)
Data Source
AI summary
A molding base material has at least a fiber-reinforced resin prepreg layer, a fiber paper layer, and a partition layer interposed between the prepreg layer and the fiber paper layer; a molded product obtained using the same; and a production method therefor. The resulting product makes it possible to achieve high thermal resistance and heat insulation as well as improved overall space efficiency and weight reduction in a fiber-reinforced resin molded product.