PMI Resin Core Material for Fiber Reinforced Composites
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Solution Overview
Problem
Existing methods for manufacturing fiber reinforced composites face challenges such as limited formability, uneven expansion, and poor surface smoothness due to specialized techniques and materials like polypropylene resin expanded articles, which restrict shape complexity and mechanical properties.
Innovation Solution
A core material made from a thermoplastic resin with specific high-temperature characteristics, containing polyphenylene ether resin and other thermoplastic resins, along with a controlled amount of gas and additives, is used to enhance workability and adhesion with fiber reinforcing materials, allowing for more complex shapes and improved mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If polypropylene resin expanded articles are used as core materials, then light weight is achieved, but rigidity with heating deteriorates which restricts compositing conditions
Solution Approach 1:
The patent changes the material parameter from polypropylene resin to polymethacrylimide (PMI) resin, which fundamentally alters the thermal properties. PMI resin maintains its rigidity at high temperatures unlike polypropylene, enabling compositing at elevated temperatures while preserving the lightweight expanded article structure.
Solution Approach 2:
The patent uses composite materials by combining PMI resin expanded articles with fiber reinforcing materials. This composite structure allows the core material to maintain rigidity during compositing while keeping the overall weight low, resolving the contradiction between lightweight and heat resistance.
2Temperature
If polymethacrylimide resin expanded articles are used, then heat resistance is improved, but manufacturing method complexity increases and shape flexibility is reduced
Solution Approach 1:
The patent applies preliminary action by pre-forming the PMI resin into expanded articles with desired shapes before compositing. This allows complex three-dimensional shapes to be created in advance, reducing manufacturing complexity during the actual compositing process while maintaining excellent heat resistance.
3Weight of moving object
If expanded articles are used to form core materials, then light weight is achieved, but formable shapes are limited and surface smoothness deteriorates due to uneven expansion
Solution Approach 1:
The patent changes the material parameters of the expanded article from conventional resins to PMI resin, which has different expansion characteristics. This material substitution enables better control over expansion uniformity, allowing formation of complex three-dimensional shapes with smooth surfaces while maintaining lightweight 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 solution provides a fiber reinforced composite with excellent heat resistance, rigidity, and surface smoothness, enabling the formation of intricate shapes while maintaining mechanical strength and adhesion, thus overcoming the limitations of previous methods.
Implementation Method 1
A core material for a fiber reinforced composite, and a fiber reinforced composite are provided. The core material is a molded product of expanded beads
Implementation Method 2
a fiber reinforcing material disposed on at least a part of a surface of the core material... exhibited an excellent workability upon being composited with a fiber reinforcing material
Data Source
AI summary
To provide a core material for a fiber reinforced composite having an excellent workability upon being composited with a fiber reinforcing material. A core material for a fiber reinforced composite of the present disclosure comprises a molded product of expanded beads containing a thermoplastic resin, and having a heat shrinkage onset temperature of 80°C or higher, a linear expansion coefficient of 10 × 10-5 mm/mm·°C or less, and a ratio of change in dimensions with heating at 130°C of -4.0% to 0%.