Composite fiber, fabric, knitted article, and composite material
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Solution Overview
Problem
Existing fiber-reinforced resin-based composite materials, particularly those using thermosetting resins, are limited in their ability to be remelted and molded again, restricting their application to complex shapes and wider purposes.
Innovation Solution
Development of composite fibers comprising polyamide resin fibers and continuous reinforcing fibers, where a specific polyamide resin with a diamine structural unit derived from xylylenediamine and a treating agent is used to achieve dispersion, allowing for thermal processing and formation of complex shapes in woven or knitted fabrics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermosetting resin is used for fiber-reinforced composite materials, then mechanical strength and moldability are improved, but the ability to be remelted and molded again is lost
Solution Approach 1:
The patent changes the chemical composition parameters of the matrix resin from thermosetting to thermoplastic polyamide resin, enabling the composite material to be remelted and remolded while maintaining mechanical strength through the specific molecular weight control and fiber reinforcement structure
Solution Approach 2:
The patent creates a composite material system combining polyamide resin matrix with discontinuous or continuous fibrous materials, where the composite structure provides both the strength of fiber reinforcement and the remoldability of thermoplastic matrix
2Ease of manufacture
If yarn-like fiber bundle is used, then ease of molding into complex shapes is improved, but dispersion of fibers is worsened
Solution Approach 1:
The patent segments the fiber bundle into discontinuous fibers with lengths of 3mm to 1/3 of the mold thickness, which prevents the fibers from remaining as undispersed yarn-like structures while still providing reinforcement, enabling both good dispersion and ease of molding
Solution Approach 2:
The patent applies different fiber length specifications in different regions of the composite material, controlling fiber length to be 3mm to 1/3 of mold thickness to achieve optimal local dispersion while maintaining overall moldability
3Stability of the object's composition
If polyamide resin with specific molecular weight is used, then fiber dispersion is improved, but mechanical strength is worsened
Solution Approach 1:
The patent optimizes the molecular weight parameter of polyamide resin to number average molecular weight Mn of 6,000 to 30,000, which provides optimal balance between resin flow for fiber dispersion and molecular chain entanglement for mechanical strength
Solution Approach 2:
The patent compensates for the lower mechanical strength of thermoplastic polyamide resin compared to thermosetting resins by incorporating discontinuous or continuous fibrous materials that provide reinforcement, creating a composite material with both good dispersion and high strength
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 composite fibers enable the creation of molded articles with enhanced mechanical strength and flexibility, particularly when thermally processed, allowing for more complex shapes and broader applications.
Implementation Method 1
the yarn-like fiber bundle could be thermally processed while the yarn-like fiber bundle is in the form of a composite fiber or after the yarn-like fiber bundle has been converted into a weave fabric or knitted fabric
Data Source
Figure 1~2(b)
AI summary
Provided is a composite fiber in which a polyamide resin fiber and a continuous reinforcing fiber are dispersed. A composite fiber comprising (A) a polyamide resin fiber made from a polyamide resin composition, (B) a continuous reinforcing fiber, and (a) a treating agent for the polyamide resin fiber (A); wherein an amount of the treating agent (a) is 0.1 to 2.0 % by mass of the polyamide resin fiber (A) ; and the polyamide resin composition comprises a polyamide resin containing a diamine structural unit, 50 mol % or more of which is derived from xylylenediamine, and having a number average molecular weight (Mn) of 6,000 to 30,000; and 0.5 to 5 % by mass of the polyamide resin has a molecular weight of 1,000 or less.