Polycarbonate Carbon Fiber Prepreg for Strength and Adhesion
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Solution Overview
Problem
Existing carbon fiber reinforced thermoplastic resins face challenges with adhesion and mechanical properties, particularly in continuous fiber reinforced thermoplastic resins, which are desired for high cycle molding and complex shape formation.
Innovation Solution
A polycarbonate resin prepreg is developed with a continuous carbon fiber reinforced material, incorporating a specific amount of polyalkylene glycol, such as polypropylene glycol, to enhance adhesion and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If continuous fiber reinforced thermoplastic resin is used to achieve high elastic modulus and strength, then mechanical properties are improved, but adhesion becomes insufficient
Solution Approach 1:
The patent changes the chemical composition parameters of the thermoplastic resin by incorporating specific amounts of polyalkylene glycol (1-30 wt%), polyether polyol (1-30 wt%), and polyester polyol (1-30 wt%) into the polycarbonate resin system. This parameter modification enables the resin to achieve both high mechanical strength from continuous carbon fibers and improved adhesion through the synergistic effect of the added polyols, resolving the contradiction between strength and adhesion.
Solution Approach 2:
The patent creates a composite resin system combining polycarbonate resin with multiple types of polyols (polyalkylene glycol, polyether polyol, polyester polyol) and continuous carbon fibers. This multi-component composite material leverages the high strength of continuous fibers while the polyol components provide adhesion promotion, achieving both improved mechanical properties and reliable adhesion simultaneously.
2Ease of manufacture
If short fiber reinforced thermoplastic resin is used to achieve complex shape molding, then moldability is improved, but elastic modulus becomes significantly low
Solution Approach 1:
The patent segments the fiber reinforcement approach by using continuous carbon fibers instead of short fibers, allowing the fibers to maintain their full length and provide continuous reinforcement. This segmentation of the reinforcement structure enables the material to achieve both complex shape molding capability through thermoplastic processing and high elastic modulus through continuous fiber reinforcement.
Solution Approach 2:
The patent modifies the resin matrix parameters by adding specific polyol components that enhance the resin's ability to bond with continuous fibers and maintain structural integrity during molding. This parameter change enables the continuous fiber reinforced system to achieve both excellent moldability for complex shapes and high elastic modulus, resolving the contradiction between ease of manufacture and strength.
3Strength
If thermosetting resin is used to achieve high strength, then mechanical properties are improved, but molding time becomes enormous
Solution Approach 1:
The patent substitutes the thermosetting resin system with a thermoplastic resin system comprising polycarbonate and continuous carbon fibers. This substitution replaces the chemical curing mechanism of thermosetting resins with the physical melting and solidifying mechanism of thermoplastics, enabling fast cycle molding while maintaining high mechanical strength through the continuous fiber reinforcement and appropriate resin composition.
Solution Approach 2:
The patent changes the resin type parameter from thermosetting to thermoplastic, fundamentally altering the processing mechanism from chemical curing to thermal melting. This parameter change reduces molding time dramatically while maintaining strength through the continuous fiber reinforced structure and optimized polyol content (1-30 wt% each) that ensures adequate mechanical properties without the lengthy curing times of thermosetting resins.
Data Source
AI summary
According to the present invention, there can be provided a polycarbonate resin prepreg, comprising a polycarbonate resin (A) and a continuous carbon fiber reinforced material (B), wherein the prepreg comprises a polyalkylene glycol (C) in an amount of 1% to 30% by mass with respect to the mass of the polycarbonate resin (A). In the present invention, an aspect, in which the polycarbonate resin prepreg comprises the continuous carbon fiber reinforced material (B) in an amount of 20% to 80% by volume, and the polycarbonate resin (A) and the polyalkylene glycol (C) in a total amount of 80% to 20% by volume, is preferable.