Polyimide Resin Molded Article Low-Pressure Compression Molding
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Solution Overview
Problem
Fiber-reinforced resin molded articles with addition-reaction type polyimide resin face challenges such as high cost due to expensive resin usage, moldability deterioration with increased filler content, warpage, and resin impregnation failures, leading to compromised mechanical strength and sliding performance.
Innovation Solution
A composition with 40 to 350 parts by weight of functional fiber and 20 to 300 parts by weight of inorganic microparticulate filler per 100 parts by weight of addition-reaction type polyimide resin, combined with a method of heat melt kneading and compression molding, ensures uniform filler distribution and reduced resin content, enabling low-pressure molding with improved sliding performance and dimensional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the content of addition-reaction type polyimide resin is decreased to reduce cost, then the manufacturing cost is reduced, but the moldability deteriorates and high pressure molding is required
Solution Approach 1:
The invention changes the particle size parameter of the inorganic filler to less than 15 μm, which fundamentally alters the rheological properties of the composition. This parameter change allows the system to achieve good moldability at low resin content by reducing filler-filler interactions and improving resin distribution, thereby resolving the contradiction between cost reduction and manufacturability
Solution Approach 2:
The invention creates a composite material system with a specific composition ratio (40-350 parts functional fiber, 20-300 parts inorganic filler per 100 parts resin) that optimizes the interaction between components. This composite approach allows the system to achieve both cost effectiveness and good moldability through synergistic effects of the multi-component system
2Quantity of substance
If the filler content is increased to decrease resin usage, then the cost is reduced, but the resin impregnation fails and mechanical strength deteriorates
Solution Approach 1:
By changing the particle size parameter to less than 15 μm, the invention fundamentally improves resin impregnation efficiency. The smaller particle size increases the surface area for resin adhesion and reduces aggregation, allowing high filler content (20-300 parts per 100 parts resin) to be achieved while maintaining adequate resin distribution and mechanical strength
Solution Approach 2:
The invention uses the inorganic microparticulate filler as an intermediary that, when properly sized, actually improves the overall structure. The fine filler particles act as nucleation sites for resin crosslinking and create a more uniform stress distribution, thereby maintaining mechanical strength even at high filler loadings
3Reliability
If addition-reaction type polyimide resin is used to improve heat resistance and mechanical strength, then the durability is improved, but the molded article warps and cannot be used as sliding member
Solution Approach 1:
The invention changes the particle size parameter of the inorganic filler to less than 15 μm, which fundamentally alters the thermal and dimensional stability of the composite. The fine filler particles create a more uniform thermal distribution and restrict polymer chain mobility during curing, thereby preventing warpage while maintaining the heat resistance benefits of the polyimide resin
Solution Approach 2:
The invention creates a composite material system where the specific combination of functional fiber, inorganic microparticulate filler, and addition-reaction type polyimide resin in controlled ratios produces synergistic effects. This composite approach allows the system to achieve both heat resistance and dimensional stability through the interacting properties of the components
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 approach reduces the cost of the molded article, prevents warpage, enhances wear resistance, maintains low dynamic friction, and improves tribological properties, allowing for efficient production of fiber-reinforced polyimide resin molded articles with excellent sliding performance and dimensional accuracy.
Implementation Method 1
The resin is crosslinked and cured with the functional fiber uniformly dispersed therein to form the article
Implementation Method 2
the resin is crosslinked and cured with the functional fiber uniformly dispersed therein
Implementation Method 3
increasing the melting viscosity of the prepolymer of the addition-reaction type polyimide resin so as to homogeneously disperse the functional fiber in the addition-reaction type polyimide resin without sedimentation or uneven distribution
Implementation Method 4
a method for producing a molded article that is excellent in tribological performance and that is obtained using this composition
Data Source
Figure 1~3
Figure 4
AI summary
The present invention provides a composition that can be molded by compressing at a low pressure even when the content of an addition-reaction type polyimide resin in use is considerably decreased, and that can make a fiber-reinforced molded article excellent in sliding performance and further shape stability during molding. The composition of the present invention contains 40 to 350 parts by weight of a functional fiber and 100 to 600 parts by weight of an inorganic microparticulate filler having an average particle diameter of less than 15 µm per 100 parts by weight of the addition-reaction type polyimide resin.