Polyurethane Resin Pre-coated Fiber Mat Panel Construction
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Solution Overview
Problem
Existing panel construction methods for automotive parts, such as resin transfer molding (RTM), are inefficient due to high production time, complexity, and incomplete fiber wetting, leading to inappropriate reinforcement and increased thickness.
Innovation Solution
A process involving spraying a polyurethane resin composition, formed by reacting isocyanate and a compound reactive towards isocyanate at an isocyanate index between 100 to 150, onto a fiber mat layer, followed by compression molding to create a pre-impregnated blank, resulting in a monolithic composite panel with improved fiber wetting and reduced thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If resin transfer molding (RTM) is used to produce panel constructions, then structural reinforcement is achieved, but production time increases and processing complexity increases
Solution Approach 1:
The fiber mat layer is pre-coated with polyurethane resin solution before compression molding, ensuring resin is already present and distributed on the fiber surfaces. This preliminary preparation eliminates the need for complex RTM resin injection processes and ensures complete fiber wetting during the subsequent compression molding step, significantly reducing production time while maintaining structural reinforcement.
2Strength
If resin transfer molding (RTM) is used to produce panel constructions, then structural reinforcement is achieved, but processing complexity increases
Solution Approach 1:
The invention extracts and eliminates the complex RTM injection and pressure control steps by using a simplified compression molding process. The polyurethane resin is applied in advance as a coating solution, and the subsequent compression molding step automatically ensures complete fiber wetting without requiring complex injection systems or pressure monitoring, thus reducing processing complexity while maintaining structural reinforcement.
3Quantity of substance
If conventional RTM techniques are used, then panel constructions are produced, but fiber wetting is incomplete especially on edges
Solution Approach 1:
The fiber mat layer is pre-coated with polyurethane resin solution before compression molding, ensuring resin is already present and distributed on the fiber surfaces including edges. This preliminary coating ensures complete fiber wetting during the subsequent compression molding step, eliminating the incomplete wetting problem associated with conventional RTM techniques.
Solution Approach 2:
The invention changes the application method from post-impregnation RTM to pre-coating with resin solution. This parameter change in the timing and method of resin application ensures complete fiber wetting, particularly on edges, by allowing the resin to penetrate and coat all fiber surfaces before the compression molding step.
4Weight of moving object
If honeycomb sandwich panels are used, then lightweight structure is achieved, but panel thickness increases
Solution Approach 1:
The invention extracts and eliminates the need for thick honeycomb core structures by using a monolithic composite construction. The polyurethane resin impregnated fiber mat layer provides sufficient structural reinforcement and lightweight properties without requiring the increased thickness associated with honeycomb sandwich panels, thus achieving both lightweight construction and reduced panel thickness.
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
This process reduces production time, ensures complete fiber wetting, and produces strong, lightweight, and cost-effective panels suitable for various automotive applications without the need for additional adhesives, enhancing mechanical properties and ease of handling.
Implementation Method 1
spraying a polyurethane resin composition onto at least one fiber mat layer
Implementation Method 2
polyurethane resin composition forms a polyurethane film on the at least one fiber mat layer
Implementation Method 3
polyurethane resin composition is obtained by reacting: (a) an isocyanate, and (b) a compound reactive towards isocyanate
Implementation Method 4
compression molding the pre-impregnated blank and resulting in the panel construction
Data Source
AI summary
Described herein is a panel construction, a process for preparing the same and a method of using the same as an automotive part.