Preform Coating for Lightweight Waterproof Porous Molded Articles
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Solution Overview
Problem
Existing methods for forming a coating layer on fiber-reinforced composite materials with voids result in material penetration, leading to inadequate designability and waterproofing, and require additional processing steps, while existing technologies for enhancing designability and waterproofing often require additional layers or complex processes.
Innovation Solution
A method involving the formation of a thin film layer on a porous body with reinforcing fibers and voids, which is then expanded and molded, preventing material penetration and allowing for high design freedom and lightweight, waterproof molded articles without the need for additional lamination or complex processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a coating layer is formed on a fiber-reinforced composite material with continuous voids, then designability is improved, but material penetration occurs leading to inadequate waterproofing
Solution Approach 1:
The patent applies preliminary action by forming the coating layer on the precursor before the voids are fully expanded. The precursor is heated to expand voids after the coating layer is already in place, preventing material penetration while maintaining designability and waterproofing properties.
2Reliability
If additional coating layers are added to enhance waterproofing, then waterproof property is improved, but device complexity increases
Solution Approach 1:
The patent merges the coating layer formation and void expansion processes into a single integrated process. The coating layer is applied to the precursor, then both the precursor and coating layer are heated simultaneously to expand voids and cure the coating, eliminating the need for separate waterproofing layers and simplifying the overall process.
3Strength
If a prepreg skin layer is used to enhance rigidity, then mechanical properties are improved, but additional preparation time is required
Solution Approach 1:
The patent makes the coating layer multi-functional by designing it to simultaneously provide waterproofing, surface finish, and structural rigidity. The coating layer is formulated with resin and filler that cure to create a rigid, waterproof surface, eliminating the need for separate prepreg skin layers and reducing preparation time.
4Reliability
If the coating layer is formed after void expansion, then material penetration is prevented, but the coating layer may delaminate
Solution Approach 1:
The patent applies preliminary action by forming the coating layer on the precursor before void expansion. The coating layer is applied to the precursor surface, then the entire assembly is heated to expand voids and cure the coating layer, ensuring strong adhesion before the voids are expanded.
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 method achieves excellent designability and waterproof properties while maintaining lightweightness, with the thin film layer adhering appropriately to the porous body, enabling convenient production and suppressing delamination, thus enhancing the mechanical and aesthetic properties of the molded article.
Implementation Method 1
heating a preform, obtained by laminating a prepreg layer with a resin layer formed of a thermosetting resin and a solid additive, so as to cure a matrix resin and the thermosetting resin in the resin layer
Data Source
AI summary
Provided is a method for producing a molded article having a thin film layer (B) formed on a surface of a porous body (A). The method includes a process (I) and a process (II) described below in this order:process (I): forming the thin film layer (B) on a surface of a precursor (a) of the porous body (A) to obtain a preform, andprocess (II): expanding and molding the precursor (a) to the porous body (A).