Prepreg Composite Impact Resistance Conductivity
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Solution Overview
Problem
Fiber reinforced composite materials face challenges in achieving both excellent impact resistance and thickness-direction conductivity, with existing methods either compromising on impact resistance or reducing conductivity, and require adjustments in carbon fiber areal weight and fiber volume content for specific applications.
Innovation Solution
A prepreg composition comprising carbon fibers, thermosetting resin, hardener, particles with a thermoplastic resin, conductive particles, and a filler material, where the ratio of conductive particles to thermoplastic resin particles is optimized to enhance both impact resistance and thickness-direction conductivity across varying carbon fiber areal weights.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a thermoplastic resin is included to enhance plastic deformability and impact resistance, then impact resistance is improved, but thickness-direction conductivity is reduced due to the formation of an insulating resin layer between layers
Solution Approach 1:
The patent applies local quality by creating distinct functional zones within the composite material structure. The interlayer section contains thermoplastic resin particles for impact resistance, while the carbon fiber layers maintain conductivity. This spatial differentiation allows each region to perform its specific function without compromising the other, resolving the contradiction between impact resistance and thickness-direction conductivity.
Solution Approach 2:
The patent uses composite materials by combining thermoplastic resin particles with carbon fibers and thermosetting resin in a layered structure. The thermoplastic resin provides plastic deformability and impact resistance, while the carbon fibers provide electrical conductivity. This composite approach allows simultaneous achievement of both impact resistance and thickness-direction conductivity that cannot be achieved with single materials.
2Reliability
If conductive particles and reinforcement are disposed in the interlayer section to enhance both impact resistance and thickness-direction conductivity, then both properties are improved, but the structure becomes more complex and requires precise control of particle sizes and distributions
Solution Approach 1:
The patent merges multiple functions into the interlayer section by incorporating both conductive particles (for thickness-direction conductivity) and thermoplastic resin particles (for impact resistance) in the same region. This consolidation achieves both improved conductivity and impact resistance while maintaining a relatively simple overall layered structure, avoiding the need for separate complex structures for each function.
3Adaptability or versatility
If carbon fiber areal weight or fiber volume content is adjusted for specific applications, then adaptability to different applications is improved, but the impact resistance reinforcement size and conductive particle size must also be adjusted to maintain desired thickness-direction resistance and physical properties
Solution Approach 1:
The patent applies parameter changes by establishing specific size ranges for thermoplastic resin particles (5-50 μm) and conductive particles (formula (1) based on carbon fiber areal weight A). These parameter specifications allow the material to adapt to different applications by simply adjusting the carbon fiber areal weight while maintaining the particle size relationships, reducing the complexity of parameter adjustments compared to requiring independent optimization of all dimensions.
Data Source
AI summary
A prepreg containing at least the following components [A]-[F], wherein the ratio Ne/Nd of the number of structures Ne of component [F] present in a range of outside 110% of the particle diameter of component [E] and the number of structures Nd of component [F] present in a range outside 110% of the particle diameter of component [D] is 0.25 or higher. [A]: Carbon fibers, [B] thermosetting resin, [C]: curing agent, [D]: particles composed mainly of thermoplastic resin having a primary particle number-average particle size of 5-50 μm, [E]: conductive particles different from component [D] and having a primary particle number-average particle size in the range of a specific expression, [F]: filler comprising a carbon material.