Prepreg Production via Dual-Resin Segmentation for Void Reduction
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Solution Overview
Problem
When a large amount of filler is mixed with the resin in prepreg production, the increased viscosity and decreased fluidity make it difficult for the reinforcing fiber to be impregnated with the resin, leading to potential voids and molding defects in the composite material.
Innovation Solution
A method for producing prepreg involves preparing a first resin with a filler and a second resin without a filler, disposing the second resin adjacent to the reinforcing fiber preform, and then impregnating the preform with both resins to ensure effective fiber impregnation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large amount of filler is mixed with the resin, then the functional properties of the composite material are improved, but the viscosity of the resin increases and fluidity decreases, making it difficult to impregnate the reinforcing fiber
Solution Approach 1:
The resin system is segmented into two distinct components: a first resin containing the filler and a second resin without filler. This segmentation allows each resin to perform its specific function - the first resin provides functional properties while the second resin ensures proper flow and impregnation, resolving the contradiction between filler content and impregnation ease
Solution Approach 2:
The second resin acts as an intermediary substance that facilitates the impregnation process. By introducing this filler-free resin, the system maintains the functional benefits of the filler-containing first resin while adding a medium that ensures adequate fluidity and penetration into the reinforcing fiber, thus mediating between functional requirements and manufacturing ease
2Reliability
If the resin viscosity increases due to filler addition, then the functional properties are enhanced, but voids remain inside the prepreg due to incomplete fiber impregnation
Solution Approach 1:
The resin system is divided into two functional segments: the first resin provides the desired functional properties through filler content, while the second resin segment ensures complete impregnation by maintaining low viscosity and high fluidity, thereby eliminating void formation
Solution Approach 2:
The invention changes the compositional parameters of the resin system by introducing a dual-resin formulation. By adjusting the ratio and properties of the two resins, the system achieves both high functional performance (through filler in first resin) and complete impregnation (through the second resin's flow characteristics), resolving the contradiction between functional enhancement and manufacturing precision
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 method allows for the successful impregnation of reinforcing fibers with resin containing fillers, reducing the likelihood of voids and molding defects in the composite material.
Implementation Method 1
these are heated and pressurized to transfer the resin so that the reinforcing fiber is impregnated with the resin
Implementation Method 2
these are heated and pressurized to transfer the resin so that the reinforcing fiber is impregnated with the resin
Implementation Method 3
a step of carbonizing the laminate
Implementation Method 4
a step of impregnating the carbonized laminate with molten silicon to mold the composite material
Data Source
AI summary
A method for producing a prepreg in which a reinforcing fiber base material is impregnated with a resin to produce a prepreg, wherein said method comprises: a step for preparing a first resin, which is the resin containing a filler, and a second resin, which is the resin not containing a filler; a step for arranging the second resin adjacent to the reinforcing fiber base material; a step for arranging the first resin adjacent to the reinforcing fiber base material and/or the second resin; and a step for impregnating the reinforcing fiber base material with the resin of the first resin and the second resin.