Prepreg laminate, method for manufacturing fiber-reinforced plastic using prepreg laminate, and fiber-reinforced plastic
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Solution Overview
Problem
Existing techniques for molding fiber-reinforced plastics using woven fabric and discontinuous fiber preregs suffer from structural disorder, making it difficult to produce complex shapes with good external appearance quality.
Innovation Solution
A prepreg laminate comprising a woven fabric prepreg and a discontinuous fiber prepreg, where the thermosetting resins have a calibrated curing rate difference to minimize structural disorder, with the woven fabric prepreg having a woven structure and thermosetting resin A curing faster than resin B, ensuring the woven structure remains intact during molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a woven fabric prepreg and discontinuous fiber prepreg are combined for molding, then shape conformity is improved, but the woven structure becomes disordered
Solution Approach 1:
The patent applies preliminary action by pre-heating the prepreg laminate before molding to control the curing sequence. The woven fabric prepreg is cured first to establish a stable structure, then the discontinuous fiber prepreg is cured to provide shape conformity. This sequential curing prevents the discontinuous fibers from disrupting the woven structure during the molding process.
Solution Approach 2:
The patent utilizes parameter changes by controlling temperature and curing time parameters during the molding process. By carefully managing the heating profile and curing conditions, the patent ensures that the woven fabric prepreg cures first while maintaining structural integrity, and the discontinuous fiber prepreg cures subsequently to achieve the desired shape conformity without disordering the woven structure.
2Strength
If continuous fibers are used for high mechanical properties, then strength is improved, but molding of complicated shapes becomes difficult
Solution Approach 1:
The patent applies segmentation by dividing the fiber reinforcement into two distinct components: continuous fibers in the woven fabric prepreg for mechanical strength, and discontinuous fibers in the separate prepreg layer for shape conformity. This segmentation allows each fiber type to fulfill its specific function without compromising the other, enabling both high strength and complex shape molding.
Solution Approach 2:
The patent utilizes composite materials by combining two different types of fiber-reinforced prepregs with distinct properties. The woven fabric prepreg with continuous fibers provides structural strength, while the discontinuous fiber prepreg provides flowability and shape conformity. This composite approach creates a multi-functional material system that achieves both mechanical performance and geometric flexibility.
3Shape
If discontinuous fiber prepreg is used for shape conformity, then external appearance quality deteriorates due to woven structure disorder
Solution Approach 1:
The patent applies preliminary action by pre-heating the prepreg laminate to initiate controlled curing of the woven fabric prepreg before the discontinuous fiber prepreg. This sequential curing process ensures that the woven structure is already stabilized when the discontinuous fibers are applied, preventing them from causing structural disorder and maintaining external appearance quality while achieving shape conformity.
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 solution effectively suppresses disorder in the woven structure during molding, resulting in a fiber-reinforced plastic with improved external appearance quality and mechanical properties suitable for complex shapes, particularly for use as outer plate members in various industrial applications.
Implementation Method 1
when each of the thermosetting resin A and the thermosetting resin B is heated using a differential scanning calorimeter from 50° C. to 130° C. at 700° C./min under a nitrogen atmosphere followed by retention at 130° C. until completion of thermal curing reaction
Data Source
AI summary
A prepreg laminate is provided which includes: a woven fabric prepreg on at least one surface layer; and a discontinuous fiber prepreg; the woven fabric prepreg including reinforcing fibers R1 having a woven structure, and a thermosetting resin A, the discontinuous fiber prepreg including unidirectionally oriented discontinuous reinforcing fibers R2 and a thermosetting resin B, the thermosetting resin A and the thermosetting resin B satisfying the following calorific value condition: calorific value condition: when each of the thermosetting resin A and the thermosetting resin B is heated using a differential scanning calorimeter from 50° C. to 130° C. at 700° C./min under a nitrogen atmosphere followed by retention at 130° C. until completion of thermal curing reaction, Tb−Ta>30, wherein Ta (s): time required for the calorific value of the thermosetting resin A to reach 50% of the gross calorific value of the thermosetting resin A; Tb (s): time required for calorific value of the thermosetting resin B to reach 50% of gross calorific value of the thermosetting resin B.