Prepreg Laminate Welding Strength and Heat Resistance
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Solution Overview
Problem
Fiber-reinforced composite materials with thermosetting or thermoplastic resins face challenges in joining complex shapes and achieving high-temperature and chemical resistance, with existing methods resulting in insufficient joining strength and prolonged processing times.
Innovation Solution
A prepreg and laminate configuration using reinforcing fibers, a thermosetting resin with a high rubbery state elastic modulus, and a thermoplastic resin, where the resins are firmly joined and can be welded together, enhancing compressive strength and interlaminar fractural toughness, particularly at high temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical joining methods (bolts, rivets, screws) are used to integrate fiber-reinforced composite materials, then the materials can be joined, but the production process is prolonged and production cost is increased due to pre-processing steps like drilling
Solution Approach 1:
The patent replaces mechanical joining methods (drilling, bolting, riveting) with adhesive bonding. The adhesive layer is applied to the surface of the fiber-reinforced composite material, eliminating the need for pre-drilling and mechanical fasteners. This substitution reduces production steps and time while maintaining or improving joining strength through chemical bonding.
Solution Approach 2:
The patent introduces an adhesive layer as an intermediary substance between the fiber-reinforced composite materials. This adhesive mediator provides a bonding interface that joins the materials together without requiring mechanical penetration or fasteners, thereby simplifying the joining process and reducing production time.
2Reliability
If adhesive joining methods are used to integrate fiber-reinforced composite materials, then the materials can be joined, but the production process is prolonged due to adhesive preparation, coating, and curing processes
Solution Approach 1:
The patent applies adhesive to the surface of the fiber-reinforced composite material in advance, before the final assembly step. This preliminary application allows the adhesive to be pre-positioned and potentially pre-cured or activated, reducing the time required during the actual joining operation. The adhesive is prepared and applied beforehand, streamlining the overall production process.
3Productivity
If thermoplastic resin is used as matrix for welding capability, then joining time may be shortened, but heat resistance and chemical resistance are insufficient compared to thermosetting resin composites
Solution Approach 1:
The patent uses fiber-reinforced composite materials with thermosetting resin as the matrix, which provides superior heat resistance and chemical resistance compared to thermoplastic resins. The reinforcing fibers (carbon or glass) embedded in the thermosetting resin matrix create a composite structure that maintains high-temperature stability and chemical inertness, making it suitable for structural members requiring excellent environmental resistance.
4Ease of manufacture
If drilling is performed for mechanical joining, then joints can be created, but the strength of the material is deteriorated due to drilling damage
Solution Approach 1:
The patent replaces mechanical joining methods that require drilling with adhesive bonding. By eliminating the drilling process entirely, the patent avoids the material damage, heat-affected zones, and stress concentrations that drilling creates. The adhesive bonding method preserves the integrity and strength of the fiber-reinforced composite material while still enabling effective joint creation.
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 allows for efficient joining of complex shapes with improved high-temperature and chemical resistance, reducing processing time and cost, and achieving superior tensile shear joining strength and compressive strength in structural applications.
Implementation Method 1
a prepreg including reinforcing fibers, a thermosetting resin, and a thermoplastic resin
Implementation Method 2
the resins are firmly joined and can be welded together
Data Source
AI summary
An object of the present invention is to provide a prepreg and a laminate for producing a laminate suitable as a structural material, which have excellent compressive strength and interlaminar fractural toughness values, and can be firmly integrated with another structural member by welding. The present invention provides a prepreg including the following structural components [A] reinforcing fibers, [B] a thermosetting resin, and [C] a thermoplastic resin, in which [B] has a rubbery state elastic modulus of 10 MPa or more at a temperature obtained by adding 50° C. to a glass transition temperature in a state in which a degree of cure is 90% or more, [C] is present in a surface of the prepreg, and the reinforcing fibers [A] are present, which are included in a resin area including {B] and a resin area including [C] across an interface between the two resin areas.