PVdF Carbon Fiber Sheet for High-Strength Composite Pipes

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Solution Overview

Problem

Conventional fiber-reinforced composite materials with fluororesin as a matrix have limitations in achieving high tensile strength.

Innovation Solution

A sheet comprising carbon fibers with a polyvinylidene fluoride (PVdF) fluororesin layer disposed around carbon monofilaments, where the PVdF is a homopolymer of vinylidene fluoride, providing a tensile strength of 400 MPa or higher, and is preferably used in the form of a tape or laminate for enhanced structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional fiber-reinforced composite materials with fluororesin as a matrix are used, then chemical resistance and corrosion resistance are improved, but tensile strength is limited and cannot reach 400 MPa or higher

Engineering Contradiction:

Improvetensile strengthVSAvoidmaterial selection flexibility

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The invention uses a composite structure consisting of carbon fiber reinforcement and fluororesin matrix, specifically selecting polyvinylidene fluoride (PVdF) as the fluororesin. This composite approach combines the high strength of carbon fiber with the chemical resistance of fluororesin, achieving tensile strength of 400 MPa or higher while maintaining corrosion resistance.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention changes the parameter of fluororesin type from conventional options to specifically polyvinylidene fluoride (PVdF), and controls the carbon fiber content to be 30-70 mass%. This parameter optimization enables the composite to achieve tensile strength of 400 MPa or higher, resolving the strength limitation of conventional materials.

Inventive Principle:

Principle #35Parameter changes

2Strength

If carbon fiber content is increased to improve tensile strength, then mechanical strength is improved, but processability and manufacturing ease may deteriorate

Engineering Contradiction:

Improvetensile strengthVSAvoidprocessability

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The invention optimizes the carbon fiber content parameter to be within 30-70 mass%, which is the critical range where both high tensile strength (400 MPa or higher) and good processability are achieved. This parameter control resolves the contradiction between strength improvement and manufacturing ease.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention ensures uniform distribution of carbon fiber within the PVdF matrix, creating local homogeneity in the composite structure. This uniform distribution allows the material to achieve high strength while maintaining good processability during molding and fabrication.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS11260637B2Sheet, laminate, pipe, riser tube, and flowline

Publication Date: 2022.03.01 DAIKIN INDUSTRIES LTD

AI summary

A sheet containing a carbon fiber and a fluororesin layer disposed around a carbon monofilament constituting the carbon fiber. A fluororesin constituting the fluororesin layer is polyvinylidene fluoride. Further, the sheet has a tensile strength of 400 MPa or higher. Also disclosed is a laminate including a first layer and a second layer that is disposed on the first layer and that includes the sheet; a pipe including the laminate; a riser tube including the pipe and a flowline including the pipe.