Random Sheet Manufacturing Using Thermoplastic Resin Powder
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Solution Overview
Problem
Existing methods for producing random sheets, such as those described in PTL 1, fail to achieve a marble-like appearance with flowing patterns, despite enhanced design features.
Innovation Solution
A method involving the spreading of thin pieces of fiber reinforced resin, application of powder from a second thermoplastic resin, and integration by heating and pressurizing, which allows for the movement of reinforcing fibers and creation of a marble-like appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a transparent thermoplastic resin film is temporarily bonded to thin pieces by roll forming and hot press molding is performed, then the design capability is enhanced, but the appearance fails to achieve flowing marble-like patterns
Solution Approach 1:
The invention changes the physical state parameter of the resin from solid film to powder form. This parameter change enables the resin to flow and penetrate between thin pieces during hot press molding, dragging carbon fibers to create flowing marble-like patterns that were not achievable with film form
Solution Approach 2:
The invention uses a composite system combining thin pieces of fiber reinforced resin with thermoplastic resin powder. The interaction between these two materials during heating and pressurizing creates the desired marble-like appearance while maintaining structural integrity
2Shape
If thermoplastic resin powder is applied to thin pieces and heating is performed, then flowing marble-like patterns are achieved, but the process complexity increases
Solution Approach 1:
The thermoplastic resin powder is applied to the thin pieces in advance before hot press molding. This preliminary action ensures that the resin is already in position to flow and create marble-like patterns when heating occurs, simplifying the overall process by eliminating the need for complex post-processing steps
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 method effectively produces random sheets with an improved marble-like appearance, enhancing their design and aesthetic appeal.
Implementation Method 1
when the molten transparent resin enters between the thin pieces during the hot press
Implementation Method 2
the molten transparent resin enters between the thin pieces during the hot press, the carbon fibers are dragged and moved
Implementation Method 3
integrating the thin pieces with each other by heating and pressurizing the thin pieces
Implementation Method 4
integrating the thin pieces with each other by heating and pressurizing the thin pieces
Data Source
AI summary
The present invention provides a method for manufacturing a random sheet having a better external appearance. This random sheet manufacturing method comprises: a step for spreading, in a planar manner, thin pieces of a fiber-reinforced resin obtained by impregnating a plurality of reinforcing fibers arranged oriented in one direction with a first thermoplastic resin; a step for adding a powder of a second thermoplastic resin to the thin pieces which have been spread; and a step for heating and pressurizing the thin pieces to which the powder has been added and unifying the thin pieces with each other.