Rapid Curing Epoxy Resin for Carbon Fiber Composites
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Solution Overview
Problem
Current epoxy resin systems used in additive manufacturing of carbon fiber composites require extended curing times, limiting their use in continuous laydown processes and preventing the creation of self-supporting complex shapes with controlled fiber alignment.
Innovation Solution
Development of a high-performance thermoset epoxy resin system with a tailored composition including an aromatic epoxy molecule, inorganic filler, catalyst, and chain extender, which allows for rapid thermal or UV curing, enabling the production of complex 3D structures with controlled fiber alignments and mechanical properties comparable to commercial amine cured epoxy resins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If conventional epoxy resin systems are used in additive manufacturing, then mechanical properties are achieved, but curing time is extended
Solution Approach 1:
The patent modifies the chemical composition parameters of the epoxy resin system by incorporating specific catalysts and reactive diluents, changing the curing kinetics to achieve rapid gelation (1-5 seconds) and full cure (10 minutes) while maintaining mechanical properties comparable to conventional systems
Solution Approach 2:
The invention creates a composite resin system combining epoxy resin with specialized catalysts, chain extenders, and inorganic fillers to achieve both rapid curing and structural integrity, effectively merging the benefits of fast-setting materials with high-performance composite materials
2Productivity
If rapid curing is achieved, then productivity is improved, but manufacturing precision may be compromised
Solution Approach 1:
The resin formulation is designed to provide an extended open time window during which fiber alignment and structural positioning can be precisely controlled before the rapid gelation phase begins, allowing manufacturing precision to be achieved before productivity acceleration takes over
Solution Approach 2:
The curing process exhibits dynamic behavior with distinct phases (initial slow gelation followed by rapid curing), allowing the system to transition from a precision-adjustment phase to a high-speed completion phase, effectively resolving the contradiction between precision and speed
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 resin system achieves rapid curing times (gelation in 1-5 seconds and full density cure in 10 minutes), allowing for the formation of complex 3D structures with controlled fiber alignments and mechanical properties on par with commercial systems, facilitating the additive manufacturing of carbon fiber composites with improved performance and scalability.
Implementation Method 1
rapid thermal/UV curing epoxy resin
Implementation Method 2
rapid thermal/UV curing epoxy resin
Data Source
AI summary
An additive manufacturing resin system includes a container; a build platform in the container; a build platform drive; an additive manufacturing resin that forms an additive manufacturing resin bath; an additive manufacturing print head; a build material supply connected to the additive manufacturing print head; an infill resin in the container, wherein the infill resin is supported by the additive manufacturing resin bath; a computer controller; and an extruded material that forms the product, wherein the infill resin at least partially surrounds the extruded material that forms the product. An infill resin supply provides the infill resin into the container and a control valve is connected to the infill resin supply. An IR light sensor is connected to the control valve and operatively connected to the infill resin in the container.