Reinforcing Fiber Mat Structure for Fluid Thermoplastic Resin Forming
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Solution Overview
Problem
Existing fiber-reinforced resin forming materials face challenges in achieving a balance between mechanical properties, fluidity during the forming process, and productivity, particularly in the production of complex shapes.
Innovation Solution
A fiber-reinforced resin forming material and method that utilizes a partially-separated fiber bundle with specific sizing agents and processing techniques to enhance mechanical properties, fluidity, and productivity, using carbon fibers, polyamide resins, and controlled fiber bundle characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If relatively long reinforcing fibers are dispersed like chopped strand and/or swirl in the thermoplastic resin to achieve excellent fluidity during forming process, then fluidity is improved, but mechanical properties of shaped product deteriorate
Solution Approach 1:
The patent applies parameter changes by controlling the fiber length within a specific range (5mm to 100mm average length) and adjusting the fiber bundle structure to contain 86 or more single yarns. This optimization of physical parameters enables the material to achieve both good fluidity during press forming and satisfactory mechanical properties in the final product.
2Productivity
If continuous production of intermediate base materials is implemented to save production cost and improve productivity, then productivity is improved, but quality consistency and mechanical properties may deteriorate
Solution Approach 1:
The patent applies preliminary action by pre-defining specific structural parameters for the fiber bundles (containing 86 or more single yarns, average length 5-100mm) before the continuous production process. These pre-established parameters ensure that even during continuous manufacturing, the material maintains consistent quality and mechanical properties throughout production.
3Ease of operation
If fiber bundles with many single yarns are used to achieve good fluidity, then fluidity is improved, but mechanical properties of shaped product deteriorate
Solution Approach 1:
The patent resolves this contradiction by optimizing the parameter of single yarn count within fiber bundles to contain 86 or more single yarns. This specific parameter range allows the material to maintain sufficient fluidity for complex shape formation while preserving adequate mechanical strength in the final product.
Data Source
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AI summary
A reinforcing fiber mat comprising reinforcing fiber bundles having an average fiber length of 5 to 100 mm, inclusive, the weight ratio of the bundles having 86 or more fibers in the bundle being more than 99 wt% and no more than 100 wt% of the reinforcing fiber bundles. Also, a fiber-reinforced resin forming material comprising the reinforcing fiber mat and a thermoplastic resin, and a method for producing a fiber-reinforced resin forming material including steps [A]-[D]. Provided are a reinforcing fiber mat and a fiber-reinforced resin forming material having excellent mechanical properties and fluidity during forming. [A] A step for producing a mat base material of reinforcing fiber bundles having a single yarn count per unit width of 500/mm to 1600/mm, inclusive, and a drape level of 120 to 240 mm, inclusive. [B] A step for spreading or laminating a thermoplastic resin on the mat base material. [C] A step for melting the thermoplastic resin. [D] A step for cooling and solidifying the melted thermoplastic resin between panel surfaces that are 5% or more thicker than the base material thickness at the time of complete resin impregnation.