Resin Composite Interface Holes for Adhesion Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional resin composites lack sufficient adhesion between the fiber-reinforced resin material and the resin expanded body, limiting their mechanical strength and usability in applications requiring high adhesion.
Innovation Solution
A resin composite design featuring first and second holes at the interface between the resin expanded body and the fiber-reinforced resin material, allowing the resin to flow into these holes for enhanced adhesion, along with a method for producing this composite by laminating the fiber-reinforced resin material onto a resin expanded body with pre-formed holes, ensuring strong integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional resin composites are used without holes at the interface, then the structure is simple and manufacturing is easier, but the adhesion between the resin expanded body and the fiber-reinforced resin material is insufficient
Solution Approach 1:
The invention introduces holes (porous structures) at the interface between the resin expanded body and the fiber-reinforced resin material. These holes allow the resin to flow into and penetrate the interface region, creating anchoring effects and increasing the adhesion strength between the two materials. The porous structure transforms the flat interface into a three-dimensional interpenetrating structure that mechanically locks the layers together.
2Strength
If resin flows into holes for enhanced adhesion, then the adhesion strength improves significantly, but the manufacturing process becomes more complex
Solution Approach 1:
The holes are pre-formed in the resin expanded body before the lamination process. This preliminary action allows the resin from the fiber-reinforced resin material to naturally flow into the holes during the lamination process under heat and pressure, eliminating the need for additional steps to create the holes or force resin infiltration. The structure is prepared in advance to facilitate the adhesion enhancement.
3Strength
If conventional lamination methods are used without holes, then the production process is simpler and faster, but the mechanical strength of the composite is limited
Solution Approach 1:
The invention changes the physical parameters of the interface by introducing holes that alter the surface area, volume, and resin flow characteristics. During the lamination process, parameters such as temperature and pressure are optimized to control the resin flow into the holes, ensuring complete infiltration while maintaining production efficiency. The parameter changes enable superior mechanical strength without proportionally increasing production time.
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 proposed solution significantly improves the adhesion between the resin expanded body and the fiber-reinforced resin material, resulting in a composite with superior mechanical strength and reduced material waste, while allowing for the use of a wider range of materials and reducing production costs.
Implementation Method 1
the fiber-reinforced resin material and the resin expanded body are integrally laminated by causing the resin of the fiber-reinforced resin material to flow into the first and second holes
Implementation Method 2
A bead expanded molded article has superior strength from being formed by a plurality of resin expanded particles that have thermally fused to each other
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
A resin composite in which a fiber-reinforced resin material comprising fibers and a resin, and a resin expanded body are integrally laminated, wherein the resin expanded body has a hole opened at the interface with the fiber-reinforced resin material and resin of the fiber-reinforced resin material is caused to flow into the hole.