Resin Supply Material Pore Structure for Fiber-Reinforced Preforms
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Solution Overview
Problem
Current methods for high-speed molding of fiber-reinforced resins, such as RTM and RFI, face challenges including resin wastage, contamination, and high labor costs due to inefficient resin handling and leakage issues, while existing support materials fail to effectively improve product yield and handling characteristics.
Innovation Solution
A resin supply material comprising a continuous porous material and thermosetting resin, with specific pore structure and resin distribution characteristics, is used to form a preform that is then pressurized and heated to produce a fiber-reinforced resin, enhancing resin storage and handling capabilities and reducing defects like warpage and sink marks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If RTM method is used to achieve high-speed molding, then productivity is improved, but resin wastage increases and cost increases
Solution Approach 1:
The patent extracts the harmful element (liquid resin at room temperature) from the system by using thermoplastic resin pellets instead. This eliminates resin wastage in injection channels while maintaining high-speed molding capability through the granular material feeding system.
Solution Approach 2:
The patent changes the physical state parameter of the resin from liquid (at room temperature in RTM) to solid pellets (thermoplastic resin). This parameter change eliminates resin leakage and wastage while allowing for efficient feeding and high-speed molding processes.
2Productivity
If RTM method is used to achieve high-speed molding, then productivity is improved, but operation site contamination increases
Solution Approach 1:
The patent changes the resin state from liquid to solid pellets, which fundamentally eliminates operation site contamination from resin leakage. The granular material can be contained and fed through closed systems, preventing contact with the operation environment.
3Object-generated harmful factors
If RFI method is used to improve handling characteristic, then operation site contamination is reduced, but time and labor for film disposal increases
Solution Approach 1:
The patent uses disposable granular thermoplastic resin materials that are fed through automated systems. Unlike RFI films that require manual disposal, the granular material system allows for continuous feeding and automated handling, reducing both time and labor while eliminating contamination.
4Object-generated harmful factors
If pore diameter of support is reduced to prevent resin leakage, then resin storage capability decreases
Solution Approach 1:
The patent changes the fundamental approach by using solid thermoplastic resin pellets instead of liquid resin absorbed in porous supports. This eliminates the pore diameter contradiction entirely, as the granular material maintains its shape without leakage while providing adequate material volume for molding.
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 resin storage and handling characteristics, leading to reduced defects and increased productivity in fiber-reinforced resin production by minimizing resin leakage and ensuring uniform impregnation, thus enhancing the external appearance quality and yield of molded products.
Implementation Method 1
a reinforcing fiber base material, and a resin film composed of an uncured thermosetting resin are disposed in a mold, and the resin film is melted by heating
Implementation Method 2
the resin film is melted by heating to be impregnated into the reinforcing fiber base material
Data Source
AI summary
A resin supply material used for press molding or vacuum-pressure molding of a fiber-reinforced resin, the resin supply material including a continuous porous material and a thermosetting resin, wherein an average pore cross-sectional area ratio P expressed by formula (I) is 1.1 or more:P=AII/AI (I)AI: average pore cross-sectional area in region IAII: average pore cross-sectional area in region IIRegion I: region occupying 10% of total volume of continuous porous material from surface layer on both surfaces thereofRegion II: whole region of continuous porous material.