Siloxane Block Copolycarbonate Composite Matrix
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Solution Overview
Problem
Multilayer composite materials with thermoplastic matrices and fiber reinforcement face issues with cracking under deformation stress and surface quality, leading to mechanical strength reduction and painting defects.
Innovation Solution
A multilayer composite material comprising continuous glass or carbon fibers embedded in a siloxane-containing block cocondensate-based thermoplastic matrix, with specific layer orientations and fiber volume content, to enhance adhesion and reduce cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional thermoplastic matrices are used in multilayer composite materials, then the materials achieve high rigidity and mechanical strength, but they exhibit cracking under deformation stress and poor surface quality
Solution Approach 1:
The patent changes the chemical composition parameters of the thermoplastic matrix by incorporating siloxane-containing block copolycarbonates with specific structural units (Formula 1 and Formula 2). This chemical parameter change results in improved adhesion between matrix and fiber layers, reducing cracking under deformation stress while maintaining mechanical strength
Solution Approach 2:
The patent creates a composite matrix system by combining siloxane-containing block copolycarbonates with conventional thermoplastic polymers. This composite material approach leverages the beneficial properties of both materials: the adhesion and flexibility from siloxane blocks and the structural strength from the thermoplastic matrix, resolving the contradiction between strength and cracking resistance
2Strength
If conventional thermoplastic matrices are used in multilayer composite materials, then the materials achieve high rigidity, but they exhibit poor surface quality and paintability
Solution Approach 1:
The patent modifies the chemical composition parameters of the matrix material by incorporating siloxane-containing block copolycarbonates. This change improves surface quality and paintability while maintaining the rigidity provided by the fiber reinforcement and thermoplastic structure
3Strength
If fiber volume content is increased to improve mechanical strength, then the composite materials achieve higher strength, but they become more prone to cracking under deformation stress
Solution Approach 1:
The patent changes the chemical parameters of the matrix material to improve its adhesion properties. This allows the matrix to better bond with fiber layers at higher fiber volume contents, preventing crack propagation and reducing cracking tendency even when mechanical strength is enhanced through increased fiber content
Data Source
Figure 1~2
Figure 3a
Figure 3b
AI summary
The present invention relates to a composite material comprising one or more layers of fiber material and a silicon-containing copolycarbonate as a matrix material. The fiber layer(s) are embedded in the matrix material. The present invention further relates to a method for producing these composite materials and their use in the manufacture of structural or housing components, as well as the structural or housing components themselves.