System for producing a fully impregnated thermoplastic prepreg
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Solution Overview
Problem
Current methods for producing continuous fiber-reinforced thermoplastic composites face challenges in achieving fully impregnated prepregs with high throughput and quality, as high viscosity of molten thermoplastic resins leads to incomplete resin impregnation and fiber orientation issues during consolidation.
Innovation Solution
A continuous manufacturing process involving a system that moves a fabric or mat through a resin application mechanism with an initiator, a press to ensure saturation, and a curing oven at controlled temperatures to polymerize the resin, achieving greater than 95% conversion of reactive resin to thermoplastic polymer, thereby fully impregnating the fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If molten thermoplastic resin is applied to fibers, then resin impregnation occurs, but high viscosity results in incomplete impregnation and low throughput
Solution Approach 1:
The patent changes the physical state of the resin from molten to reactive (low viscosity) state, and changes the temperature parameter from high (molten) to controlled low temperature (40-100°C) range, enabling both complete impregnation and high throughput production
Solution Approach 2:
The patent utilizes phase transition by applying reactive resin in liquid state that polymerizes to form solid thermoplastic polymer, achieving impregnation before final polymerization to ensure complete fiber saturation
2Reliability
If high pressure is applied in consolidation step to promote additional impregnation, then resin impregnation improves, but excessive resin flow occurs and fiber orientation changes detrimentally
Solution Approach 1:
The patent performs resin impregnation during the coating step before consolidation, using reactive resin that cures in place to lock fiber orientation, eliminating the need for high-pressure consolidation and preventing detrimental fiber reorientation
Solution Approach 2:
The patent replaces mechanical pressure-based impregnation with chemical reaction-based impregnation, where reactive resin flows and cures at low pressure, avoiding mechanical disruption of fiber orientation while achieving complete impregnation
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 process enables efficient and complete impregnation of fibers with thermoplastic polymer, reducing manufacturing time and cost, and allowing for the production of flexible prepregs with high fiber content that can be easily molded into desired shapes.
Implementation Method 1
The initiator facilitates in polymerizing the MMA resin to form polymethyl methacrylate (PMMA)
Implementation Method 2
The curing oven is configured to effect polymerization of the MMA resin to form PMMA as the fabric or mat is moved through the curing oven
Data Source
AI summary
According to one embodiment, a system for manufacturing a polymethyl methacrylate (PMMA) prepreg includes a mechanism for continuously moving a fabric or mat and a resin application component that applies a methyl methacrylate (MMA) resin to the fabric or mat. The system also includes a press mechanism that presses the fabric or mat during the continuous movement subsequent to the application of the MMA resin to ensure that the MMA resin fully saturates the fabric or mat. The system further includes a curing oven through which the fabric or mat is continuously moved. The curing oven is maintained at a temperature of between 40° C. and 100° C. to polymerize the MMA resin and thereby form PMMA so that upon exiting the curing oven, the fabric or mat is fully impregnated with PMMA.