Thermoplastic-Surfaced Prepreg Welding for Fast Composite Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing fiber-reinforced composite materials face challenges in manufacturing complex shapes due to time-consuming bonding processes using adhesives or mechanical methods, and they lack sufficient bonding strength and heat resistance for applications like aircraft structural members.
Innovation Solution
A prepreg composed of reinforcing fibers, a thermosetting resin, and a thermoplastic resin, with a thermoplastic resin on the surface, allows for welding and improved bonding strength through a controlled reaction with dual curing agents, enabling faster molding and enhanced dimensional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive bonding method is used to bond fiber-reinforced composite materials, then bonding strength is improved, but manufacturing time increases and adhesion reliability is insufficient
Solution Approach 1:
The patent replaces adhesive bonding (chemical/mechanical process) with welding (thermal process) by incorporating thermoplastic resin into the prepreg. The thermoplastic resin allows direct welding bonding between composite members, eliminating the need for adhesive application, spreading, and curing processes, thus reducing manufacturing time while maintaining bonding strength.
Solution Approach 2:
The patent changes the bonding mechanism from chemical adhesion to thermal welding by controlling the melting and solidification parameters of the thermoplastic resin during the bonding process. This parameter change enables rapid bonding without the time-consuming adhesive curing process.
2Strength
If mechanical bonding method is used to bond fiber-reinforced composite materials, then bonding strength is improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent replaces mechanical bonding methods (bolts, rivets, screws requiring drilling and fastening operations) with thermal welding. This substitution eliminates complex mechanical fastening processes and reduces manufacturing complexity while achieving equivalent or superior bonding strength.
3Speed
If thermoplastic resin is used as matrix material, then bonding speed is improved, but heat resistance and chemical resistance deteriorate
Solution Approach 1:
The patent uses a composite resin system combining thermosetting resin (for heat and chemical resistance) with thermoplastic resin (for bonding speed and weldability). The thermosetting resin provides the structural integrity and environmental resistance, while the thermoplastic resin enables rapid welding bonding, achieving both fast bonding speed and high heat resistance in the final composite material.
4Temperature
If thermosetting resin is used as matrix material, then heat resistance and chemical resistance are improved, but bonding speed deteriorates
Solution Approach 1:
The patent combines thermosetting resin (providing heat and chemical resistance) with thermoplastic resin (providing fast bonding speed). The thermoplastic resin component enables rapid welding while the thermosetting resin matrix maintains high heat resistance, resolving the contradiction between bonding speed and thermal stability.
5Ease of manufacture
If drilling holes for mechanical bonding is performed, then bonding capability is improved, but material strength decreases and manufacturing time increases
Solution Approach 1:
The patent replaces mechanical drilling and fastening operations with thermal welding. This eliminates the need to drill holes for bolts or rivets, preserving the full material strength of the composite members while enabling effective bonding. The thermal welding process bonds surfaces directly without creating stress concentration points from holes.
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 prepreg and laminate achieve rapid bonding, high strength, and excellent interlaminar toughness, reducing manufacturing time and cost while maintaining structural integrity in complex shapes.
Implementation Method 1
The fiber-reinforced composite material using a thermoplastic resin as the matrix bonds between members by welding
Implementation Method 2
a prepreg composed of reinforcing fibers, a thermosetting resin, and a thermoplastic resin, with a thermoplastic resin on the surface, allows for welding and improved bonding strength through a controlled reaction with dual curing agents
Data Source
AI summary
A prepreg includes composition elements [A], [B], and [C] described below,[A] a reinforcing fiber,[B] a thermosetting resin, and[C] a thermoplastic resin. [C] is present on a surface of the prepreg, [B] contains a first curing agent [b1] and a second curing agent [b2], and the reinforcing fiber of [A] that crosses over a boundary surface between a resin region containing [B] and a resin region containing [C] and that is in contact with both resin regions is present.