Thin Plate Molding Composition for Lightweight High-Rigidity Parts
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Solution Overview
Problem
Existing molding materials struggle to achieve a balance between thin plate moldability, specific strength, and specific rigidity, particularly when forming complex shapes like beads, due to high glass fiber density and reduced fluidity, which hinders weight reduction and mechanical property enhancement.
Innovation Solution
A thin plate molding material comprising a resin composition with a specific ratio of reinforced fibers (21-28 vol%) and fiber length (10-60 mm) combined with a resin component (49-56 vol%), along with fillers like hollow glass or milled carbon fibers, to enhance moldability and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glass fiber content is increased to improve mechanical properties, then specific strength and specific rigidity are improved, but density increases and weight reduction effect decreases
Solution Approach 1:
The patent changes the fiber length parameter from conventional short fibers to long fibers (10-60mm), which fundamentally alters the reinforcement mechanism. Long fibers provide better structural integrity and strength per unit weight compared to short fibers, achieving improved specific strength without proportionally increasing density
Solution Approach 2:
The patent uses a composite approach by combining long glass fibers with a specific resin composition (unsaturated polyester resin with controlled molecular weight and styrene content). This composite structure optimizes the strength-to-weight ratio by selecting materials that provide high specific strength while controlling overall density
2Strength
If glass fiber content is increased to improve mechanical properties, then specific rigidity is improved, but fluidity of molding material is reduced and thin plate moldability deteriorates
Solution Approach 1:
The patent optimizes multiple parameters simultaneously: fiber length (10-60mm), resin molecular weight (2000-10000), and styrene content (30-70 mass%). This multi-parameter optimization achieves a balance where long fibers provide rigidity while the controlled resin properties maintain sufficient fluidity for thin plate molding
Solution Approach 2:
The patent creates local quality variations in the molding material by controlling fiber distribution and resin composition. The long fibers are distributed to provide localized reinforcement where rigidity is needed, while the resin matrix maintains fluidity in regions requiring flow during molding
3Weight of moving object
If plate thickness is reduced to achieve weight reduction, then weight and material consumption are reduced, but mechanical properties become insufficient
Solution Approach 1:
The patent changes the fundamental parameter of fiber length to long fibers (10-60mm), which provides superior strength per unit thickness. This allows thin plates to achieve sufficient mechanical properties because long fibers span across potential stress concentration points and provide continuous reinforcement pathways
Solution Approach 2:
The patent employs a composite material system where long glass fibers embedded in a specifically formulated resin matrix create a lightweight structure with high strength-to-weight ratio. This composite enables thin plate construction that maintains mechanical integrity
4Shape
If resin component ratio is decreased to increase filling material content for smoothness, then surface quality is improved, but thin plate moldability deteriorates
Solution Approach 1:
The patent optimizes the resin component ratio (45-55 mass%) along with fiber length and molecular weight parameters. This balanced composition provides enough resin to maintain fluidity and fill thin mold cavities while allowing sufficient filling material content for surface smoothness
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 material achieves excellent moldability for thin plates with high specific strength and rigidity, enabling lightweight components with complex shapes while maintaining structural integrity.
Implementation Method 1
a resin composition containing a curable polymer having a double bond and a polymerizable monomer
Data Source
AI summary
A thin plate molding material includes a resin composition containing a resin component and a filling material, and a reinforced fiber with a predetermined fiber length. The content ratio of the reinforced fiber is a predetermined ratio. The mixing ratio of the resin component is a predetermined ratio.