Thread Structure with Thermoplastic Matrix for Uniform Composite
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Solution Overview
Problem
Existing prepreg structures face challenges in achieving uniform stabilization and material properties across the entire surface of the final product, with issues such as air inclusions and variable material characteristics due to gaps between thread bundles.
Innovation Solution
A thread structure with thermoplastic matrix-filled thread bundles, where the matrix flows between bundles during pressing to create a uniformly composite material, ensuring homogeneous material properties and allowing for easy adjustment of thread dimensions and lattice values, using compatible thermoplastic or thermosetting plastics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If gaps are left between thread bundles during manufacturing, then the thermoplastic matrix can flow into spaces during pressing to ensure uniform laying, but air inclusions may remain in the final product
Solution Approach 1:
The patent applies preliminary action by pre-positioning the thermoplastic matrix within the thread bundles before the pressing process. The matrix is incorporated into the bundles at controlled amounts (30-70% of bundle cross-section), creating a reservoir that will flow outward during pressing to fill gaps between bundles, ensuring uniform material distribution while minimizing air entrapment.
Solution Approach 2:
The patent utilizes parameter changes by controlling the thermal and pressure conditions during the pressing process. By applying specific temperature ranges (above the melting point of the thermoplastic matrix) and pressure conditions, the matrix transitions from a solid state within bundles to a flowing state that fills inter-bundle spaces, achieving uniform impregnation while expelling air inclusions.
2Volume of moving object
If thread bundles are tightly packed, then the structure is more compact, but the thermoplastic matrix cannot flow uniformly into spaces between bundles
Solution Approach 1:
The patent applies local quality by creating non-uniform distribution of the thermoplastic matrix - concentrating it within the thread bundles at specific volume fractions (30-70% of bundle cross-section). This localized concentration ensures that when pressing occurs, sufficient matrix material is available at each bundle location to flow into adjacent gaps, achieving uniform overall distribution while maintaining compact bundle structure.
Solution Approach 2:
The patent uses partial action by incorporating the thermoplastic matrix only in specific portions of the thread bundle cross-section (30-70% filling ratio), rather than completely filling all spaces. This partial impregnation allows the matrix to flow outward during pressing to fill the remaining gaps between bundles, achieving uniform distribution without requiring excessive matrix material that would compromise compactness.
3Manufacturing precision
If the thermoplastic matrix volume in bundles is increased, then uniform impregnation of the final product is achieved, but the production cost increases
Solution Approach 1:
The patent applies partial action by determining the optimal matrix volume fraction (30-70% of bundle cross-section) that is sufficient to achieve uniform impregnation during pressing without excessive material usage. This optimized quantity ensures complete gap filling between bundles while minimizing matrix consumption and associated costs.
Solution Approach 2:
The patent uses parameter changes by optimizing the matrix volume fraction within specific ranges (30-70%) and controlling the pressing parameters (temperature, pressure, time) to achieve maximum impregnation efficiency. By adjusting these parameters, the process achieves homogeneous material properties with minimal matrix material, reducing production costs while maintaining quality.
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 solution results in a dimensionally stable, homogeneous material with improved tensile strength and reduced air inclusions, enabling reliable predictions of material characteristics and flexible processing options, including capillary and chemical anchoring, while maintaining low production costs.
Implementation Method 1
the thermoplastic matrix is present in a volume which, in a subsequent pressing process under the known influencing factors of pressure, temperature and time, can flow into the spaces provided between the individual fiber bundles
Implementation Method 2
the thermoplastic matrix in the individual thread bundles stabilizes not only the thread bundles but also the entire thread structure
Implementation Method 3
a lower pressure is sufficient to bring the thermoplastic materials into capillary bond with each other
Data Source
Figure 1~3
Figure 4~6
AI summary
The present invention relates to a thread structure with thread bundles which are laid in parallel with respect to one another, composed of individual threads which are mutually crossing each other and form spacings between the thread bundles, each of which being provided with a thermoplast matrix in a volume-filling manner in the manner of a composite material.