Unidirectional Prepreg Auxiliary Fiber Arrangement

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Solution Overview

Problem

The existing UniDirectional (UD) prepreg materials face limitations in post-processing due to fiber arrangement scattering caused by shrinkage and expansion, restricting the variety of possible post-processes and desirable appearances in electronic device housings.

Innovation Solution

Incorporating auxiliary fibers that cross the reinforced fibers to maintain their arrangement, which are then impregnated and cured with a coupling material, allowing for stable post-processing and enhanced appearance options.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If UD prepreg is post-processed before composite material formation, then appearance variety is improved, but fiber arrangement stability deteriorates due to shrinkage and expansion

Engineering Contradiction:

Improvepost-processing varietyVSAvoidfiber arrangement stability

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The patent applies preliminary action by pre-forming the composite material board with basic materials stacked and attached under the UD prepreg before post-processing. This preliminary composite structure provides mechanical support that prevents fiber arrangement scattering during subsequent post-processing operations, allowing appearance variety to be achieved while maintaining fiber stability.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses composite materials by combining basic materials (such as foam or honeycomb structures) with the UD prepreg to form a composite material board. This composite structure provides the necessary mechanical support to maintain fiber arrangement stability during post-processing while enabling various appearance treatments on the UD prepreg surface.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If UD prepreg is post-processed independently before composite formation, then manufacturing flexibility is improved, but fiber arrangement scattering occurs

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidfiber arrangement precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent reverses the conventional sequence by performing preliminary composite material formation before post-processing. The basic materials are stacked and attached under the UD prepreg to create a stable substrate, then post-processing is performed on the already-supported UD prepreg, maintaining both manufacturing flexibility and fiber arrangement precision.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The basic materials serve as an intermediary structure between the UD prepreg and the post-processing operations. This intermediary composite material board provides mechanical support that prevents fiber scattering during post-processing while allowing the UD prepreg to undergo various appearance treatments.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Stability of the object's composition

If basic materials are stacked and attached under UD prepreg, then fiber arrangement stability is improved, but process complexity increases

Engineering Contradiction:

Improvefiber arrangement stabilityVSAvoidcomposite material formation complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent applies segmentation by dividing the manufacturing process into distinct stages: first forming the composite material board by stacking and attaching basic materials, then performing post-processing on the UD prepreg separately. This segmentation allows each stage to be optimized independently, maintaining fiber stability without excessively increasing overall process complexity.

Inventive Principle:

Principle #1Segmentation

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

This approach enables stable fiber arrangement during post-processing, expanding the range of possible post-processes and achieving a desirable appearance for electronic device housings without fiber scattering, thus improving the manufacturing flexibility and aesthetic appeal.

Implementation Method 1

The plurality of reinforced fibers and the at least one auxiliary fiber are impregnated with a coupling material

Methodology Applied

Scientific EffectImpregnation: Absorption (physical)

Implementation Method 2

the coupling material is cured with the plurality of reinforced fibers and the at least one auxiliary fiber

Methodology Applied

Scientific EffectCuring: Chemical Bonding

Data Source

PatentUS10443162B2Unidirectional prepreg and processing method thereof

Publication Date: 2019.10.15 SAMSUNG ELECTRONICS CO LTD

AI summary

A UniDirectional (UD) preimpregnated material (prepreg) and method of production are provided. A plurality of reinforced fibers are arranged in one direction. At least one auxiliary fiber is arranged such that it crosses the plurality of reinforced fibers to maintain the arrangement of the plurality of reinforced fibers. The plurality of reinforced fibers and the at least one auxiliary fiber are impregnated with a coupling material, and the coupling material is cured with the plurality of reinforced fibers and the at least one auxiliary fiber.