Urethane Methacrylate Prepreg Viscosity Control
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Solution Overview
Problem
Fiber-reinforced resin composite materials face challenges with prepregs that require high temperatures for curing, leading to unstable product-weight and poor workability due to resin viscosity issues and catalyst-induced curing reactions, affecting the quality and handleability of molded articles.
Innovation Solution
A prepreg composition including a urethane (meth)acrylate, a polymerization initiator, and an acid-blocked amine catalyst, along with reinforcement fibers, is developed, where the urethane (meth)acrylate is a reaction product of a polyisocyanate and a hydroxyl group-containing compound, and the amine catalyst has a dissociation temperature of 50° C. to 70° C., ensuring stable viscosity and reduced thickening, allowing for improved workability and product stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a radically polymerizable resin composition is used to achieve high productivity, then curing speed is improved, but interlayer adhesion becomes insufficient
Solution Approach 1:
The invention uses a composite resin composition combining radically polymerizable resin (for fast curing) and thermosetting resin (for strong adhesion). This dual-resin system allows the prepreg to cure quickly while maintaining excellent interlayer adhesion, resolving the contradiction between productivity and reliability.
Solution Approach 2:
The invention adjusts the composition ratio and molecular weight parameters of the resin components to optimize both curing speed and adhesion. By controlling the ratio of radically polymerizable resin to thermosetting resin and selecting appropriate molecular weights, the system achieves fast curing without sacrificing interlayer bonding strength.
2Ease of operation
If UV curing is applied to improve workability, then tack property is improved, but interlayer adhesion becomes insufficient
Solution Approach 1:
The dual-resin system enables UV curing to provide immediate tack for handling while the thermosetting resin component ensures strong interlayer adhesion during subsequent heating. This resolves the contradiction between ease of operation and reliability.
3Ease of manufacture
If resin composition viscosity is reduced to improve impregnation, then impregnating properties are improved, but fiber movement increases and product-weight becomes unstable
Solution Approach 1:
The invention optimizes the viscosity parameter of the resin composition to achieve a balance: low enough to ensure good impregnation of reinforcement fibers, but high enough to prevent excessive fiber movement and maintain stable product weight. This is achieved by selecting appropriate molecular weights and composition ratios.
4Stability of the object's composition
If resin composition viscosity is increased to reduce fiber movement, then product-weight stability is improved, but impregnation properties decrease
Solution Approach 1:
The invention finds an optimal viscosity range through parameter optimization, ensuring the resin is viscous enough to stabilize fiber position but remains fluid enough to penetrate and impregnate the reinforcement fibers effectively during the manufacturing process.
5Productivity
If catalyst is added to accelerate curing, then curability is improved, but viscosity increases and pot life shortens
Solution Approach 1:
The invention optimizes the catalyst concentration parameter to achieve sufficient curing acceleration while minimizing viscosity increase and pot life reduction. By carefully controlling the amount and type of catalyst, the system maintains adequate working time while ensuring complete curing.
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 prepreg with stable product-weight and excellent workability, reducing the occurrence of poor molding and enhancing the handleability of molded articles, suitable for various applications including automotive, aerospace, and building components.
Implementation Method 1
a radically polymerizable resin composition capable of achieving high productivity has been under development
Implementation Method 2
an amine catalyst (C)
Data Source
AI summary
Provided is a prepreg including: a resin composition including a urethane (meth)acrylate (A), a polymerization initiator (B), and an amine catalyst (C); and reinforcement fibers (D). The urethane (meth)acrylate (A) is a reaction product of a polyisocyanate compound (al) and a hydroxyl group-containing compound (a2), the polyisocyanate compound (a1) including polymethylene polyphenyl polyisocyanate and diphenylmethane diisocyanate, the hydroxyl group-containing compound (a2) including a compound having a hydroxyl group and a (meth)acryloyl group. This prepreg has excellent workability and product stability, reduces the occurrence of poor molding, and allows a molded article having excellent workability and handleability to be obtained, and therefore can be used in, for example, automobile components, railway vehicle components, aerospace craft components, ship components, housing equipment components, sporting components, light vehicle components, building and civil engineering components, and casings of OA equipment.