Fiber bundle filament spreading device with arc-shaped roller and static roller

Abstract

The invention belongs to the technical field of fiber prepreg tape preparation, and relates to a fiber bundle filament spreading device with an arc-shaped roller and a static roller. The static filament spreading roller group comprises a yarn guide roller (13), a plurality of cylindrical static rollers (6) and two arc-shaped static rollers (11) which are mounted on a roller group mounting plate (2), and is used for guiding the fiber bundles to move along a preset path, improving the uniformity of filament spreading and inhibiting fiber shrinkage, and cooperating with the dynamic filament spreading roller group to apply normal force or frictional resistance to the fibers so as to assist in spreading; the dynamic silk spreading roller set comprises a fiber diffusion plate (7) and a movable roller (5) mounted on the fiber diffusion plate (7), and transverse force, centrifugal force and frictional resistance are transmitted to fiber bundles through reciprocating motion so as to promote widening; a driving mechanism; an amplitude adjusting unit; and a frequency control unit.

Description

Technical Field

[0001] This invention belongs to the field of fiber prepreg tape preparation technology, and specifically relates to a fiber spreading method. Background Technology

[0002] In the production of composite prepregs, uniform fiber bundle spreading is a core step in ensuring prepreg quality. Traditional fiber spreading equipment generally uses cylindrical smooth rollers as the main fiber spreading mechanism, but this has some inherent drawbacks: Insufficient fiber spreading uniformity: The cylindrical roller is in linear contact with the fiber bundle, and the pressure distribution is concentrated on a single generatrix, which can easily lead to inconsistent spreading between the center and the edge of the fiber bundle, forming defects such as "fishbone pattern" or "edge fuzz".

[0003] High risk of fiber damage: Localized pressure concentration can easily cause monofilament breakage, especially for high modulus carbon fibers (such as T800 grade and above), where mechanical property loss can reach 5%-10%.

[0004] Poor dynamic adaptability: When running at high speed, the fluctuation of the friction coefficient between the fiber bundle and the roller surface can easily cause slippage, resulting in unstable fiber spreading width and affecting the consistency of the prepreg surface density (the industry usually requires control of ≤±3%).

[0005] Limited process adjustment: The fiber spreading effect can only be controlled by adjusting the roller spacing or pressure, lacking the ability to actively guide the fiber direction, making it difficult to adapt to the rapid switching requirements of multiple specifications of filament bundles (such as 3K / 6K / 12K). Summary of the Invention

[0006] This invention addresses the problems of low efficiency, high damage rate, and insufficient width control in existing fiber bundle spreading technologies by providing a fiber bundle spreading device with an arc-shaped stationary roller. The core technology lies in utilizing the arc surface structure to solve the problem of uneven force on the fiber bundle on traditional cylindrical rollers, thereby improving the uniformity of spreading. Furthermore, the arc-shaped stationary roller design, similar to a Mayer's rod, not only guides the fiber filaments but also inhibits fiber shrinkage, thus further improving the uniformity of spreading.

[0007] The technical solution adopted in this invention is: a fiber bundle spreading device with an arc-shaped stationary roller, comprising: Frame assembly: includes columns (1) and roller mounting plates (2) that connect the columns for providing support; Static yarn spreading roller group: includes a yarn guide roller (13) mounted on the roller group mounting plate (2), multiple cylindrical static rollers (6) and two arc-shaped static rollers (11), used to guide the fiber bundle to move along a preset path, improve the uniformity of yarn spreading, suppress fiber shrinkage, and work with the dynamic yarn spreading roller group to apply normal force or frictional resistance to the fiber to assist in spreading. Dynamic fiber spreading roller assembly: includes fiber diffuser plate (7) and moving roller (5) mounted on fiber diffuser plate (7), which transmits transverse force, centrifugal force and frictional resistance to fiber bundle through reciprocating motion to promote spreading; Drive mechanism: includes an eccentric cam (5) and a rocker arm (8). The eccentric cam (5) is mounted on the cam mounting plate (3) and is driven to rotate by a motor. The rocker arm (8) connects the eccentric cam (5) and the fiber diffuser plate (7) to convert the cam rotation into the periodic reciprocating motion of the dynamic fiber spreading roller group. Amplitude adjustment unit: By replacing the eccentric cam (5) with different eccentric distances, the amplitude of the reciprocating motion of the rocker arm (8) is controlled; in one embodiment, the eccentric distance of the different eccentric cams is 4-20mm, and the frequency adjustment range is 0-20Hz.

[0008] Frequency control unit: The motor is a variable frequency motor. By adjusting the speed of the motor, the frequency of the reciprocating motion is controlled. The frequency range of the reciprocating motion is 0-20Hz.

[0009] There are four columns (1), and the line connecting the four columns on the same horizontal plane is a rectangle. The roller assembly mounting plate (2) consists of two parallel and symmetrical pieces. Each end of the roller assembly mounting plate is mounted on a column. The base of each column is fixed by two aluminum angle brackets (12) to enhance stability.

[0010] The yarn guide roller (13) is mounted on the threaded screw (14), which is fixed to the roller assembly mounting plate (2) by nuts at both ends. The yarn guide roller (13) is made of stainless steel or wear-resistant polymer (such as PA). The cylindrical stationary roller (6) is a stainless steel mirror roller or a low-roughness roller (such as a polished DP ceramic roller). The cylindrical stationary roller (6) has threads at both ends and is fixed to the roller assembly mounting plate (2) by nuts at both ends. The arc-shaped stationary roller (11) is made of the same material as the cylindrical stationary roller (6). The arc-shaped stationary roller (11) has externally threaded cylinders at both ends and is fixed to the roller assembly mounting plate (2) by nuts at both ends.

[0011] The fiber diffusion plate (7) consists of two symmetrical pieces in a parallel structure. The two ends of the moving roller (5) are respectively fixedly connected to a fiber diffusion plate (which can be bolted). The fiber diffusion plate (7) is located between the roller group fixing plates (2). The swing rod 8 includes a vertical rod and a horizontal rod connected in a vertical shape. The horizontal rod is fixedly connected to the two fiber diffusion plates. The horizontal rod is connected to the two roller group fixing plates through a flange bearing (10). The length of the moving roller (5) is less than that of the stationary roller (6). The outer ring of the eccentric cam (4) has a groove. The vertical rod of the swing rod (8) rests in the groove. The shaft of the eccentric cam is connected to the vertical rod of the swing rod (8) through a constraint spring to ensure that the vertical rod of the swing rod (8) always keeps in contact with the eccentric cam in use. The eccentric cam drives the vertical rod to perform a combined reciprocating motion in the horizontal and vertical directions.

[0012] Each fiber diffusion plate has a centrally symmetrical "wave-shaped" structure. The center of the plate (the center of the length direction) has a circular hole for installing the moving roller (5), and there is a bushing at the corresponding position of the circular hole. The crossbar is fixedly connected to each fiber diffusion plate by a pin (9) (the corresponding positions of the bushing and the crossbar have pin holes).

[0013] A cam mounting plate (3) parallel to the roller assembly fixing plate (2) is installed on a column. The cam mounting plate (3) is provided with an eccentric cam shaft mounting groove. The eccentric cam shaft is fixedly installed on the eccentric cam shaft mounting groove (the eccentric cam shaft mounting groove is a rectangular groove with a thread on one side of the eccentric cam shaft. The eccentric cam shaft is fixed by a nut, so that the position of the eccentric cam shaft can be adjusted along the eccentric cam shaft mounting groove). The eccentric cam (4) is driven to rotate by a variable frequency motor (stepper) installed on the cam mounting plate (3). By replacing the eccentric cam, the swing amplitude of the longitudinal rod can be adjusted.

[0014] The eccentric cam includes at least five cams with different eccentricities. Depending on the required swing amplitude of the longitudinal rod, different eccentric cams are installed on the cam mounting plate (3). In one embodiment, the five different eccentricities are 4mm, 8mm, 12mm, 16mm, and 20mm, corresponding to a reciprocating motion amplitude of 4-20mm.

[0015] Both the cylindrical stationary roller (6) and the moving roller (5) can switch between a fixed mode and a rotating mode: Fixed mode: Roller locking increases frictional resistance between the roller and the fiber bundle to enhance lateral diffusion (increased exit tension).

[0016] Rotation mode: The roller rotates freely with the fiber, resulting in minimal frictional resistance (exit tension ≈ initial tension), thus reducing fiber breakage rate.

[0017] Guide rollers guide the fiber path and reduce friction; two types of stationary rollers guide the path and apply normal or frictional force to the fibers. An eccentric cam drives a rocker arm, causing the moving rollers to reciprocate laterally, efficiently spreading the fiber bundle. The fiber bundle is introduced by the yarn-separating and guiding mechanism, first passing through the guide rollers, then winding in an "S" shape through the stationary and moving rollers. The moving rollers on both sides of the rocker arm move in opposite directions (lever principle), one side lifting while the other falls, generating a large normal force on the fiber bundle. The fibers sliding on the rollers generate frictional resistance, resulting in an exit tension > initial tension. When the lateral separation force inside the fiber bundle is greater than the maximum static friction force applied by the rollers (roller-fiber friction coefficient < fiber opening force), the fiber bundle spreads laterally on the rollers. The lower the friction coefficient, the easier it is to spread. The accumulation of tension further increases the normal component force, promoting lateral widening. The amplitude is adjusted by changing the eccentricity (4-20mm) cam; the frequency is controlled by a stepper motor speed control (1-20Hz) to adapt to different fibers and processes. The constraint spring and the chamfered cam (groove on the outer ring of the wheel) ensure stable reciprocating motion; the positioning guide roller corrects the fiber path in real time to prevent deviation and twisting.

[0018] This invention significantly improves diffusion (width expansion by 3-5 times), reduces damage rate (<5%), and enhances uniformity and production efficiency by dynamically adjusting vibration parameters and using a low-friction design. It is suitable for manufacturing high-precision fiber-reinforced composite materials. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a side view of the present invention; Figure 3 This is a schematic diagram of the arc-shaped roller with grooves according to the present invention; The components include: 1. Column; 2. Roller assembly fixing plate; 3. Cam fixing plate; 4. Eccentric cam; 5. Moving roller; 6. Stationary roller; 7. Fiber diffusion plate; 8. Swing rod; 9. Pin; 10. Flange bearing; 11. Arc roller; 12. Aluminum alloy corner bracket; 13. Yarn guide roller; 14. Spiral screw. Detailed Implementation

[0020] like Figure 1-3 As shown, a fiber bundle spreading device with an arc-shaped stationary roller includes: Frame assembly: includes uprights 1 and roller mounting plates 2 connecting the uprights, for providing support. There are four uprights 1, and the line connecting the four uprights on the same horizontal plane forms a rectangle. The roller mounting plates 2 are two parallel and symmetrical pieces, with each end of the roller mounting plate mounted on one upright. The base of each upright is fixed by two aluminum angle brackets 12 to enhance stability.

[0021] In one embodiment, such as Figure 1 and2 As shown, each roller assembly mounting plate is a rectangular structure of the same size, with corresponding stationary roller mounting holes, column connection holes, screw rod mounting holes, and swing arm mounting holes. The columns are rectangular columns made of high-strength aluminum alloy, with at least one side having a corresponding T-slot for bolting the roller assembly mounting plates (the bolt cap is inserted into the T-slot, passes through the column connection hole, and is then secured with a nut). The columns undergo anodized surface treatment, and aluminum alloy angle brackets are bolted to the bottom to enhance stability.

[0022] Static yarn spreading roller assembly: includes a yarn guide roller 13 mounted on roller assembly mounting plate 2, multiple cylindrical static rollers 6 and two arc-shaped static rollers 11, used to guide the fiber bundle to move along a preset path, improve the uniformity of yarn spreading, suppress fiber shrinkage, and work in conjunction with the dynamic yarn spreading roller assembly to apply normal force or frictional resistance to the fiber to assist in widening.

[0023] like Figure 1 , Figure 2 , Figure 3 As shown, in one embodiment, the guide roller 13 has a groove depth of 7 mm and a width of 12 mm. The guide roller 13 is mounted on a threaded screw 14, which is fixed to the roller assembly mounting plate by nuts at both ends. The guide roller 13 is made of stainless steel or a wear-resistant polymer (such as PA) and is used for centering and initially spreading the fiber bundle. The guide roller 13 and the threaded screw 14 are connected by bearings.

[0024] In one embodiment, the stationary rollers include four stainless steel mirror-finished cylindrical stationary rollers and two stainless steel mirror-finished arc-shaped stationary rollers. Each stainless steel mirror-finished arc-shaped stationary roller has multiple parallel annular grooves with a groove depth of 180 μm, a groove spacing of 220 μm, and a groove width of 350 μm. The arc-shaped stationary rollers are thicker in the middle and thinner at both ends (forming a tapered shape at both ends), and the equation of the parabola of the arc surface (from one end to the other) satisfies y=x² / 900. All stationary rollers are fixed to the roller assembly mounting plate by bolts, and the stationary rollers are connected to the roller assembly mounting plate by bearings. The nuts at both ends serve as limiters.

[0025] Dynamic spreading roller assembly: includes fiber diffuser plate 7 and moving roller (5) mounted on fiber diffuser plate 7, which transmits transverse force, centrifugal force and frictional resistance to the fiber bundle through reciprocating motion to promote spreading.

[0026] The fiber diffusion plate 7 consists of two symmetrical pieces with a parallel structure. Each fiber diffusion plate has a centrally symmetrical "wave-shaped" structure, with a circular hole for mounting the moving roller 5 in the middle of the plate surface (the middle of the length direction), and a bushing at the position corresponding to the circular hole; the crossbar is fixedly connected to each fiber diffusion plate by pins 9 (pin holes are located at the corresponding positions of the bushing and the crossbar). The two ends of the moving roller 5 (25mm in diameter in one embodiment) are fixedly connected to a fiber diffusion plate (which may be bolted). The fiber diffusion plate 7 is located between the roller assembly fixing plates 2. The swing rod 8 includes a vertically connected longitudinal rod and a horizontal rod. The horizontal rod is fixedly connected to the two fiber diffusion plates. The horizontal rod is connected to the two roller assembly fixing plates through a flange bearing 10. The length of the moving roller 5 is less than that of the stationary roller 6. The outer ring of the eccentric cam 4 has a groove. The longitudinal rod of the swing rod 8 rests in the groove. The shaft of the eccentric cam is connected to the longitudinal rod of the swing rod 8 through a constraint spring to ensure that the longitudinal rod of the swing rod 8 always maintains contact with the eccentric cam in use. The eccentric cam drives the longitudinal rod to perform a combined reciprocating motion in the transverse and vertical directions.

[0027] Both the cylindrical stationary and moving rollers can switch between fixed and rotating modes: Fixed mode: The roller is locked, increasing the frictional resistance between the roller and the fiber bundle to enhance lateral diffusion (increased exit tension). Rotating mode: The roller rotates freely with the fiber, resulting in minimal frictional resistance (exit tension ≈ initial tension), reducing fiber breakage rate.

[0028] Drive mechanism: includes eccentric cam 5 and rocker arm 8. Eccentric cam 5 is mounted on cam mounting plate 3 and is driven to rotate by motor. Rocker arm 8 connects eccentric cam 5 and fiber diffuser plate 7, converting cam rotation into periodic reciprocating motion of dynamic fiber spreading roller group.

[0029] A cam mounting plate 3 parallel to the roller assembly fixing plate 2 is installed on a column. The cam mounting plate 3 is provided with an eccentric cam shaft mounting groove. The eccentric cam shaft is fixedly installed on the eccentric cam shaft mounting groove (the eccentric cam shaft mounting groove is a cuboid groove with a thread on one side of the eccentric cam shaft. The eccentric cam shaft is fixed by a nut, so that the position of the eccentric cam shaft can be adjusted along the eccentric cam shaft mounting groove). The eccentric cam 4 is driven to rotate by a variable frequency motor (stepper) installed on the cam mounting plate 3. By replacing the eccentric cam, the swing amplitude of the longitudinal rod can be adjusted.

[0030] The eccentric cam includes at least five cams with different eccentricities. Depending on the required swing amplitude of the longitudinal rod, different eccentric cams are installed on the cam mounting plate (3). In one embodiment, the five different eccentricities are 4mm, 8mm, 12mm, 16mm, and 20mm, corresponding to a reciprocating motion amplitude of 4-20mm.

[0031] Amplitude adjustment unit: By replacing the eccentric cam 5 with different eccentric distances, the amplitude of the reciprocating motion of the rocker arm 8 is controlled; in one embodiment, the eccentric distance of the different eccentric cams is 4-20mm, and the frequency adjustment range is 0-20Hz.

[0032] Frequency control unit: The motor is a variable frequency motor. By adjusting the speed of the motor, the frequency of the reciprocating motion is controlled. The frequency range of the reciprocating motion is 0-20Hz.

[0033] Operation: The fiber bundle passes through the guide roller 13 and winds around the stationary and moving rollers in an "S" shape, keeping the path centered and taut. Select the cam (e.g., 4mm amplitude) and frequency (e.g., 15Hz) according to the fiber and target width. Select the roller mode: Fixed mode: Increases the exit tension (e.g., from 3N to 5.4N), enhancing the lateral separation force. Rotary mode: Maintains the initial tension, reducing frictional heat. Start the motor; the eccentric cam 4 drives the swing arm 8 to reciprocate, causing the moving roller 5 to vibrate, thus achieving lateral unfolding of the fiber bundle.

[0034] Experimental results: Carbon fiber (initial width 6.5mm): at an amplitude of 16mm and a frequency of 12Hz, it expands to 26.5mm (expansion ratio 4.1 times), with a uniformity standard deviation of 0.25mm (better than traditional equipment: ≤3 times, deviation >1mm).

[0035] Damage rate: <3% in rotation mode, <5% in stationary mode (significantly lower than the average >8% of traditional equipment). Applicability: Compatible with carbon fiber (6K / 12K: 6-28mm widening), glass fiber (S2: 8-25mm), aramid fiber (6-15mm), etc., through amplitude modulation and frequency modulation.

[0036] This device combines dynamic adjustment of vibration parameters and dual-mode switching to help the arc roller expand its filament uniformity, guide its direction, and suppress shrinkage to achieve efficient filament widening (4-5 times), low damage (<4%), and high-precision control (deviation <±0.2mm). It has a simple structure, is easy to maintain, and has a compact space, making it suitable for the production of high-performance composite materials.

Claims

1. A fiber bundle spreading device with an arc-shaped stationary roller, characterized in that, include: Frame assembly: includes columns (1) and roller mounting plates (2) that connect the columns for providing support; Static yarn spreading roller group: includes a yarn guide roller (13) mounted on the roller group mounting plate (2), multiple cylindrical static rollers (6) and two arc-shaped static rollers (11), used to guide the fiber bundle to move along a preset path, improve the uniformity of yarn spreading, suppress fiber shrinkage, and work with the dynamic yarn spreading roller group to apply normal force or frictional resistance to the fiber to assist in spreading. Dynamic fiber spreading roller assembly: includes fiber diffuser plate (7) and moving roller (5) mounted on fiber diffuser plate (7), which transmits transverse force, centrifugal force and frictional resistance to fiber bundle through reciprocating motion to promote spreading; Drive mechanism: includes an eccentric cam (5) and a rocker arm (8). The eccentric cam (5) is mounted on the cam mounting plate (3) and is driven to rotate by a motor. The rocker arm (8) connects the eccentric cam (5) and the fiber diffuser plate (7) to convert the cam rotation into the periodic reciprocating motion of the dynamic fiber spreading roller group. Amplitude adjustment unit: By replacing the eccentric cam (5) with different eccentric distances, the amplitude of the reciprocating motion of the rocker arm (8) is controlled; Frequency control unit: The motor is a variable frequency motor. By adjusting the speed of the motor, the frequency of the reciprocating motion is controlled. The frequency range of the reciprocating motion is 0-20Hz.

2. The filament spreading device according to claim 1, characterized in that: There are four columns (1), and the line connecting the four columns on the same horizontal plane is a rectangle. The roller assembly mounting plate (2) consists of two parallel and symmetrical pieces. Each end of the roller assembly mounting plate is mounted on a column. The base of each column is fixed by two aluminum angle brackets (12) to enhance stability.

3. The filament spreading device according to claim 2, characterized in that: The yarn guide roller (13) is mounted on the threaded screw (14), which is fixed to the roller assembly mounting plate (2) by nuts at both ends. The yarn guide roller (13) is made of stainless steel or wear-resistant polymer. The cylindrical stationary roller (6) is a stainless steel mirror roller or a low-roughness roller. The cylindrical stationary roller (6) has threads at both ends and is fixed to the roller assembly mounting plate (2) by nuts at both ends. The arc-shaped stationary roller (11) is made of the same material as the cylindrical stationary roller (6). The arc-shaped stationary roller (11) has externally threaded cylinders at both ends and is fixed to the roller assembly mounting plate (2) by nuts at both ends.

4. The filament spreading device according to claim 3, characterized in that: The fiber diffusion plate (7) consists of two symmetrical pieces in a parallel structure. The two ends of the moving roller (5) are respectively fixedly connected to a fiber diffusion plate. The fiber diffusion plate (7) is located between the roller group fixing plates (2). The swing rod 8 includes a vertical rod and a horizontal rod connected in a vertical shape. The horizontal rod is fixedly connected to the two fiber diffusion plates. The horizontal rod is connected to the two roller group fixing plates through a flange bearing (10). The length of the moving roller (5) is less than that of the stationary roller (6). The outer ring of the eccentric cam (4) has a groove. The vertical rod of the swing rod (8) rests in the groove. The shaft of the eccentric cam is connected to the vertical rod of the swing rod (8) through a constraint spring to ensure that the vertical rod of the swing rod (8) always keeps in contact with the eccentric cam in use. The eccentric cam drives the vertical rod to perform a combined reciprocating motion in the horizontal and vertical directions.

5. The filament spreading device according to claim 4, characterized in that: Each fiber diffusion plate has a centrally symmetrical "wave-shaped" structure. A circular hole for installing the moving roller (5) is provided in the middle of the plate surface, and a bushing is provided at the position corresponding to the circular hole. The crossbar is fixedly connected to each fiber diffusion plate by a pin (9).

6. The filament spreading device according to claim 5, characterized in that: A cam mounting plate (3) parallel to the roller assembly fixing plate (2) is installed on a column. The cam mounting plate (3) is provided with an eccentric cam shaft mounting groove. The eccentric cam shaft is fixedly installed on the eccentric cam shaft mounting groove. The eccentric cam (4) is connected to the cam mounting plate (3) by a frequency converter motor. By replacing the eccentric cam, the swing amplitude of the longitudinal rod can be adjusted.

7. The filament spreading device according to claim 6, characterized in that: The eccentric cam includes at least five cams with different eccentricities. Depending on the required swing amplitude of the longitudinal rod, different eccentric cams are installed on the cam mounting plate (3). In one embodiment, the five different eccentricities are 4mm, 8mm, 12mm, 16mm, and 20mm, corresponding to a reciprocating motion amplitude of 4-20mm.

8. The filament spreading device according to claim 1, characterized in that: Both the cylindrical stationary roller (6) and the moving roller (5) can switch between fixed mode and rotating mode: Fixed mode: Roller locking increases frictional resistance between the roller and the fiber bundle to enhance lateral diffusion; Rotation mode: The roller rotates freely with the fiber, resulting in minimal frictional resistance and reducing fiber breakage rate.

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