Adjustable Tine Apparatus for Binder Resin Control on Fiber Threads
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Solution Overview
Problem
Existing filament winding processes for laminate production face issues with excessive binder resin loss and variability in laminate weight due to factors like temperature, thread speed, and thread quality, leading to inefficiencies and increased production costs.
Innovation Solution
A binder resin regulator apparatus with adjustable tine sets that form a rectilinear or angular guide track for the thread, allowing controlled and adjustable scraping of excess resin, ensuring consistent resin distribution and reducing waste, featuring a rotatable actuator for automatic displacement of tine sets and integration with programmable devices for optimized scraping sequences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the fibre thread is pulled through a scraper die or passive flat scraper to remove excess binder resin, then the binder resin loss is reduced, but the fibre thread may break when the knot passes the scraper
Solution Approach 1:
The invention replaces static scrapers with dynamic rotating rollers that actively rotate to remove excess resin. The rotation creates a gentler, more controlled scraping action that reduces the risk of fibre thread breakage while maintaining effective resin removal. The rollers can be adjusted in speed and pressure to adapt to different thread conditions.
Solution Approach 2:
The invention changes the operational parameters of the scraping mechanism by introducing controlled rotation to the rollers. This dynamic parameter change allows the system to maintain optimal scraping effectiveness while reducing mechanical stress on the fibre thread, particularly when knots pass through the system.
2Manufacturing precision
If the fibre thread is saturated with binder resin to prevent dry portions in the laminate, then the laminate quality is improved, but the excess binder resin running off between the filament winder and mandrel increases material waste
Solution Approach 1:
The rotating rollers perform preliminary scraping of excess binder resin immediately after impregnation, before the thread reaches the winding area. This preliminary action prevents excess resin from running off during the winding process, thereby reducing material waste while maintaining adequate saturation for laminate quality.
Solution Approach 2:
The invention extracts the excess binder resin removal function from the passive scraping system and implements it as an active rotating roller system positioned strategically to remove excess resin before it can cause waste during winding.
3Manufacturing precision
If the saturation of binder resin is adjusted by changing temperature, thread speed, or thread quality, then the resin distribution can be optimized, but it becomes difficult to maintain constant laminate weight
Solution Approach 1:
The rotating rollers provide a mechanical parameter change approach to control resin distribution, independent of temperature, speed, or thread quality variations. By adjusting roller speed, pressure, or surface properties, the system maintains consistent resin removal effectiveness regardless of other process parameter fluctuations, thereby stabilizing laminate weight.
Solution Approach 2:
The active rotating roller system provides a more responsive and controllable mechanism for resin removal, allowing for real-time adjustment to maintain constant laminate weight even when other process parameters vary.
4Manufacturing precision
If the rotational speed of the mandrel is adjusted to maintain constant filament amount on conical mandrel, then the filament distribution is improved, but the production time increases and costs increase
Solution Approach 1:
The invention extracts the resin control function from the mandrel rotation system and implements it separately through rotating rollers. This separation allows the mandrel to rotate at optimal speed for production efficiency while the rollers independently control resin distribution, eliminating the need to slow down mandrel rotation for resin management.
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 apparatus effectively reduces binder resin loss and maintains consistent laminate weight by optimizing resin distribution, enhancing production efficiency and reducing costs through controlled scraping and automatic adjustment mechanisms.
Implementation Method 1
The first tine set and the second tine set are arranged parallel and displaceably to each other in an axial direction. In a neutral position, the tine sets form a rectilinear guide track for the thread, and, in a displaced position, they form an angular guide track.
Data Source
AI summary
An apparatus is arranged to control a quantity of binder resin that is carried by a thread, the apparatus comprising at least one first tine row being arranged parallel and displaceably to at least one second tine row, wherein a guide track for the thread is formed transversely to the tine rows and a displacement of at least one tine row the guide track. A method for controlling the quantity of binder resin by using tines is described as well.