Blended fiber mat formation for structural applications
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Solution Overview
Problem
Current methods for forming fiber mats with blended fibers, such as glass and carbon fibers, face challenges in achieving uniform fiber density and orientation due to differences in fiber diameter and interactions, leading to inhomogeneous preforms and difficulties in debundling carbon fibers for production-scale applications.
Innovation Solution
A process and system that simultaneously cuts multiple types of fiber tows into chopped fibers, coats them with a binder, and uses a treatment chamber to form a blended fiber mat, incorporating plasma treatment and particulate fillers to enhance fiber dispersion and orientation, ensuring a homogeneous layer of randomly oriented fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glass fibers and carbon fibers are mixed in a slurry for preform formation, then fiber reinforcement is achieved, but fiber density becomes inhomogeneous due to differences in fiber diameter and interactions
Solution Approach 1:
The invention separates the fiber delivery system into independent channels for different fiber types (glass and carbon), allowing each fiber type to be delivered separately rather than mixed in a slurry. This segmentation prevents fiber aggregation and ensures uniform distribution of each fiber type throughout the preform.
Solution Approach 2:
The invention implements local control of fiber delivery by using separate nozzles or channels positioned at different locations to deliver specific fiber types to specific regions of the preform. This allows optimization of fiber distribution in different areas, ensuring uniform fiber density throughout the entire preform structure.
2Weight of moving object
If carbon fiber tows are used to replace glass fibers, then weight reduction is achieved, but debundling becomes difficult at production scale
Solution Approach 1:
The invention performs preliminary debundling of carbon fiber tows before they are delivered to the preform. By separating the carbon fiber filaments in advance using mechanical means such as rollers or airflow, the system eliminates the difficult debundling step that would otherwise be required at production scale, while still achieving the weight reduction benefits of carbon fiber.
3Shape
If fibers are delivered from a slurry on a contoured screen, then preform shape is formed, but fiber orientation becomes non-random due to fiber movement and aggregation
Solution Approach 1:
The invention introduces an intermediary delivery mechanism (such as a conveyor belt or automated placement system) that transports individual fibers or small fiber groups to the preform formation area. This intermediary system allows fibers to be deposited in a controlled manner that maintains random orientation while still forming the desired preform shape, avoiding the aggregation and preferential orientation that occurs with slurry-based methods.
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 process achieves a uniform distribution of fibers, improving the strength and quality of molded parts by ensuring even fiber distribution and orientation, suitable for structural applications like vehicle and aerospace components.
Implementation Method 1
uses a treatment chamber to form a blended fiber mat, incorporating plasma treatment and particulate fillers to enhance fiber dispersion and orientation
Data Source
AI summary
A process and system are provided for introducing a blend of chopped and dispersed fibers on an automated production line amenable for inclusion in molding compositions as a blended fiber mat for structural applications. The blend of fibers are simultaneously supplied to an automated cutting machine illustratively including a rotary blade chopper disposed above a vortex supporting chamber. The blend of chopped fibers and binder form a chopped mat. The chopped mat has a veil mat placed on either side, and is consolidated with the veil mat using heated rollers maintained at the softening temperature of thermoplastic binder, with consolidated mats being amenable to being stored in rolls or as flat sheets. A charge pattern is made using the consolidated mat, and the charge pattern can be compression molded in a mold maintained at a temperature lower than the melting point of the thermoplastic fibers.