Carbon Fiber Bundle Spreading via Solvent Sizing Removal
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Solution Overview
Problem
Carbon fiber reinforced thermoplastic composites face challenges in achieving excellent mechanical properties due to low elongation and wettability issues with matrix resin, leading to high manufacturing costs and low productivity, especially when using continuous carbon fibers with 3000 fiber bundles.
Innovation Solution
A method involving sizing continuous carbon fibers with a water-soluble resin and removing the sizing agent using a solvent with a solubility parameter difference of 2.0 or below, followed by impregnating the carbon fibers in thermoplastic resin, which widens the fiber bundle width to 4-8 times the initial, improving handling and impregnation properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional sizing agents are used on carbon fibers, then handling and wettability are improved, but mechanical properties of the composite degrade due to poor spreading characteristics of carbon fiber bundles
Solution Approach 1:
The patent removes the sizing agent from the carbon fiber surface through treatment with a specific solvent system, extracting the harmful coating that prevents proper bundle spreading while retaining the underlying fiber structure intact
Solution Approach 2:
The patent changes the chemical parameters of the fiber surface by controlling the solubility parameter difference between the sizing agent and treatment solvent to be 2.0 or less, enabling selective removal of the sizing agent without damaging the carbon fibers
2Ease of manufacture
If 3000 fiber bundles are used for continuous carbon fiber reinforced thermoplastic composites, then manufacturing can proceed, but costs increase and productivity decreases
Solution Approach 1:
The patent performs preliminary treatment of the carbon fiber bundles before impregnation, removing sizing agents and improving spreading characteristics in advance, which enables more efficient subsequent processing and higher productivity
Solution Approach 2:
The patent works with divided carbon fiber bundles rather than requiring continuous 3000-fiber bundles, allowing flexible processing and impregnation of smaller, more manageable fiber groups that improve manufacturing efficiency
3Ease of operation
If carbon fiber bundles are not properly spread, then handling is easier, but impregnation quality and mechanical properties suffer
Solution Approach 1:
The patent uses a solvent system with specific solubility parameters as an intermediary to selectively remove sizing agents from carbon fiber surfaces, enabling proper bundle spreading and impregnation without compromising handling during processing
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 enhances mechanical properties such as flexural strength and stiffness, reduces manufacturing costs, and increases productivity by allowing the use of fewer, larger fiber bundles, resulting in composites with improved impregnation and mechanical performance.
Implementation Method 1
removing the sizing agent by using a solvent having a difference of solubility parameter with the water soluble resin of 2.0 or below based on SI units (MPa1/2)
Data Source
AI summary
The present disclosure includes a continuous carbon fiber reinforced thermoplastic plastic composite. The continuous carbon fiber reinforced thermoplastic plastic composite includes a continuous carbon fiber impregnated in thermoplastic resin, and the continuous carbon fiber is a continuous carbon fiber has the width of 4 times to 8 times as wide as the original fiber bundle.