Carbon Fiber Package Winding for High Density and Shape Stability
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Solution Overview
Problem
Carbon fiber packages with high fineness (25,000 to 35,000 deniers) face issues with irregular impregnation and looseness due to gaps between winding units, leading to suboptimal shape and increased forming time, especially in large structural applications.
Innovation Solution
A carbon fiber package is formed by winding bundles with a specific range of fineness, traverse angles, and fractional winding ratios (0.07 to 0.93 and 13 to 14°) to achieve high wound density and prevent looseness, using a square-end type bobbin configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If carbon fiber bundles with 7,000 to 20,000 deniers are lined up to form large structural materials, then the required fineness can be obtained, but gaps are opened between lining up units causing irregular impregnation of resin
Solution Approach 1:
The invention divides the carbon fiber bundle into multiple sub-bundles (typically 2-10 sub-bundles) within the larger bundle structure. Each sub-bundle can be independently wound and positioned, eliminating gaps between lining up units while maintaining the required overall fineness. This segmentation allows continuous impregnation without the irregularities caused by gaps between separate bundles.
Solution Approach 2:
Instead of lining up bundles in a linear arrangement that creates gaps, the invention transitions to a dimensional approach where multiple sub-bundles are arranged concentrically or in layered patterns around the bobbin. This dimensional reorganization eliminates the gap problem inherent in linear lining up while achieving the same fineness requirement.
2Volume of moving object
If carbon fiber bundles with 7,000 to 20,000 deniers are used for large and thick formed bodies, then the required thickness can be achieved, but the laminating number and winding number must be increased leading to increased forming time
Solution Approach 1:
The invention merges multiple sub-bundles into a single integrated package structure with fineness of 25,000 to 35,000 deniers. By combining the functionality of multiple thinner bundles into one thicker package that maintains structural integrity, the laminating number is reduced. This allows large and thick formed bodies to be produced with fewer layers, significantly reducing forming time while achieving the required thickness.
3Productivity
If a package of carbon fibers with large number of filaments and large thickness is available, then the laminating number can be reduced and forming time shortened, but the package must maintain high wound density and resistance to looseness
Solution Approach 1:
The invention optimizes critical parameters including the fineness range (25,000 to 35,000 deniers), the number of sub-bundles (2-10), and the winding tension parameters. These parameter changes ensure that the package achieves both high wound density for shape stability and resistance to looseness, while simultaneously enabling reduced laminating numbers and improved forming efficiency. The specific parameter ranges are calibrated to balance productivity and reliability requirements.
4Reliability
If the fractional portion W0 of the winding ratio W is in the range of 0.12 to 0.88 as in conventional packages, then the package can be formed, but the wound density is insufficient and the package becomes loose
Solution Approach 1:
The invention changes the fractional portion W0 of the winding ratio to specific ranges (0.01 to 0.06 or 0.94 to 0.99) rather than using conventional values of 0.12 to 0.88. This parameter change fundamentally alters the winding pattern to achieve both high wound density and package tightness. The new fractional portions create a winding pattern that prevents looseness while maintaining accurate wound density, resolving the contradiction between reliability and manufacturing precision.
Data Source
Figure 1~2
AI summary
It is an object of the present invention to provide a package in an optimal form obtained by winding a carbon fiber bundle having a fineness of 25,000 to 35,000 deniers, which has a high wound density and is less apt to become loose, and a method for producing the same. The present invention is a carbon fiber package obtained by winding a carbon fiber bundle having a fineness of 25,000 to 35,000 deniers on a bobbin in a square-end type, wherein the width per unit fineness of the carbon fiber bundle is in the range of 0.30×10-3 to 0.63×10-3 mm/denier, the traverse angle in the beginning of winding is in the range of 13 to 14°, the traverse angle in the end of winding is 3° or larger, and the fractional portion W0 of the winding ratio W is in the range of 0.07 to 0.08.