Carbon Fiber Random Mat Production Using Segmented Wide Tows
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Solution Overview
Problem
The production of carbon fiber composite materials with high mechanical properties is costly due to the need for complex machinery and expensive fiber tows, limiting their widespread industrial application.
Innovation Solution
A method for producing a carbon fiber random mat using wider fiber tows (e.g., 12K or 24K) with controlled fiber bundle sizes and angles, processed using conventional machinery to achieve high mechanical properties without increasing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wider fiber tows (12K or 24K) are used to reduce production costs, then manufacturing cost decreases, but mechanical properties and followability of carbon fibers deteriorate
Solution Approach 1:
The patent divides the wide fiber tow (12K or 24K) into multiple narrow bundles (each containing 90-1000 fibers) through a segmentation process. This is achieved by controlling the number of revolutions of the guide roller relative to the paying-out roller, which mechanically separates the wide tow into finer bundles that maintain excellent mechanical properties while utilizing the cost-effective wider fiber tow material
Solution Approach 2:
The patent changes the parameter of fiber bundle configuration by precisely controlling the average number of fibers per bundle (90-1000) and the standard deviation (50-500) through adjustment of roller revolution ratios. This parameter control transforms the properties of the fiber assembly, enabling wide tows to produce bundles with optimal mechanical characteristics
2Strength
If the proportion of carbon fiber bundles is increased to improve mechanical properties, then mechanical properties improve, but followability to small parts and uniformity deteriorate
Solution Approach 1:
The patent optimizes the parameter of bundle fineness by controlling the average number of fibers per bundle to be 90-1000, which represents an optimal range that balances mechanical strength and followability. The standard deviation control (50-500) further refines this parameter to ensure uniformity while maintaining good drape and conformability to complex shapes
3Strength
If complex machinery equipment is used to produce refined carbon fiber bundles, then mechanical properties improve, but production cost increases
Solution Approach 1:
The patent employs conventional paying-out roller and guide roller equipment that performs multiple functions: it pays out the fiber tow, segments it into bundles, and controls the bundle characteristics all in one process. This multi-functional use of simple equipment avoids the need for complex specialized machinery while achieving excellent mechanical properties
Solution Approach 2:
The segmentation process utilizes the natural properties of the fiber tow and the differential rotation between rollers to automatically divide the wide tow into appropriate bundle sizes. The system self-regulates the bundle formation through the revolution ratio control without requiring additional complex processing equipment
Data Source
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AI summary
The present invention relates to a random mat material and its production method, and specifically, to a carbon fiber random mat and carbon fiber composite material made of the mat which has high mechanical properties. The invention relates to a process for producing such fiber random mat without complex steps.