Carbon Fiber Thread Production System with Jointed Portion Separation
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Solution Overview
Problem
Existing methods for producing carbon fiber threads result in lower strength at jointed portions, leading to quality degradation and operational challenges due to mal-detection of these areas, which complicates the production process and increases costs.
Innovation Solution
A production system that includes an oxidization oven, carbonization furnace, winder with a switchover mechanism, detection means for thickness differences, and positional information-acquisition means to identify and separate carbon fiber threads with and without jointed portions, allowing precise cutting and winding around different bobbins to prevent jointed portion mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If continuous heat treatment is applied to carbon fiber thread precursors with jointed portions, then productivity is improved, but the jointed portions suffer from heat accumulation causing fiber breakage and quality degradation
Solution Approach 1:
The jointed portion is subjected to oxidization treatment in advance before the continuous heat treatment process. This preliminary oxidization creates a more heat-resistant structure at the jointed portion, preventing fiber breakage during subsequent carbonization while maintaining continuous production efficiency
Solution Approach 2:
The oxidization treatment changes the chemical and physical parameters of the jointed portion, making it more resistant to heat accumulation. This parameter change allows the jointed portion to withstand the high temperatures of continuous carbonization without suffering fiber breakage
2Device complexity
If visual inspection is used to detect jointed portions, then device complexity is reduced, but detection precision deteriorates leading to mal-detection and quality issues
Solution Approach 1:
The manual visual inspection method is replaced with an automated optical detection system. This substitution uses optical sensors and imaging technology to automatically detect jointed portions, eliminating mal-detection issues while maintaining relatively simple system architecture
Solution Approach 2:
An optical detection system acts as an intermediary between the jointed portion and the control system. This intermediary automatically identifies jointed portions and provides positional information, enabling precise detection without requiring complex manual inspection procedures
3Ease of operation
If jointed portions are not separately managed, then ease of operation is improved, but product quality deteriorates due to jointed portion mixing
Solution Approach 1:
The winding process is segmented into two separate operations: one for jointed portions and one for non-jointed portions. This segmentation is achieved by using separate bobbins and controlled winding operations, ensuring that jointed portions do not mix with non-jointed portions while maintaining operational simplicity through automation
Solution Approach 2:
The detection system provides feedback information about the position of jointed portions to the winding control system. This feedback enables the winder to automatically adjust its operation, directing jointed portions to appropriate bobbins and preventing mixing, thereby maintaining both ease of operation and product quality
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 operational efficiency and quality by preventing jointed portion mixing, improving the cost-effectiveness and reliability of carbon fiber thread production while maintaining high-quality standards.
Implementation Method 1
an oxidization treatment at 200 to 300°C under an oxidizing atmosphere
Implementation Method 2
subjecting the carbon fiber thread precursor to an oxidization treatment
Implementation Method 3
a carbonization treatment at 1,000°C under an inert atmosphere
Implementation Method 4
subjecting the oxidized fiber thread thus obtained to a carbonization treatment
Data Source
Figure 1
Figure 2
AI summary
Disclosed is a production system (1) for a carbon fiber thread (Z) by continuously subjecting a carbon fiber thread precursor (X) having a jointed portion (a) connecting respective ends of two carbon fiber thread precursors (X) to heat treatment, which contains an oxidization oven (10) for subjecting the carbon fiber thread precursor (X) to an oxidization treatment, a carbonization furnace (12) for subjecting a thus obtained oxidized fiber thread to a carbonization treatment, a winder (18) for winding the carbon fiber thread (Z) around a winding bobbin, a detection means (24) for detecting the jointed portion (a), a positional information-acquisition means (26) for acquiring positional information of the jointed portion (a), a control means (28) for controlling the winder (18) in such a way that a carbon fiber thread including the jointed portion (a) and a carbon fiber thread not including the jointed portion (a) are separately wound up around different winding bobbins based on the positional information. Also disclosed is a production method for a carbon fiber thread by use of the production system (1).