Chopped Fiber Bundle Production with Guide-Based Overlap Prevention
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Solution Overview
Problem
The existing methods for producing chopped fiber bundles face challenges such as fiber bundle overlap during high-speed supply, leading to connected fibers, anisotropy in composite materials, and reduced productivity due to blade wear and vibration, as well as the generation of rubber scraps in the cutting process.
Innovation Solution
A producing device and method that includes a cutting blade with a steel material and a specific blade angle, oscillating guide and cutting means, and a cutter roller design with flat blades to prevent fiber bundle overlap, reduce blade wear, and minimize rubber damage, ensuring continuous high-productivity fiber bundle cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If long fiber bundles are supplied at high speed to improve productivity, then productivity increases, but fiber bundles overlap and become thick causing cutting difficulties
Solution Approach 1:
The guide means is designed to dynamically adjust and restrict the travel direction of fiber bundles during high-speed supply. The guide means includes guide rollers and guide plates that actively control fiber bundle positioning, preventing overlap while maintaining high supply speed. This dynamic directional control allows the system to achieve both high productivity and consistent cutting quality.
2Productivity
If cutting blades are used to cut fiber bundles, then fiber bundles are cut into chopped fibers, but blades wear locally reducing their service life
Solution Approach 1:
The guide means is positioned to distribute fiber bundle contact across multiple guide surfaces rather than concentrating pressure on a single blade location. This local distribution of contact points prevents localized blade wear by spreading the mechanical stress across the entire blade edge, thereby extending blade service life while maintaining continuous cutting capability.
3Manufacturing precision
If fiber bundles are restricted by guide means to prevent overlap, then cutting quality improves, but device complexity increases
Solution Approach 1:
The guide means employs simple, homogeneous components such as guide rollers and guide plates that uniformly restrict fiber bundle travel direction. These standardized components create consistent guidance throughout the cutting zone without introducing complex mechanisms, thereby achieving improved cutting quality while minimizing device complexity.
4Productivity
If cutting blades press against anvil roller to cut fiber bundles, then cutting is effective, but rubber roller surface is damaged generating scraps
Solution Approach 1:
The guide means performs preliminary action by positioning and aligning fiber bundles before they reach the cutting zone. This pre-positioning ensures that fiber bundles are properly oriented and spaced, reducing the pressing force required by the cutting blades against the anvil roller. Consequently, cutting efficiency is maintained while minimizing damage to the rubber roller surface and reducing rubber scrap generation.
Data Source
AI summary
One mode of the invention relates to a producing a device for chopped fiber bundles having a chopper unit including a cutting blade for cutting long fiber bundles, a guide for restricting the travel direction of the fiber bundles to be supplied to the cutting means, and a structure, provided between the chopper unit and the guide, that widens the fiber bundles. The invention also relates to method for producing chopped fiber bundles by widening fiber bundles while restricting the travel direction of the long fiber bundles to be supplied to chopper unit by a guide, and obtaining chopped fiber bundles by cutting the fiber bundles with the chopper unit.