Stampable Composite Mixing via Electric Field Homogenization
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Solution Overview
Problem
Conventional methods for producing composite semi-finished products with fiber-reinforced plastics are inefficient due to complex and costly mixing processes, requiring fine powder particles and specific fiber sizes, which can lead to heterogeneous mixtures and increased production costs.
Innovation Solution
A method involving the deposition of fibers on a conveyor, sprinkling with plastic powder, and applying an electric field perpendicular to the conveyor to homogenize the mixture, allowing for a broader particle size range and reducing the complexity of mixing operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional mixing methods (needling or cycloning) are used to mix powder particles with fibers, then the mixture can be homogenized, but the process becomes complex and costly, requiring fine powder particles and specific fiber sizes
Solution Approach 1:
The patent replaces complex mechanical mixing systems (needling machines, cyclone separators) with a simple vibratory mechanism. The vibration table generates vibratory motion that facilitates homogeneous mixing of powder and fibers through basic physical vibration, eliminating the need for complex mechanical intervention while achieving the same mixing homogeneity.
Solution Approach 2:
The patent changes the physical state and motion parameters of the mixing system by introducing vibratory motion. The vibration frequency and amplitude are optimized to enable effective mixing without requiring fine powder particles or specific fiber sizes, thus simplifying the process while maintaining mixture homogeneity.
2Manufacturing precision
If needling is used to bind fibers together and homogenize particle distribution, then mixture homogeneity is improved, but the process causes pollution and requires confinement or complete cleaning before producing new semi-finished products
Solution Approach 1:
The patent replaces the needling mechanical process with a vibratory mixing mechanism that does not involve penetrating or binding fibers through mechanical needles. This substitution eliminates the pollution and contamination issues associated with needling while achieving homogeneous particle distribution through vibration-assisted mixing.
Solution Approach 2:
The vibratory mixing process uses a simple, non-invasive mechanism that does not require complex cleaning or confinement infrastructure. The process is inherently cleaner and does not generate the same level of contamination as needling, reducing the need for expensive cleaning and confinement systems.
3Manufacturing precision
If fine powder particles are used to achieve homogeneous mixture, then mixing homogeneity is improved, but the cost of raw materials increases
Solution Approach 1:
The patent changes the motion parameters of the mixing system by introducing vibration, which enables effective mixing of coarser powder particles. The vibratory energy facilitates particle-fiber contact and distribution without requiring the powder to be ground to fine sizes, thus reducing raw material costs while maintaining mixture homogeneity.
4Manufacturing precision
If cycloning is used to mix fibers with powder particles, then mixing is achieved, but the equipment required is expensive and bulky, and the method is reserved for large production volumes only
Solution Approach 1:
The patent replaces expensive and bulky cyclone separation and mixing equipment with a simple vibratory table. The vibratory mechanism achieves homogeneous mixing through basic physical vibration, eliminating the need for complex pneumatic systems, cyclones, and associated infrastructure, thus reducing equipment cost and size while maintaining mixing effectiveness.
Solution Approach 2:
The vibratory mixing system uses simple, inexpensive components that can be easily implemented at various production scales. Unlike cycloning equipment that is reserved for large production volumes, the vibratory table can be effectively used across different production scales, making it accessible and cost-effective for various manufacturing needs.
5Manufacturing precision
If a long and complex process with three stages of heating, three stages of powder deposition and two stages of compression is used, then homogeneous mixture is achieved, but the production line becomes long and costly
Solution Approach 1:
The patent merges multiple separate process stages (heating, powder deposition, mixing, compression) into a more integrated and streamlined sequence. The vibratory mixing is performed in-line during the deposition process, and heating and compression stages are optimized to occur in a more compact sequence, reducing the overall length and cost of the production line while maintaining mixture homogeneity.
Solution Approach 2:
The patent replaces complex multi-stage mechanical processing with a simplified sequence that uses vibratory mixing to achieve homogeneity in a single stage, eliminating the need for multiple heating, deposition, and compression stages. This substitution reduces the production line length and associated costs while maintaining the required mixture 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 enables the rapid, economical, and homogeneous mixing of powder and fibers, improving the mechanical properties of the composite semi-finished product while simplifying the production process and reducing material costs.
Implementation Method 1
subjecting the mixture to at least one electric field substantially perpendicular to the direction of advance of the conveyor and able to move the particles and the fibers or the filaments so as to homogenize the mixed
Data Source
AI summary
Process for producing a stampable reinforced composite semi-finished product comprising one or more plastics and chopped fibres or continuous filaments (4), the softening temperature of which is above the highest of the softening temperatures of said materials, which process comprises the steps consisting in: depositing said fibres or filaments (4), especially by gravity, onto a conveyor (1); sprinkling particles (6) of a powder of said plastics onto said fibres or said filaments (4), in a proportion of between 5% and 90% of the total weight; blending said particles (6) with said fibres or said filaments (4); and heating the blend to a temperature above the softening temperatures of said materials, characterized in that the blending step includes subjecting said blend (4, 6) to at least one electric field approximately perpendicular to the direction of advance (15) of said conveyor (1).