Composite Fiber Forming With a Translating Die for Fast Curing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The conventional pultrusion process for manufacturing fiber reinforced polymers faces limitations in speed due to the length of the die, process temperature, process friction, and binder bath inefficiencies, especially when using fast-curing thermosetting polymers, leading to high costs and inconsistent product quality.
Innovation Solution
A method involving preheating fibers, applying a low-viscosity binder with short chain monomers, and using a continuously-conformable translating die that moves with the fibers through multiple shaping stations, allowing for controlled binder application and increased process speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the die length is increased to ensure proper curing of the binder, then the curing quality is improved, but the process speed decreases
Solution Approach 1:
The patent changes the physical parameters of the binder by using low-viscosity binders with specific molecular weight ranges (500-5000 g/mol) and controlled gel times (5-60 seconds). This allows the binder to flow and cure properly in a shorter die length while maintaining curing quality, thus resolving the contradiction between curing quality and process speed.
Solution Approach 2:
The patent applies preliminary heating to the binder before it enters the die, pre-conditioning it for optimal flow and curing characteristics. This preliminary action ensures that the binder is ready to cure efficiently within the shortened die length, maintaining reliability while enabling faster production.
2Reliability
If the binder bath volume is increased to accommodate fast-curing polymers, then the curing capacity is improved, but the operating cost and waste increase
Solution Approach 1:
The patent extracts the binder from the traditional large-volume bath system and delivers it directly to the fibers through a controlled application system. This eliminates the need for excessive binder volume, reducing waste while maintaining adequate curing capacity through precise binder dosing and controlled gel time parameters.
Solution Approach 2:
The patent changes the binder delivery method from immersion in a large bath to controlled application with specific viscosity and gel time parameters. This allows for efficient binder utilization with minimal waste, as the binder is applied only where needed and cures within a controlled time window.
3Speed
If the process temperature is increased to speed up curing, then the process speed is improved, but the friction and energy consumption increase
Solution Approach 1:
The patent changes the curing mechanism from relying solely on high temperature to utilizing binders with controlled gel times that cure at moderate temperatures. This allows for fast curing speed while reducing energy consumption and friction-related issues associated with excessive heat.
Solution Approach 2:
The patent applies preliminary heating to the binder and/or fibers before they enter the die, initiating the curing process early. This reduces the temperature requirement and energy consumption needed during the main curing phase while maintaining fast overall process speed.
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
Enables high-speed, consistent production of fiber reinforced polymer composites with improved control over binder application and curing, reducing waste and energy consumption while maintaining product quality.
Implementation Method 1
The binder has a viscosity below 25 centipoise (cP) at 30°C and includes at least one short chain length monomer
Implementation Method 2
preheating a plurality of fibers to a first temperature, moving the preheated fibers along an assembly line and applying a binder to at least one of the preheated fibers
Implementation Method 3
maintaining a temperature of the plurality of fibers at a temperature substantially similar to the first temperature
Implementation Method 4
compressing the plurality of fibers within the die while maintaining a temperature
Implementation Method 5
Binders have curing profiles that are dictated by chemical reactions (curing, crosslinking, drying, etc.)
Implementation Method 6
Binders have curing profiles that are dictated by chemical reactions (curing, crosslinking, drying, etc.)
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A method of manufacturing a structural member includes preheating a plurality of fibers (5) to a first temperature, moving the preheated fibers along an assembly line (10), applying a binder (25) having a viscosity lower than 25 centipoise to at least one of the preheated fibers, providing a die (30) shaped to receive the preheated fibers, wherein the die moves together with the preheated fibers along at least a portion of the assembly line, maintaining a temperature of the plurality of fibers at a temperature substantially similar to the first temperature, and compressing the plurality of fibers within the die while maintaining a temperature.