Reinforcing fiber bundle
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Solution Overview
Problem
Current fiber-reinforced thermoplastic resin forming materials face challenges in achieving a balance between mechanical properties and fluidity during the forming process, particularly in continuous production, where discontinuous reinforcing fibers result in poor mechanical properties and limited productivity.
Innovation Solution
A continuous reinforcing fiber bundle with specific structural and sizing agent configurations, including regions with controlled fiber density, adhesion, and sizing agent distribution, is developed to enhance mechanical properties and fluidity, comprising regions with varying fiber densities and sizing agent amounts to optimize connection and reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If discontinuous reinforcing fibers are used in sheet-shaped materials, then fluidity during forming process is improved, but mechanical properties of shaped product deteriorate
Solution Approach 1:
The fiber bundle is divided into multiple single yarns (6-1000 single yarns per bundle), creating a hierarchical structure that combines the fluidity of dispersed fibers with the strength of continuous fiber networks. This segmentation allows fibers to flow during forming while maintaining structural integrity in the final product.
Solution Approach 2:
The invention applies different structural characteristics to different scales: at the macro level, fiber bundles provide continuous reinforcement for strength, while at the micro level, individual single yarns within bundles provide fluidity. The sizing agent is also applied with specific adhesion amounts (0.1-10 wt%) to optimize local fiber-fiber and fiber-resin interactions.
2Strength
If continuous fiber bundles are used, then mechanical properties are improved, but fluidity during forming process deteriorates
Solution Approach 1:
Continuous fiber bundles are segmented into multiple single yarns (6-1000 per bundle), which reduces bundle stiffness and improves fluidity during forming. The segmented structure allows bundles to flex and flow more easily while maintaining continuous fiber reinforcement for mechanical strength.
Solution Approach 2:
The invention optimizes key parameters including: number of single yarns per bundle (6-1000), single yarn number per unit width (600-1600 fibers/mm), and sizing agent adhesion amount (0.1-10 wt%). These parameter adjustments transform rigid continuous bundles into flexible yet strong reinforcing elements that maintain fluidity during forming.
3Strength
If fiber bundle density is increased, then mechanical properties are improved, but processing difficulty increases
Solution Approach 1:
The invention creates local variations in fiber distribution through controlled bundle segmentation. Regions with higher single yarn density provide enhanced mechanical properties, while the overall distributed bundle structure maintains processability. The sizing agent adhesion is also locally optimized at 0.1-10 wt% to facilitate handling.
4Productivity
If discontinuous reinforcing fibers are used, then productivity is improved, but mechanical properties of shaped product deteriorate
Solution Approach 1:
The invention uses continuous fiber bundles that are processed in a continuous manner, eliminating the need for discontinuous fiber chopping and realignment. The continuous bundles maintain fiber continuity for strength while being processed through continuous forming operations, achieving both high productivity and superior mechanical properties.
Data Source
AI summary
A reinforcing fiber bundle is a continuous reinforcing fiber bundle having a length of at least 1 m and is characterized by the number of monofilaments per unit width being at most 1,600/mm and the average number of fibers in the bundle being at most 1,000 in a region (I), and the drape level found in a region (II) being 120-240 mm. The continuous reinforcing fiber bundle has a length of at least 1 m and is characterized by the adhesion amount of a sizing agent (I) in the region (I) being 0.5-10% by weight and the drape level found in the region (II) being 120-240 mm. The continuous reinforcing fiber bundle has superior mechanical properties, formability into complex shapes, and continuous producibility.