Device for manufcaturing chopped fiber bundle and method for manufacturing same
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing chopped fiber bundles with inclined cutting angles are complex and costly, especially for high-strength fibers like carbon and aramid, as they require specialized cutting tools and processes that are difficult to maintain and scale for producing fibers with small cutting angles.
Innovation Solution
A device comprising a cutter roll with disk blades and a nip roll, along with a reciprocating and traverse mechanism, allows for continuous inclined cutting of reinforcing fiber yarns with independent control of movement and velocity, enabling precise cutting angles without the need for fiber hardening or complex blade configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a cutting roll with obliquely arranged cutting blades is used to achieve inclined cutting, then the breaking strength of the fiber reinforced plastic is improved, but the device complexity and production cost increase significantly
Solution Approach 1:
The cutting roll is segmented into a body portion and a separately replaceable blade portion. The blade portion can be detached and replaced independently from the body, simplifying maintenance and reducing costs while maintaining the inclined cutting capability needed to improve breaking strength.
Solution Approach 2:
Instead of arranging blades obliquely on a rotating roll (complex), the invention inverts the approach by using a linear cutter that moves perpendicular to the fiber direction. The inclined cutting angle is achieved through the movement trajectory rather than blade arrangement, simplifying the device structure.
2Manufacturing precision
If the fiber yarn is introduced at a large inclination angle to achieve small cutting angle, then the cutting effectiveness is improved, but it becomes difficult to continuously introduce fibers with constant angle and stable shape
Solution Approach 1:
The invention uses dynamic movement of the linear cutter perpendicular to the fiber drawing direction to achieve inclined cutting. Instead of static oblique blade arrangement or large-angle fiber introduction, the system dynamically creates the inclined cutting action through coordinated movement, maintaining fiber stability while achieving precise cutting angles.
3Reliability
If blades are made inseparable from the cutting roll body to achieve oblique cutting, then the cutting performance is improved, but the blade exchange cost increases for high-strength fibers
Solution Approach 1:
The cutting tool is divided into separable components: a body portion and a blade portion that can be detached and replaced independently. This segmentation allows for reliable cutting performance during operation while enabling cost-effective blade replacement when wearing occurs, especially important for cutting high-strength fibers like carbon and aramid.
4Stability of the object's composition
If the fiber yarn is hardened by resin impregnation to maintain shape during oblique introduction, then the fiber shape stability is improved, but the production cost increases
Solution Approach 1:
The invention maintains fiber shape stability through dynamic control of the linear cutter's movement perpendicular to the fiber direction, rather than through resin impregnation. The coordinated movement between the cutter and fiber feed system ensures constant introduction angle and stable fiber shape without requiring additional hardening materials, thus avoiding increased production costs.
Data Source
AI summary
A device for manufacturing a chopped fiber bundle includes a cutter roll provided with one or more disk blades on a circumference of a roll core having a center axis coinciding with a rotation axis of the roll core and a nip roll provided in parallel with the rotation axis of the roll core, to feed a reinforcing fiber yarn to be continuously cut between the nip roll and the cutter roll, further including a rotary drive mechanism that rotates the cutter roll and at least one of: a reciprocating drive mechanism that reciprocates the cutter roll along the rotation axis of the roll core; and a traverse guide that traverses the reinforcing fiber yarn along the rotation axis of the roll core.