Die Gate Passage Projection for Uniform Resin Impregnation
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Solution Overview
Problem
Current fiber roving technologies face challenges in achieving desired strength, durability, and temperature performance due to inadequate resin impregnation, particularly with thermoplastic resins that exhibit poor wetting and high temperature limitations.
Innovation Solution
A die and method for impregnating fiber rovings with a polymer resin using a manifold assembly, gate passage, and impregnation zone, where the gate passage includes projections to diffuse resin and ensure uniform coating, and an extrusion device is used to apply the resin uniformly across the fibers, enhancing impregnation and reducing voids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermoplastic resins are used to impregnate fiber rovings, then ease of manufacture and bonding characteristics are improved, but inadequate wetting of fibers occurs resulting in poor durability and strength
Solution Approach 1:
The gate passage includes a projection that creates a localized resin reservoir and controls resin flow distribution. This local structural modification ensures uniform resin coating on the fiber rovings, improving wetting characteristics while maintaining the ease of manufacture associated with thermoplastic resins.
Solution Approach 2:
The projection in the gate passage modifies the resin flow parameters by creating a diffusion effect that distributes resin more uniformly across the fiber surface. This parameter change in resin distribution improves fiber wetting and subsequent bonding without changing the resin material itself.
2Device complexity
If conventional die design is used for resin impregnation, then device complexity is minimized, but non-uniform resin distribution and void formation occur reducing manufacturing precision
Solution Approach 1:
A projection is added to the gate passage to create a localized resin diffusion zone. This local structural feature improves resin distribution uniformity without significantly increasing overall die complexity. The projection acts as a flow distributor that eliminates non-uniform coating and void formation.
3Device complexity
If simple gate passage design is used, then device complexity is reduced, but resin flow diffusion is insufficient leading to poor impregnation quality
Solution Approach 1:
The gate passage includes a projection that creates a localized diffusion zone for resin flow. This simple local feature significantly improves resin distribution and impregnation uniformity without requiring complex gate passage design. The projection serves as an effective flow distributor that enhances impregnation 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
The solution achieves improved uniformity and increased strength of fiber-reinforced composites by ensuring thorough resin impregnation, reducing voids, and maintaining performance at high temperatures, thus addressing the limitations of existing technologies.
Implementation Method 1
The gate passage includes a projection. The projection is configured to diffuse resin flowing through the gate passage.
Implementation Method 2
The manifold assembly flows the resin therethrough, and includes a channel.
Implementation Method 3
The impregnation zone is in fluid communication with the manifold assembly, and is configured to impregnate the roving with the resin.
Data Source
AI summary
A die and a method for impregnating fiber rovings with a polymer resin are disclosed. The die includes a manifold assembly (220), an impregnation zone (250), and a gate passage (270). The manifold assembly (220) flows the resin therethrough, and includes a channel (222). The impregnation zone (250) is in fluid communication with the manifold assembly (220), and is configured to impregnate the roving with the resin. The gate passage (270) is between the manifold assembly (220) and the impregnation zone (250), and flows the resin from the manifold assembly (220) such that the resin coats the roving. The gate passage (270) includes a projection (300). The projection (300) is configured to diffuse resin flowing through the gate passage (270).