Electrostatic Powdering for Continuous Reinforcement Tape
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Solution Overview
Problem
Current methods for producing continuous reinforcement tapes with carbon fibers are limited by the need for cutting, which leads to edge filament protrusions, non-parallel orientation, and discontinuities, resulting in reduced mechanical properties and high waste levels, especially when trying to achieve long lengths without splices.
Innovation Solution
A method for manufacturing a continuous tape with strictly parallel filaments and controlled polymer distribution, allowing for lengths exceeding 1,000 meters, using electrostatic powder coating and calendering to ensure uniform width and impregnation, eliminating the need for cutting and splices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cutting is used to produce continuous reinforcement tapes, then the tape can be obtained with controlled width, but filaments jut out from edges and orientation is not strictly parallel, reducing mechanical properties
Solution Approach 1:
The patent removes the cutting operation from the manufacturing process entirely. Instead of cutting pre-impregnated strands to length, the system feeds continuous strands through an impregnation zone where polymer is applied only to the required sections, eliminating edge filament protrusion and orientation issues associated with cutting.
Solution Approach 2:
The patent applies polymer impregnation to specific sections of the strand before final assembly, rather than impregnating the entire strand and then cutting. This preliminary, selective impregnation ensures that polymer is present only where needed, maintaining filament alignment and mechanical integrity without requiring post-impregnation cutting.
2Ease of manufacture
If cutting and splicing are used to achieve long lengths, then the tape can be produced in manageable sections, but discontinuities are introduced reducing mechanical properties
Solution Approach 1:
The patent implements a continuous manufacturing process where strands are fed continuously through the impregnation and assembly zones without interruption. The system can produce tapes exceeding 1,000 meters in length without splices by maintaining continuous filament feed and continuous polymer application, eliminating discontinuities that would compromise mechanical integrity.
3Quantity of substance
If traditional impregnation methods are used, then polymer can be applied to strands, but cutting causes waste and reduces productivity
Solution Approach 1:
The patent applies polymer impregnation locally to specific sections of the strand rather than impregnating the entire length. The impregnation zone is confined to where polymer is actually needed for matrix formation, reducing waste material and allowing faster processing speeds since non-impregnated sections can be handled more efficiently.
4Manufacturing precision
If cutting is performed to control tape width, then precise dimensions can be achieved, but filaments are not strictly oriented in longitudinal direction
Solution Approach 1:
The patent performs selective impregnation before final tape formation, allowing the polymer to set and lock filaments in their longitudinal orientation before any width control measures are applied. This preliminary impregnation stabilizes filament position, ensuring strict longitudinal orientation is maintained throughout subsequent processing.
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 method produces tapes with high mechanical properties, low waste, and flexibility, enabling efficient automated fiber placement with consistent polymer distribution and reduced energy consumption, while maintaining high mechanical integrity and flexibility.
Implementation Method 1
deposition of the polymer in powder form on the strand by electrostatic powder coating
Implementation Method 2
melting of the deposited polymer
Data Source
AI summary
The invention relates to a method and facility for manufacturing a tape of reinforcement filaments impregnated by a polymer matrix, as well as a tape produced thereby, said tape having a constant width across the entire length thereof, wherein the filaments extend in a direction parallel to the length of the tape, from a strand of filaments coming from a feeding reel. The method including steps and units that make it possible to manage the unwinding tension of the strand, to guide the strand on the axis of the machine, to manage the width of the strand, to deposit the polymer on the strand by electrostatic powdering, with a polymer weight ratio of around 20% to around 75% to melt the polymer, to calibrate the width and thickness of the tape and to collect the tape on the storage reel.