Extruder Faceplate Gap and Heated Screen for High Fiber Density Resin
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Solution Overview
Problem
Conventional extruders face challenges in producing high-fiber density reinforced resin structures due to plugging of faceplate sizing holes, especially when fiber volume exceeds 50%, leading to reduced tensile strength and increased downtime, and existing fiber-reinforced tapes lack adequate bonding properties for applications like subsea reinforcement.
Innovation Solution
An extruder design with a faceplate spaced apart from the impregnation chamber allows excess resin to backflow, preventing pressure buildup and fiber accumulation, and a method for producing high-fiber content tapes with improved bonding properties by embedding fibers in a polymer resin with resin-rich and fiber-rich portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fiber volume content is increased to exceed 50% for high tensile strength, then the tensile strength of the final product is improved, but the faceplate sizing holes become plugged with broken or loose fibers causing production downtime
Solution Approach 1:
The faceplate is segmented into multiple sizing holes instead of a single slot, allowing resin to flow through multiple pathways. This segmentation prevents fiber accumulation in any single hole while maintaining high fiber volume content in the final product, thus resolving the plugging issue without sacrificing tensile strength
Solution Approach 2:
A heated screen is introduced as an intermediary component between the impregnation chamber and faceplate. This screen acts as a filter that captures broken fibers before they reach the sizing holes, preventing plugging while allowing resin and intact fibers to pass through, thereby maintaining both high fiber content and production continuity
2Reliability
If fiber volume content is increased to exceed 50% for high tensile strength, then the quality of the final product is improved, but the sizing holes accumulate fiber debris requiring shutdown for maintenance
Solution Approach 1:
The heated screen performs preliminary filtration of broken fibers before they can accumulate in the sizing holes. By removing fiber debris in advance, the screen prevents plugging issues that would otherwise require production shutdown and restringing operations, thus maintaining both product quality and continuous production
Solution Approach 2:
The heated screen is designed to be easily removable and replaceable, allowing operators to clean or replace the screen itself rather than disassembling the entire faceplate and restringing rovings. This self-service approach minimizes downtime while maintaining product quality through continuous filtration
3Manufacturing precision
If highly viscous thermoplastics are used for complete roving impregnation, then the impregnation quality is improved, but pressure surges occur that promote fiber plugging of sizing holes
Solution Approach 1:
The heated screen serves as a protective intermediary that filters broken fibers caused by pressure surges. When high viscosity thermoplastics create pressure fluctuations, the screen captures the resulting broken fibers before they can plug the sizing holes, allowing complete impregnation with viscous materials without the harmful plugging effect
Solution Approach 2:
The heated screen provides beforehand protection against the harmful effects of pressure surges. By positioning the screen upstream of the sizing holes, it cushions the system against fiber debris generated during pressure fluctuations, enabling the use of highly viscous thermoplastics without risking plugging of critical components
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 enables continuous production of high-fiber content resin structures without plugging issues during pressure surges and enhances bonding properties of the resulting tapes, ensuring higher tensile strength and durability suitable for demanding applications.
Implementation Method 1
positioned upstream of the faceplate to remove broken fibers from the resin
Implementation Method 2
Hot, pressurized molten resin is continuously introduced into the channel
Implementation Method 3
Hot, pressurized molten resin is continuously introduced into the channel
Data Source
AI summary
An extruder (1) and a method for producing high-fiber volume reinforced thermoplastic resin structures (50), as well as a tape (156) having opposing resin rich portions (302) and a fiber rich portion (304) disposed therebetween and a method for impregnating at least one fiber roving (142) with a polymer resin to form a tape (156. The extruder (1) includes an impregnation die (3) having a channel (4) that applies pressurized molten thermoplastic resin to a plurality of rovings (142) drawn through the channel (4), and a die (3) faceplate (5) facing the downstream side (34) of said die (3). The faceplate (5) has a plurality of sizing holes (42) or a slot (75) arranged along a line that the resin-impregnated rovings (142) are simultaneously drawn through that remove excess resin and pultrude the resin-impregnated rovings (142) into rod-shaped or sheet-shaped structures. The faceplate (5) is spaced apart from the downstream side (34) of the die (4) to provide a gap (6) between the die (4) and a back side of the faceplate (5).