Method of Producing Fiber Assembly and Method of Producing Prepreg Sheet
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Solution Overview
Problem
Existing methods for producing fiber assemblies struggle to achieve high bulk density while maintaining fiber length without cutting, and efficiently supplying fibers in fiber-reinforced resin compositions.
Innovation Solution
A method involving stirring and granulating fibers with a fiber treatment agent in a stirring tank using specific conditions, such as inclined stirring blades and controlled peripheral speeds, to align fibers and achieve high bulk density without cutting, allowing for efficient fiber alignment and supply in fiber-reinforced resin compositions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional granulation methods are used to produce fiber assemblies, then fibers can be bundled and handled, but the bulk density remains low and fibers may be cut or misaligned
Solution Approach 1:
The patent changes the physical parameters of the granulation process by using a stirring tank with controlled stirring speed and blade configuration. The stirring speed is maintained at 10-50 rpm, and the tank rotates at 5-20 rpm, creating gentle mixing that aligns fibers without cutting them while achieving high bulk density of 0.1-0.8 g/cm³.
Solution Approach 2:
The patent employs dynamic rotation of both the stirring blade and the tank itself, creating a controlled dynamic environment where fibers are gradually aligned and bundled. The differential rotation between the blade and tank allows fibers to be gently manipulated into aligned configurations rather than being statically compressed.
2Ease of operation
If fibers are bundled to improve handling workability, then feeding becomes easier, but fiber dispersibility in the resin matrix deteriorates
Solution Approach 1:
The patent creates fiber assemblies with a specific segmented structure where fibers are aligned in bundles but maintain individual fiber integrity. The granulation process produces discrete fiber assemblies with controlled size and shape, allowing them to be easily handled while dispersing uniformly in the resin matrix during composite fabrication.
Solution Approach 2:
The patent applies local quality by creating regions of high fiber alignment within the assembly while maintaining overall bundle integrity. The stirring process creates localized alignment zones where fibers orient in specific directions, providing both handling ease and good dispersibility when the assembly is broken up during resin impregnation.
3Quantity of substance
If high bulk density is achieved through compression, then storage and handling efficiency improves, but fiber length is reduced due to cutting
Solution Approach 1:
The patent uses dynamic stirring and rotation to achieve fiber alignment and bundling without static compression. The moving blades and rotating tank create a dynamic environment where fibers naturally align and bundle through flow patterns, achieving high bulk density while maintaining fiber length through gentle mechanical action rather than crushing forces.
Solution Approach 2:
The patent employs fluid dynamics through the stirring mechanism, using the movement of liquid or air in the tank to facilitate fiber alignment and bundling. The hydraulic or pneumatic flow patterns created by the stirring blade guide fibers into aligned configurations without direct mechanical contact that would cause cutting.
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 effectively produces fiber assemblies with high bulk density and aligned fibers, improving the physical properties of carbon fibers and enabling stable fiber supply in resin compositions, reducing bridging issues in feeders.
Implementation Method 1
stirring a mixture of the fibers and the fiber treatment agent with a stirring blade to granulate the mixture
Data Source
AI summary
A method for producing a fiber assembly, including: putting a plurality of fibers and a fiber treatment agent into a stirring tank; and stirring a mixture of the fibers and the fiber treatment agent with a stirring blade to granulate the mixture, wherein the fibers include carbon fibers, and the mixture is granulated such that the fibers are aligned. A method for producing a fiber assembly, wherein a plurality of fibers containing carbon fibers and a liquid are put into a stirring tank and the mixture of the fibers and the liquid is stirred with a stirring blade, thereby obtaining a fiber assembly which has a spheroidal shape or a strand shape.