Precursor Fiber Bundle Joining to Prevent Oxidation Joint Breakage
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Solution Overview
Problem
The existing methods for manufacturing carbon fiber bundles face challenges such as fiber breakage at or near the joint during the oxidization and carbonization processes, leading to reduced productivity and increased trouble in the joining process.
Innovation Solution
A method involving the application of an oiling agent with a concentration of 0.15 to 0.85 wt % to the joint area of precursor fiber bundles before joining, followed by heat treatment and fluid entanglement to enhance the entanglement strength and stability of the joint, using a joining apparatus that includes an oiling agent application unit, heat-treatment unit, and joining unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the rate of production, linear density, and number of fiber bundles are increased, then productivity is improved, but fiber breakage at or near the joint occurs during oxidization and carbonization processes
Solution Approach 1:
The oiling agent is applied to the joint area of the precursor fiber bundle before the joining process. This preliminary application ensures that the joint area is adequately lubricated and protected before undergoing the high-stress oxidization and carbonization processes, preventing fiber breakage while maintaining high productivity
Solution Approach 2:
The patent specifies a precise quantity range for the oiling agent (0.15 to 0.85 wt %) to optimize the balance between preventing fiber breakage and maintaining production efficiency. This parameter control ensures adequate protection without excessive oil accumulation that could interfere with subsequent processing
2Ease of manufacture
If joining process is simplified, then ease of manufacture is improved, but entanglement strength and joint stability are insufficient
Solution Approach 1:
The oiling agent serves as an intermediary substance that facilitates the joining process by reducing friction and enabling better fiber intermingling between the upstream and downstream bundles. This mediator allows for effective joining with minimal complex equipment while achieving sufficient entanglement strength
Solution Approach 2:
The joining apparatus utilizes fluid (gas or liquid) jetting to enhance the entanglement of fibers at the joint area. This pneumatic or hydraulic mechanism provides an effective joining method that maintains process simplicity while achieving the required joint stability and strength
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
This approach results in high productivity and stable production of carbon fiber bundles with reduced fiber breakage at the joint, achieving an entanglement strength of 25 mN/tex or more, thereby improving the manufacturing throughput and reducing operational issues.
Implementation Method 1
applying an oiling agent to a joint area of a joining target precursor fiber bundle before joining the joining target precursor fiber bundle and the joining fiber bundle together
Implementation Method 2
a heat-treatment unit that heat-treats the joining target fiber bundle having the oiling agent applied
Implementation Method 3
a joining unit that causes the heat-treated joining target fiber bundle and the joining fiber bundle to overlap each other, and jets a fluid to the overlap to join the heat-treated joining target fiber bundles and the joining fiber bundle together
Implementation Method 4
oxidizing the joined precursor fiber bundles by feeding the joined precursor fiber bundles through an oxidization furnace
Data Source
AI summary
A manufacturing method and an apparatus enable high productivity. A method for manufacturing an oxidized fiber bundle includes joining an upstream precursor fiber bundle and a downstream precursor fiber bundle together with a joining fiber bundle, and oxidizing the joined precursor fiber bundles by feeding the joined precursor fiber bundles through an oxidization furnace. The joining includes applying an oiling agent to a joint area of a joining target precursor fiber bundle before joining the joining target precursor fiber bundle and the joining fiber bundle together. A quantity of the oiling agent adhering to the joint area is 0.15 to 0.85 wt %.