Fiber Bundle Joint with Segmented Interlacing for Heat Management
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Solution Overview
Problem
Existing methods for joining precursor fiber bundles in carbon fiber production lead to heat accumulation and breakage issues during the calcination process, reducing productivity and requiring lower furnace temperatures to prevent thermal destruction.
Innovation Solution
A fiber bundle with a fiber joint portion comprising superposed and interlaced fiber portions, along with an unraveled portion for heat dissipation, is created using a specific interlacing apparatus to prevent heat accumulation and ensure continuous production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If pressurized fluid jets are used to interlace fibers in the fiber joint portion, then the fiber bundles can be joined together, but the fiber density becomes too high causing heat accumulation and runaway oxidization reaction
Solution Approach 1:
The fiber joint portion is divided into multiple interlaced fiber portions (first, second, and subsequent interlaced fiber portions) spaced at intervals along the length direction. This segmentation reduces the fiber density in any single location, preventing heat accumulation while maintaining binding strength through distributed interlacing points.
Solution Approach 2:
Different regions of the fiber joint portion have different structures: interlaced fiber portions provide binding strength while unraveled fiber portions between them provide heat dissipation. This local differentiation allows the joint portion to simultaneously achieve strong bonding and effective heat management.
2Temperature
If the temperature of the oxidizing step is lowered to prevent thermal destruction, then heat accumulation is reduced, but the oxidizing step requires significantly longer time reducing productivity
Solution Approach 1:
By segmenting the fiber joint portion into multiple interlaced portions spaced at intervals, the overall fiber density is reduced. This allows the oxidizing step to proceed at standard temperatures without runaway reactions, maintaining productivity while preventing thermal destruction.
3Quantity of substance
If precursor fiber bundles are composed of a large number of filaments, then the desired carbon fiber properties are achieved, but pressurized fluid jets cannot cover the entire bundles preventing proper interlacing
Solution Approach 1:
The fluid jetting apparatus introduces a time dimension by sequentially jetting different regions of the fiber bundle at different times. The jetting holes are arranged to cover different areas in sequence, ensuring complete coverage of large filament bundles through temporal rather than simultaneous spatial coverage.
4Ease of manufacture
If sub-bundles are interlaced instead of individual filaments, then the processing becomes feasible, but uneven interlacing causes local fiber density increase and heat accumulation
Solution Approach 1:
The interlacing process is segmented into multiple sequential stages with fluid jets targeting different regions. This ensures uniform distribution of interlaced portions along the fiber bundle length, preventing local density increases and associated heat accumulation problems.
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 allows for continuous calcination at standard temperatures, preventing breakage and slippage, and significantly improving the productivity of carbon fiber production by efficiently managing heat in the joint portion.
Implementation Method 1
applying pressurized fluid jets emitted from jetting nozzles to interlace the fibers
Implementation Method 2
an unraveled fiber portion in which said fibers are unraveled and that is located between said two or more interlaced fiber portions
Data Source
AI summary
A fiber bundle which has a pieced part formed by jetting a pressurized fluid against a fiber-bundle overlap is formed either by directly superposing the ending part of a fiber bundle composed of many fibers on the beginning part of another fiber bundle composed of many fibers or by superposing the end part and the beginning part on a jointing fiber bundle composed of many fibers, whereby the many fibers of the fiber bundles are interlaced with one another to thereby piece up the fiber bundles. The pieced part comprises an opened-fiber part in which the fibers have been opened and interlaced-fiber parts respectively located on both sides thereof, each interlaced-fiber part being composed of a plurality of constituent interlaced parts located apart in the width direction for the fiber bundle.