Stabilized Fiber Bundle Oxidation Air Velocity Control
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Solution Overview
Problem
The stabilization process in carbon fiber bundle manufacturing is inefficient due to fiber bundle swinging caused by variations in air velocity and density, leading to quality deterioration and increased equipment costs.
Innovation Solution
A method involving a controlled air velocity ratio between first and second hot air in a horizontal flow system, where 0.2≤Vf/Vm≤2.0, to minimize fiber bundle swinging and turbulence, using a CTE hot air system with guide rollers and auxiliary air supply to optimize fiber bundle alignment and reduce equipment size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the density of fiber bundles in the oxidation oven is increased to enhance productivity, then the treatment efficiency is improved, but fiber bundle swinging occurs due to drag variation and contact frequency increases causing yarn gathering and single fiber break
Solution Approach 1:
A guide roller is introduced as an intermediary component between the fiber bundles and the oxidation atmosphere. The guide roller supports and guides the fiber bundles during treatment, preventing direct contact between adjacent bundles while maintaining high density arrangement. This mediator eliminates the harmful interaction causing yarn gathering and single fiber break while preserving the productivity benefits of increased bundle density.
Solution Approach 2:
The invention changes the physical state and distribution parameters of the oxidation atmosphere by controlling air flow patterns. By adjusting the air flow velocity and distribution characteristics, the patent minimizes drag-induced fiber bundle swinging while maintaining sufficient oxygen supply for effective oxidation treatment, thus resolving the contradiction between high density arrangement and alignment stability.
2Productivity
If the travelling speed of fiber bundles is increased to enhance productivity, then the treatment efficiency is improved, but the oxidation oven size must be increased leading to increased equipment cost
Solution Approach 1:
The invention transitions from a conventional horizontal linear treatment approach to a multi-dimensional treatment path using the guide roller to create a three-dimensional treatment space. Fiber bundles follow a curved or multi-directional path through the oxidation oven, effectively increasing the treatment path length without proportionally increasing the oven's external dimensions, thus maintaining high productivity while controlling equipment size and cost.
3Volume of stationary object
If the oxidation oven length is increased to suppress equipment size and cost, then the height direction size is reduced, but the amount of fiber bundle suspension increases causing single fiber break and contact between adjacent fiber bundles
Solution Approach 1:
The guide roller serves as a supporting intermediary that bears the weight and tension of fiber bundles during treatment. By providing mechanical support at strategic positions, the guide roller reduces the effective suspension length of fiber bundles, preventing excessive sagging and contact between adjacent bundles even in longer oxidation ovens, thus maintaining fiber bundle integrity while allowing compact equipment design.
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 enhances the production efficiency of high-quality stabilized and carbon fiber bundles by reducing fiber bundle swinging, preventing yarn gathering and single fiber breaks, and minimizing equipment costs.
Implementation Method 1
exposing the fiber bundle to hot air in an oxidizing atmosphere, for example, air supplied from a hot air supply nozzle placed in the oxidation oven and heated to 200 to 300° C., thereby subjecting the fiber bundle to a heating treatment (stabilization treatment)
Implementation Method 2
a system that supplies hot air in a substantially horizontal direction to a travelling direction of a fiber bundle is commonly called horizontal flow system
Data Source
AI summary
A method of manufacturing a stabilized fiber bundle is described, which includes subjecting an acrylic fiber bundle aligned, to a heat treatment in an oxidizing atmosphere, with the acrylic fiber bundle being turned around by a guide roller placed on each of both ends outside a hot air heating-type oxidation oven, wherein an air velocity Vm of first hot air sent through a supply nozzle(s) disposed above and/or under a fiber bundle travelled in the oxidation oven, in a substantially horizontal direction to a travelling direction of the fiber bundle, and an air velocity Vf of second hot air flowing in a fiber bundle passing a flow channel in which the fiber bundle is travelled that satisfies expression 1)0.2≤Vf/Vm≤2.0 1)to produce a high-quality stabilized fiber bundle and a high-quality carbon fiber bundle at high efficiencies without any process troubles.