Impregnated Fiber Bundle Manufacturing via High-Pressure Resin Infiltration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional fiber fabric manufacturing methods result in poor bonding between fiber bundles due to low glue penetration, leading to limited structural strength, rigidity, and elasticity, as the glue fails to soak into the fibers and form adequate layers, especially in narrow spaces and contacting points.
Innovation Solution
A method involving a device that feeds fiber bundles through a surface roughening unit to create cavities, followed by high-pressure resin infiltration to form an outer resin layer, and semi-curing under controlled temperature and pressure to enhance bonding, resulting in improved resin soaking and bonding force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional gluing method is used to form glue layer on fabric surface, then the process is simple, but the glue cannot soak into fiber bundles resulting in poor bonding and low structural strength
Solution Approach 1:
The device segments the impregnation process into multiple zones: a first impregnation zone with first rolling elements for initial glue application, and a second impregnation zone with second rolling elements for further penetration. This segmentation allows progressive glue infiltration into fiber bundles, improving bonding strength while maintaining manageable device complexity through modular zone design.
Solution Approach 2:
The device performs preliminary action by applying glue in stages - first through the first rolling elements to coat the fabric surface, then through the second rolling elements to push glue deeper into the fiber bundles. This staged preliminary impregnation ensures thorough glue penetration before the fabric enters the molding press, resolving the contradiction between bonding strength and device complexity.
2Quantity of substance
If high viscosity glue is used to form adequate glue layers, then the glue layer can be sufficient, but the glue becomes difficult to penetrate into fiber bundles resulting in low bonding force
Solution Approach 1:
The device employs dynamic pressure application through adjustable rolling elements that can apply varying degrees of mechanical pressure. The first and second rolling elements dynamically compress the fabric to different extents, progressively forcing glue into the fiber bundles. This dynamic mechanical action enables high viscosity glue to penetrate deeply, achieving both sufficient glue quantity and easy penetration.
Solution Approach 2:
The device incorporates a molding press that uses hydraulic or pneumatic pressure to further force glue into the fiber bundles after the rolling element impregnation. This pressure-based system overcomes the high viscosity of the glue, ensuring adequate penetration and distribution throughout the fabric structure, thus achieving both sufficient glue quantity and penetration ease.
3Strength
If multiple layers of fiber fabric are laminated to enhance structure strength, then the thickness and structure strength are enhanced, but air remains between gluing layers causing poor bonding and disconnection
Solution Approach 1:
The device performs preliminary impregnation of each fabric layer with glue before lamination, using the first and second rolling elements to ensure thorough glue penetration into all fiber bundles. This preliminary glue saturation eliminates air pockets between layers during lamination, ensuring reliable bonding while maintaining the enhanced structural strength provided by multiple layers.
Solution Approach 2:
The device uses the rolling elements and molding press as intermediaries to apply controlled pressure and distribute glue uniformly between laminated layers. This intermediary action ensures complete wetting of interfaces between layers, eliminating air entrapment and disconnection issues while preserving the structural strength benefits of multi-layer construction.
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 ensures thorough resin impregnation of fiber bundles, forming a strong outer resin layer that enhances the structural strength, rigidity, and flexibility of the woven fabric by improving bonding between fibers.
Implementation Method 1
feeding resin to the fiber bundle in a high pressure manner to make the resin infiltrate the fiber bundle and to form an outer resin layer on the outer surface of the fiber bundle
Implementation Method 2
semi curing the resin inside and outside the resin impregnated fiber bundle by controlling temperature and pressure
Data Source
AI summary
A method for manufacturing impregnated fiber bundle includes: a step of feeding material including feeding at least one fiber bundle to a feeding wheel assembly; a step of resin molding including feeding resin to the fiber bundle in a high pressure manner to make the resin infiltrate the fiber bundle and to form an outer resin layer on the outer surface of the fiber bundle, so as to make the fiber bundle become a resin impregnated fiber bundle; a step of semi-cured molding including semi curing the resin inside and outside the resin impregnated fiber bundle by controlling temperature and pressure; and a step of reeling including reeling up the resin impregnated fiber bundle which is to be woven into a fabric.