Reinforcing Fiber Bundle Connection via Sizing Agent Control
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Solution Overview
Problem
The existing method for connecting reinforcing fiber bundles in the production of long fiber reinforced thermoplastic resin pellets results in uneven distribution of the sizing agent, leading to excessive surface friction and reduced connection strength, causing breakages and inefficiencies in production.
Innovation Solution
Adjusting the amount of sizing agent on the reinforcing fiber bundles to between 0 wt% and 4 wt% by heating or scraping, ensuring sufficient entwinement and connection strength during the air splicing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a drying operation is performed to remove extra water from the wound body, then water is evaporated from the outer peripheral surface side, but water moves from the center side to the outer peripheral surface side causing concentration phenomenon of sizing agent on the outer peripheral surface
Solution Approach 1:
The patent applies preliminary action by performing a sizing agent removal treatment before the connection process. The front end of the reinforcing fiber bundle from the new wound body and the tail end of the preceding wound body are subjected to sizing agent removal (reducing to 0-4 wt%) prior to air splicing. This preliminary treatment prevents the concentration phenomenon from affecting the connection quality, as the excessive sizing agent that would normally concentrate on the outer peripheral surface during drying is removed in advance.
2Ease of operation
If the amount of sizing agent is high on the reinforcing fiber bundle, then the gathered state is maintained and flexibility is generated, but surface friction becomes excessively small making entwinement difficult and reducing connection strength
Solution Approach 1:
The patent applies local quality by creating different sizing agent concentrations in different parts of the fiber bundle processing system. The front end and tail end portions (connection zones) have reduced sizing agent content (0-4 wt%) to enable proper entwinement and connection strength, while other portions of the fiber bundle maintain sufficient sizing agent for flexibility and gathered state. This localized differentiation allows each region to have the properties needed for its specific function.
3Ease of manufacture
If pressurized air is blown to unravel the fiber bundles for connection, then the fiber bundles are entwined, but breakage occurs at the connection part or in the long fiber reinforced resin strand due to insufficient connection strength
Solution Approach 1:
The patent applies preliminary action by performing sizing agent removal treatment on the connection portions before the air splicing operation. By reducing the sizing agent content to 0-4 wt% in advance, the fiber surfaces become sufficiently rough and adhesive to allow strong entwinement when pressurized air unravels and entangles the fibers. This preliminary preparation ensures that the connection achieves adequate strength to prevent breakage during subsequent processing.
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 adjustment provides the necessary connection strength to prevent breakages and enhance production efficiency by ensuring robust entwinement of the fiber bundles, maintaining the required tensile strength during the pellet production process.
Implementation Method 1
both the tail end and the front end are installed in an air splicer (a device for blowing pressurized air), the fiber bundles are unraveled to long fibers with the pressurised air
Implementation Method 2
heating or scraping, ensuring sufficient entwinement and connection strength
Data Source
AI summary
A method for connecting a tail end portion of a reinforcing fiber bundle of a preceding wound body to a front end portion of a reinforcing fiber bundle unwound from a new wound body by blowing pressurized air to both of the ends to unravel and entwine both of the reinforcing fiber bundles, wherein the method includes a preparation step for adjusting the amount of a sizing agent contained in the front end of the reinforcing fiber bundle unwound from the new wound body and the tail end of the preceding wound body to not less than 0wt% and not more than 4wt%, and the reinforcing fiber bundles are connected after the preparation step. It is thus possible for the reinforcing fiber bundle at the time of producing a long fiber reinforced thermoplastic resin pellet that is a material for the pellet to have a required connection strength, and to avoid the occurrence of interruption due to breakage, and accordingly allowing improvement in the production efficiency of the long fiber reinforced thermoplastic resin pellet, etc.