Longitudinal Splitting of Fiber Bundles for High Volume Fraction Preforms
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Solution Overview
Problem
Current methods for producing fiber preforms with high fiber volume percentages are cost-inefficient due to the high cost of high linear density fiber bundles and the difficulty in achieving high fiber volume fractions, which results in components with weak points and limited mechanical characteristics.
Innovation Solution
A deposition device with a controllable positioning unit, longitudinal splitting device, and cut-to-length unit that processes continuous, ribbon-shaped strands of reinforcing fibers with a binder to produce fiber bundles with reduced filament counts, allowing for high fiber volume percentages while using cost-efficient high linear density yarns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If high linear density fiber bundles are used to achieve high fiber volume percentages, then fiber volume fraction is improved, but production cost increases significantly
Solution Approach 1:
The invention divides high linear density fiber bundles into multiple smaller bundles through a splitting device. This segmentation allows the use of more numerous, smaller bundles (e.g., 1000-3000 filaments each) instead of fewer, larger bundles, achieving high fiber volume fractions while using cost-efficient standard fiber bundle sizes. The splitting device mechanically divides the continuous fiber strand into separate bundles that can be deposited individually.
2Quantity of substance
If high linear density fiber bundles are used to achieve high fiber volume percentages, then fiber volume fraction is improved, but the number of available source materials decreases
Solution Approach 1:
The invention segments continuous fiber strands into multiple smaller bundles, enabling the use of standard, readily available fiber bundle specifications (1000-3000 filaments) as source materials. This approach increases adaptability by working with common materials rather than requiring specialized high linear density bundles, thus expanding the pool of available source materials while maintaining high fiber volume fractions.
3Productivity
If short-cut fibers are sprayed and dispersed on a screen to produce fiber preforms, then deposition speed is improved, but fiber volume fraction remains limited to approximately 15 vol. %
Solution Approach 1:
The invention performs preliminary splitting of continuous fiber strands into smaller bundles before the deposition process. This preliminary action enables the deposition of higher fiber volume fractions (above 15 vol.%) while maintaining continuous spray deposition methodology. The splitting occurs in advance, allowing the deposition system to process pre-divided bundles that pack more efficiently on the mold surface.
4Quantity of substance
If fiber bundles with low filament counts are used to achieve high fiber volume percentages, then fiber volume fraction is improved, but production cost increases
Solution Approach 1:
The invention segments continuous fiber strands into multiple smaller bundles with moderate filament counts (1000-3000 filaments each). This segmentation strategy achieves high fiber volume fractions by using many smaller bundles rather than few large bundles, while the moderate filament count per bundle corresponds to standard, cost-efficient fiber materials. The splitting device enables this segmentation without requiring expensive specialized low filament count bundles.
Data Source
AI summary
A deposition device for controlled deposition of reinforcing fiber bundles on a surface, including a deposition head and a controllable positioning unit, means for providing at least one strand of reinforcing fibers provided with a binder, and a first conveying device, arranged on the deposition head conveys the at least one strand to the deposition head, wherein, when viewed in the conveying direction, means for spreading the at least one strand are arranged on the deposition head, and the deposition head has a second conveying device arranged after the first conveying device, a longitudinal splitting device, arranged between the first and second conveying devices, with at least one splitting element for splitting the at least one strand along the longitudinal extension thereof into two or more partial strands, and a cut-to-length unit arranged after the second conveying device for cutting-to-length the two or more partial strands into fiber bundles.