Fiber Composite Material with Binder Ribbon Yarns
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Solution Overview
Problem
Existing methods for producing hybrid fiber composite materials face challenges in evenly applying the matrix material and integrating different types of filaments with varying mechanical properties, leading to inconsistencies in the final product.
Innovation Solution
The use of ribbon yarns with a specific width-to-thickness ratio, fixed with binders, in a sandwich structure with reinforcing fibers or filaments, allows for even matrix distribution and simplified processing, enabling uniform and cost-effective production of fiber composite materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If different types of filaments are separated or spread out to produce hybrid fiber composites, then the mechanical properties can be optimized, but it leads to problems in handling and uneven distribution of matrix material
Solution Approach 1:
The patent applies composite materials by combining reinforcing filaments with binder filaments to form a hybrid yarn structure. This composite yarn integrates multiple material types (glass, aramid, carbon filaments with polyester or polyamide binders) into a unified structure that maintains optimized mechanical properties while eliminating handling difficulties and ensuring even matrix distribution during composite production.
2Manufacturing precision
If matrix material is applied over and/or under reinforcing fibers to produce fiber composites, then the composite structure is formed, but it is difficult to apply the matrix material evenly
Solution Approach 1:
The patent merges the matrix material function into the yarn structure itself by incorporating binder filaments (polyester or polyamide) within the hybrid yarn. This integration ensures that as the yarn is laid down during composite production, the matrix material is automatically and evenly distributed along with the reinforcing filaments, eliminating application difficulties and ensuring uniform distribution.
Solution Approach 2:
The binder filaments act as an intermediary between the reinforcing filaments and the external matrix material application process. These binder filaments are already positioned within the yarn structure, serving as pre-placed intermediaries that ensure even matrix distribution and proper bonding between reinforcing filaments during composite formation.
3Strength
If continuous endless filaments are used as reinforcing fibers, then the fiber composite material achieves high strength, but the production process requires temperature and pressure treatment to melt the matrix material
Solution Approach 1:
The patent applies parameter changes by selecting binder filaments with lower melting points (polyester or polyamide) compared to traditional matrix materials. This parameter change in material selection allows the composite to achieve high strength through continuous filaments while reducing the energy required for the melting and consolidation process, as these binder materials melt at lower temperatures under pressure.
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 results in a very even and uniform fiber composite material with improved handling and processing capabilities, achieving short consolidation paths and consistent product quality.
Implementation Method 1
This arrangement is fixed using suitable binders, such as sizings or thermoplastic adhesives.
Implementation Method 2
The matrix material is then melted using temperature and, if necessary, pressure in order to obtain the fiber composite material.
Implementation Method 3
The fiber composite material obtained in this way is then consolidated thermally and/or under pressure in order to be further processed as so-called organo sheet
Data Source
Figure 1
AI summary
the invention relates to a fiber composite material comprising one or more layer(s) of reinforcing fibers or reinforcing filaments and containing one or more layer(s) of tape yarn connected thereto, and to a method for producing the same.