Long Fiber Composite Impregnation Using Adjustable Through-Hole Plates
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Solution Overview
Problem
Existing methods for manufacturing long fiber composite materials face challenges in uniformly impregnating resin onto fiber bundles, especially with high-viscosity resins, leading to poor dispersibility and irregular pores, which affect mechanical and physical properties, and require complex zigzag arrangements in high-temperature environments, increasing work hazards and processing time.
Innovation Solution
A manufacturing method and apparatus that adjust the heights of through-hole plates to control fiber bundle tension and facilitate uniform resin impregnation, allowing for easy zigzag arrangement and reduced processing time, using a main body with first and second through-hole plates of varying heights to guide fiber bundles and adjust tension based on fiber and resin types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fiber bundles are arranged in a zigzag manner to apply tension for resin impregnation, then resin coating uniformity is improved, but device complexity and work hazard increase
Solution Approach 1:
The patent employs movable guide rollers that can dynamically adjust their positions to create zigzag paths for fiber bundles. This dynamic arrangement allows the system to apply tension effectively while avoiding the complexity of fixed zigzag structures, and reduces work hazards by enabling safe adjustment away from high-temperature zones.
Solution Approach 2:
The patent introduces vertical dimension by arranging guide rollers at different heights and using movable components that can shift positions in three-dimensional space. This creates effective zigzag tensioning paths without requiring complex horizontal arrangements, simplifying the overall device structure while maintaining resin coating uniformity.
2Manufacturing precision
If fiber bundles are arranged in a zigzag manner for tension application, then resin impregnation is improved, but processing time increases
Solution Approach 1:
The patent implements continuous movement of fiber bundles through the impregnation system with guide rollers that maintain constant tension. The movable guide rollers enable continuous zigzag path adjustment without stopping the production line, ensuring continuous resin impregnation while maintaining quality, thus reducing overall processing time compared to batch or intermittent methods.
3Strength
If high-viscosity resin is used for coating, then mechanical strength is improved, but resin dispersibility worsens
Solution Approach 1:
The patent applies tension to fiber bundles using movable guide rollers before resin impregnation occurs. This preliminary tensioning action separates and aligns fiber filaments, creating better pathways for high-viscosity resin to penetrate and distribute evenly throughout the bundle, thereby improving dispersibility while maintaining the strength benefits of high-viscosity resin.
Solution Approach 2:
The patent changes the physical state and arrangement parameters of fiber bundles by applying dynamic tension through movable guide rollers. This alters the fiber bundle configuration from a compact, hard-to-impregnate state to an extended, well-separated state that facilitates better resin distribution, enabling effective use of high-viscosity resins with improved dispersibility.
Data Source
AI summary
A manufacturing method of a long fiber composite material according to an exemplary embodiment of the present invention includes: preparing a main body where inlets and outlets through which a plurality of fiber bundles are respectively charged into and discharged from are formed; adjusting a height of a plurality of first through-hole plates and a height of a second through-hole plate that are disposed in the main body to be the same; having the plurality of fiber bundles penetrated through the first through-hole plate and the second through-hole plate; and adjusting the height of the first through-hole plate and the height of the second through-hole plate to be different from each other after penetrating the plurality of fiber bundles through the first through-hole plate and the second through-hole plate.