Continuous Fiber Connecting Device for Resin Impregnated Composites
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Solution Overview
Problem
Existing three-dimensional object forming apparatuses face challenges in maintaining the rigidity of formed components due to fiber meandering, which can lead to decreased structural integrity, and struggle with efficient connection of continuous fiber bundles during the forming process.
Innovation Solution
A forming-material connecting device that includes a cutter to cut continuous fiber bundles and a joining portion to heat and join the resin materials of cut portions, ensuring seamless connection between trailing and leading ends of forming materials, thereby maintaining the structural integrity and preventing fiber meandering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If continuous fiber bundles are cut and connected during the forming process, then the forming material can be supplied continuously without breaks, but fiber meandering may occur at the cutting point which decreases rigidity
Solution Approach 1:
The cutter is positioned upstream of the heating portion to cut the forming material before it reaches the heating zone. This preliminary cutting allows the trailing end portion to be properly prepared and positioned for joining, ensuring that the cut surface is clean and ready for thermal bonding, thereby preventing fiber meandering at the connection point
Solution Approach 2:
The patent replaces mechanical joining methods with thermal joining using the heating portion. The heating portion melts the resin material at the cut surface and trailing end portion, creating a strong bond between the leading end portion of the current forming material and the trailing end portion. This thermal bonding process ensures proper fiber alignment and prevents meandering that would occur with mechanical joining methods
2Adaptability or versatility
If the cutter cuts all continuous fiber bundles, then the forming material can be disconnected and reconnected, but the structural integrity may be compromised at the cutting point
Solution Approach 1:
The heating portion changes the physical state of the resin material from solid to molten and back to solid, creating a strong thermal bond at the connection point. By controlling the temperature parameter, the system ensures that the resin material properly fuses the trailing end portion to the leading end portion, maintaining structural integrity while allowing disconnection and reconnection of the forming material
Solution Approach 2:
The forming material consists of continuous fiber bundles impregnated with resin material. The thermal joining process bonds both the fiber bundles and the resin material together at the connection point, creating a composite structure that maintains the structural integrity of the original continuous material. The resin material acts as a matrix that binds the fibers and provides additional strength at the joined interface
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 solution effectively suppresses fiber meandering, maintains the rigidity of formed components, and ensures continuous supply of forming materials without breaks, enhancing the layer forming efficiency and preventing defects like parting lines.
Implementation Method 1
a heating portion that, while heating, supports the trailing end portion of the forming material supplied by the delivering roller
Implementation Method 2
heating to join the resin materials of the portions of the forming material
Data Source
AI summary
A forming-material connecting device includes a cutter that cuts a forming material constituted by plural continuous fiber bundles being impregnated with a resin material and supplied in a supply direction corresponding to an extending direction of the plural continuous fiber bundles. The cutter cuts at least a portion of the plural continuous fiber bundles. The forming-material connecting device also includes a joining portion joining portions of the forming material, which are cut by the cutter at a cutting point in the forming material, on a downstream and upstream side with respect to the cutting point in the supply direction by heating to join the resin materials of the portions of the forming material, or the joining portion joins a preceding forming material's trailing end portion and a leading end portion of a following forming material by heating to join resin materials of the preceding forming material and following forming material.