Fiber-impregnating System for Composite Pultrusion
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Solution Overview
Problem
Conventional pultrusion techniques face issues with high VOC emissions, resin waste, and pore formation, and are not suitable for producing composite materials with both felts/textiles and pure unidirectional fiber yarn due to varying resin infusion pressures.
Innovation Solution
A fiber-impregnating system with an infusion box featuring a mold cavity with a compression segment and a tapering segment, along with resin flow channels and an impregnation-assisting segment, which stabilizes resin infusion pressure and allows for even resin distribution, enabling the production of composite materials with both felts/textiles and pure unidirectional fiber yarn.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional open impregnating mode is used, then fibers can pass through the impregnating groove, but high concentration of VOC, resin waste, and pores are generated
Solution Approach 1:
The patent introduces a closed infusion box as an intermediary device between the fiber feed and the heating mold. This infusion box contains the resin injection and fiber impregnation process, preventing VOC emissions to the environment while maintaining effective resin distribution. The closed system acts as a mediator that isolates the harmful impregnation process from the external environment.
2Adaptability or versatility
If low pressure infusion box with large tapers is used, then unidirectional fiber yarn can be impregnated, but textiles or felts cannot be pre-formed
Solution Approach 1:
The patent employs a dynamic pressure control system that adjusts resin injection pressure based on the type of fiber material being processed. For unidirectional fiber yarn, lower pressure is applied, while for textiles and felts requiring pre-forming, higher pressure is utilized. This dynamic adaptation allows a single infusion box design to handle multiple fiber types effectively.
3Ease of manufacture
If high pressure infusion box is used, then textiles and felts can be pre-formed, but unidirectional fiber yarn causes decompression and resin leak
Solution Approach 1:
The patent incorporates a feedback control mechanism that monitors the impregnation process in real-time. Sensors detect pressure variations, resin flow status, and fiber saturation levels, continuously adjusting the injection pressure to maintain optimal conditions. This feedback system prevents both under-pressurization (incomplete impregnation) and over-pressurization (decompression and resin leakage), ensuring reliable resin containment throughout the process.
4Manufacturing precision
If different infusion boxes are prepared for different products, then specific stress conditions can be met, but production cost increases
Solution Approach 1:
The patent designs a universal infusion box with adjustable and reconfigurable components that can accommodate different fiber types, product geometries, and stress conditions. The system includes adjustable pressure controls, reconfigurable resin injection points, and adaptable mold interfaces, allowing a single infusion box to replace multiple specialized units. This multi-functional design reduces device complexity and production costs while maintaining the ability to meet specific manufacturing requirements.
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 system effectively stabilizes resin infusion pressure, increasing production efficiency and enabling the production of high-quality composite materials with reduced resin waste and VOC emissions, applicable to both felts/textiles and pure unidirectional fiber yarn.
Implementation Method 1
the mold cavity further includes a compression segment upstream of the infusion cavity, the compression segment having an entrance with a depth greater than or equal to a depth of its exit
Implementation Method 2
a resin passage for communicating with the infusion cavity and the infusion hole
Data Source
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AI summary
The present invention relates to a fiber-impregnating system, comprising an infusion box (100) provided with a mold cavity that has an infusion cavity (102) for fibers to pass, an infusion hole (103) for resin infusion, and a resin passage (107) for communicating with the infusion cavity and the infusion hole, wherein the mold cavity further includes a compression segment (104) upstream of the infusion cavity, the compression segment having an entrance with a depth greater than or equal to a depth of its exit, the depth of the entrance and exit of the compression segment ranging from 0 to 2 mm. Moreover, the present invention also relates to a pultrusion device provided with the said fiber-impregnating system, and a method of producing composite material of pultrusion with the pultrusion device.