Long Fiber Composite Impregnation with Stacked 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 apparatus with a main body featuring adjustable first and second through-hole plates with protrusions, allowing fiber bundles to penetrate in a zigzag pattern, enabling uniform resin impregnation and tension control, facilitating easy arrangement and reducing processing time and hazards.
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 processing time increase
Solution Approach 1:
The device divides the fiber bundle processing into multiple segments by using several through-hole plates (first through-hole plate, second through-hole plate, third through-hole plate) arranged in sequence. Each plate creates a localized tension zone, breaking down the complex zigzag arrangement into simpler, modular sections that collectively achieve uniform resin impregnation without requiring a single complex zigzag structure
Solution Approach 2:
The invention transitions from a planar zigzag arrangement to a three-dimensional structure by stacking multiple through-hole plates vertically. The fiber bundles pass through holes in different plates at different positions, creating a spatial distribution that applies tension more effectively and uniformly across the fiber bundle cross-section, eliminating the need for complex two-dimensional zigzag routing
2Manufacturing precision
If fiber bundles are arranged in a zigzag manner in high-temperature impregnation die, then resin impregnation is improved, but work hazard increases
Solution Approach 1:
The through-hole plates are designed with self-aligning features where the holes are positioned to automatically guide fiber bundles through the tension zones without requiring manual manipulation. The structure itself creates the necessary tension and routing, eliminating the need for workers to manually arrange fiber bundles in hazardous high-temperature environments
Solution Approach 2:
The fiber bundles are pre-routed through the series of through-hole plates before entering the high-temperature impregnation zone. The tension and arrangement are established in advance by the plate configuration, so that when fibers enter the hot zone, they are already properly positioned and tensioned, eliminating the need for hazardous post-positioning operations
3Strength
If resin has high viscosity for structural strength, then mechanical strength is improved, but resin permeation between filaments deteriorates
Solution Approach 1:
The device applies tension to fiber bundles before they enter the resin impregnation zone by routing them through the stacked through-hole plates. This pre-tensioning action opens up the fiber bundle structure and creates channels for resin penetration in advance, allowing high-viscosity resin to permeate effectively without requiring viscosity reduction
Solution Approach 2:
The invention replaces chemical methods (such as heating to reduce viscosity) with a mechanical approach. The stacked through-hole plates create mechanical tension that physically opens the fiber bundle structure, allowing high-viscosity resin to penetrate through the created channels without needing to chemically or thermally modify the resin properties
4Productivity
If fiber bundles are continuously drawn at high speed, then productivity is improved, but intense tension causes imperfect coating and poor dispersibility
Solution Approach 1:
The continuous high-speed fiber drawing process is divided into multiple discrete tension zones by the stacked through-hole plates. Each plate provides a localized tension application point, distributing the total tension requirement across several stages rather than one intense point, which prevents fiber damage and maintains coating quality at high speeds
Solution Approach 2:
The device is designed to dynamically adapt to high-speed continuous operation by using the vertical stacking of through-hole plates that allows fiber bundles to pass through multiple tension zones in rapid succession. The modular plate structure enables the system to maintain proper tension and coating quality even as operating speed increases, unlike fixed single-point tension systems
Data Source
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AI summary
A manufacturing apparatus of a long fiber composite material according to an exemplary embodiment of the present invention includes: a main body where an inlet through which a plurality of fiber bundles are penetrated is formed at one side and an outlet through the fiber bundles are discharged is formed at the other side; a plurality of first through-hole plates that are arranged in parallel with each other along a first direction in the main body and having a plurality of through-holes through which the plurality of fiber bundles are penetrated formed therein; and a second through-hole plate that is disposed between a pair of first through-hole plates that are adjacent to each other among the plurality of first through-hole plates, and through which the plurality of fiber bundles penetrated through the first through-hole plates are penetrated.