Monomer Saturation of Fiber Structures via Round Nozzle and Roll Pressure
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Solution Overview
Problem
Existing methods for producing saturated fiber structures, such as those used in reinforced polymers, face issues like nozzle blockages due to premature polymerization of monomers and inefficient distribution of solutions, particularly with slot nozzles and immersion baths.
Innovation Solution
A process involving the application of a monomer solution with a round nozzle of small diameter to a fiber structure on a conveyor belt, followed by passage through a roll pair under pressure, ensuring uniform distribution before solidification, while maintaining low viscosity to prevent polymerization and nozzle blockages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If slot nozzles are used for saturation, then the fiber structure can be saturated with monomer solution, but the monomer polymerizes in the nozzle and causes blockage
Solution Approach 1:
The patent changes the geometric parameters of the nozzle from a slot shape to a round cross-section with small diameter (0.1-2.0 mm). This parameter change reduces the hold-up volume of monomer in the nozzle, preventing premature polymerization and blockage while maintaining effective saturation of the fiber structure.
Solution Approach 2:
The patent employs a round nozzle cross-section instead of a slot nozzle. The curved/spherical geometry of the round nozzle reduces dead zones and minimizes monomer retention, thereby preventing polymerization-induced blockage compared to the flat slot geometry.
2Quantity of substance
If immersion bath is used for saturation, then the fiber structure can be saturated with monomer solution, but premature polymerization occurs in the bath
Solution Approach 1:
The patent extracts the saturation process from a large immersion bath environment and replaces it with targeted application through round nozzles followed by roll pressure. This eliminates the large volume of monomer solution that would otherwise be present and prone to premature polymerization.
Solution Approach 2:
The patent introduces rolls as an intermediary mechanism between monomer application and fiber saturation. The rolls apply pressure to force monomer into the fiber structure, eliminating the need for a large immersion bath and preventing premature polymerization.
3Quantity of substance
If spray-application or trickle-application is used, then the fiber structure can be coated with monomer solution, but uniform distribution is difficult to achieve
Solution Approach 1:
The patent uses rolls as an intermediary to transfer and distribute monomer uniformly across the fiber structure. The rolls apply controlled pressure to ensure even penetration and distribution of monomer, overcoming the non-uniformity inherent in spray or trickle application methods.
Solution Approach 2:
The patent replaces the aerodynamic/surface-tension-based spray or trickle application with a mechanical pressure system using rolls. This mechanical approach provides controlled, uniform distribution of monomer through direct pressure application, ensuring consistent saturation.
4Quantity of substance
If the monomer solution is applied and allowed to dry or cool before rolling, then the fiber structure can be saturated, but the viscosity rises and distribution becomes non-uniform
Solution Approach 1:
The patent performs the rolling operation immediately after monomer application, before the monomer can cool or evaporate and increase in viscosity. This preliminary action ensures the monomer remains in a low-viscosity state for uniform distribution while achieving saturation.
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 process ensures uniform distribution and prevents nozzle blockages, allowing for efficient production of saturated fiber structures that can be further processed into high-quality fiber-reinforced polymer components with reduced storage and processing time.
Implementation Method 1
cooling of the fiber structure, so that the monomer solidifies
Implementation Method 2
passage of the fiber structure with the solution through at least one roll pair in which pressure is exerted on the fiber structure
Data Source
AI summary
The invention relates to a process for the production of saturated fiber structures. The process includes (a) introduction of a fiber structure onto a conveyor belt; (b) application of a solution including monomer and optionally including activator, and optionally including catalyst in at least one line to the fiber structure; (c) passage of the fiber structure with the solution through at least one roll pair in which pressure is exerted on the fiber structure; and (d) cooling of the saturated fiber structure, so that the monomer solidifies.