Fiber-Reinforced Resin Sheet With Random Fiber Orientation
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Solution Overview
Problem
Existing methods for manufacturing fiber-reinforced resin materials, such as SMC and stampable sheets, result in directional alignment of fiber bundles, leading to uneven strength distribution and reduced productivity due to directionality and the generation of fluff during the manufacturing process.
Innovation Solution
A manufacturing device and method that utilizes rods or gas diffusion to disperse cut fiber bundles uniformly without directionality, combined with a fiber bundle group inspection device to ensure stable and continuous production of fiber-reinforced resin materials with uniform strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the conveying speed of the sheet is decreased to reduce fiber bundle directionality, then the strength uniformity improves, but the productivity deteriorates
Solution Approach 1:
The fiber bundles are scattered on the paste before the sheet is conveyed, creating a random orientation pattern in advance. This preliminary scattering action ensures that even when the sheet moves at high speed, the fiber bundles maintain their random orientation and do not align in the conveying direction, thus preserving strength uniformity while allowing high productivity
Solution Approach 2:
Instead of relying on slow conveyance to prevent fiber alignment, the invention inverts the approach by actively scattering fibers in random directions before conveyance. The scattering mechanism creates an opposite effect to the natural alignment tendency, ensuring random orientation even at high conveying speeds
2Strength
If a rotating drum is used to disperse fiber bundles and reduce directionality, then the strength uniformity improves, but fluff generation increases and device complexity increases
Solution Approach 1:
The harmful rotating drum mechanism is completely removed from the system. Instead of using mechanical rotation to disperse fibers, the invention extracts only the essential function of random scattering by having cut fiber bundles naturally scatter on the paste surface, eliminating fluff generation while maintaining strength uniformity
Solution Approach 2:
The fiber bundles scatter themselves randomly on the paste surface without requiring external mechanical assistance. The cutting process and gravity-driven dropping create natural random orientation, eliminating the need for rotating drums and associated fluff generation while achieving the desired strength uniformity
Data Source
Figure 1
Figure 2~3
Figure 4A~4C
AI summary
The disclosure provides a fiber-reinforced resin material having minimal directionality of strength as well as excellent productivity, a method and device for manufacturing a fiber-reinforced resin material whereby a molded article is obtained, and a device for inspecting a fiber bundle group. A method for manufacturing a sheet-shaped fiber-reinforced resin material in which a paste (P1) is impregnated between cut fiber bundles (CF), the method for manufacturing a fiber-reinforced resin material including a coating step applying a coating of a paste (P1) on a first sheet (S11) conveyed in a predetermined direction, a cutting step for cutting a long fiber bundle (CF) using a cutter (113A), a scattering step for dispersing the cut fiber bundles (CF) and scattering the cut fiber bundles (CF) on the paste (P1), and an impregnation step for pressing a fiber bundle group (F1) and the paste (P1) on the first sheet (S11) and impregnating the paste (P1) between the fiber bundles (CF).