Fiber Roving Impregnation Die with Branched Manifold
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Solution Overview
Problem
Current fiber roving impregnation methods using thermoset resins face challenges with bonding characteristics and temperature performance, leading to poor durability and strength in applications like composite rods and profiles.
Innovation Solution
A die and method involving a manifold assembly with branched runners and an impregnation zone, where the polymer resin is flowed through to coat and impregnate fiber rovings under tension, ensuring uniform distribution and high temperature performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermoset resins are used to achieve desired strength properties, then strength is improved, but bonding characteristics and temperature performance deteriorate
Solution Approach 1:
The patent changes the material parameter from thermoset resin to thermoplastic resin, which fundamentally alters the bonding characteristics and temperature performance. Thermoplastic resins provide reversible bonding through melting and solidification, enabling better temperature performance and reworkability while maintaining strength through proper processing parameters.
Solution Approach 2:
The patent creates a composite material system using thermoplastic resin combined with fiber rovings (carbon fiber, glass fiber, or aramid fiber). This composite structure achieves the desired strength properties while the thermoplastic matrix provides improved bonding characteristics and temperature performance compared to thermoset systems.
2Ease of manufacture
If Bryant et al. method is used to embed carbon fibers into thermoplastic resin, then manufacturing is simplified, but durability and strength deteriorate due to inadequate wetting
Solution Approach 1:
The patent applies preliminary action by pre-heating the thermoplastic resin to its melting point before fiber impregnation. This ensures the resin is in a fluid state with optimal wetting characteristics before contact with fibers, preventing inadequate wetting and resulting flaws. The resin is then cooled to solidify and bond the fibers together.
Solution Approach 2:
The patent changes the processing parameters by controlling temperature through heating and cooling cycles. The resin is heated to melt and wet the fibers thoroughly, then cooled to solidify and create strong bonds. This temperature control ensures complete impregnation without voids or dry spots, achieving both ease of manufacture and high strength.
3Ease of manufacture
If conventional impregnation methods are used, then manufacturing is simpler, but void fractions increase leading to poor durability
Solution Approach 1:
The patent applies preliminary action by pre-heating the thermoplastic resin to its melting point before fiber impregnation. This ensures the resin is in a fluid state with optimal wetting characteristics before contact with fibers, preventing inadequate wetting and resulting flaws. The resin is then cooled to solidify and bond the fibers together.
Solution Approach 2:
The patent ensures continuous impregnation by maintaining the resin in a molten state throughout the fiber passage, allowing continuous wetting and impregnation without interruption. This continuous process prevents void formation and ensures complete fiber coverage, improving durability while maintaining manufacturing simplicity.
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 achieves improved strength, durability, and temperature performance of fiber-reinforced composites by ensuring thorough resin impregnation and uniform coating of fiber rovings, reducing void fractions and enhancing mechanical properties.
Implementation Method 1
The manifold assembly flows the resin therethrough... The gate passage flows the resin from the manifold assembly...
Implementation Method 2
the resin coats the roving... impregnate the roving with the resin... ensuring thorough resin impregnation and uniform coating
Implementation Method 3
The roving is under a tension of from about 5 Newtons to about 300 Newtons within the impregnation zone
Data Source
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AI summary
A die and a method for impregnating fiber rovings (142) with a polymer resin (214) are disclosed. The die includes a manifold assembly (220), an impregnation zone, and a gate passage (270). The manifold assembly flows the resin (214) therethrough, and includes a plurality of branched runners (222). The impregnation zone is in fluid communication with the manifold assembly, and is configured to impregnate the roving with the resin. The gate passage (270) is between the manifold assembly and the impregnation zone (250), and flows the resin from the manifold assembly such that the resin coats the roving. The method includes flowing a polymer resin through a manifold assembly. The method further includes coating at least one fiber roving with the resin, and traversing the coated roving through an impregnation zone to impregnate the roving with the resin. The roving is under a tension of from about 5 Newtons to about 300 Newtons within the impregnation zone.