Fiber Spreading for Composite Pultrusion
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Solution Overview
Problem
Current methods for producing fiber-reinforced composite materials, such as those used in tension members and suspension elements, lack the ability to achieve a controlled and reproducible arrangement of fibers, leading to inconsistent mechanical properties and high production costs, particularly for belt-shaped materials with a greater width than height.
Innovation Solution
A continuous process involving the spreading of rovings to create a wider cross-section with an even distribution and alignment of fibers, followed by impregnation with a polymer and pultrusion, allowing for precise control over fiber orientation and distribution, resulting in a composite material with enhanced mechanical properties suitable for load applications like elevator systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional discontinuous towpreg production is used, then fiber coating is achieved, but production speed is slow and costs are high
Solution Approach 1:
The patent implements a continuous production process where fibers are constantly fed through the extrusion zone without interruption. The continuous feeding device maintains steady fiber supply while the extruder continuously deposits polymer matrix, eliminating the batch-by-batch operations of conventional towpreg production and enabling high-speed manufacturing.
Solution Approach 2:
The patent pre-arranges fibers in a specific configuration using the spreading device before they enter the impregnation zone. This preliminary fiber arrangement ensures optimal fiber distribution and orientation is established prior to polymer deposition, enabling continuous processing without requiring post-processing alignment steps.
2Manufacturing precision
If pultrusion with liquid polymer is used, then fiber impregnation is achieved, but fiber distribution is uneven and non-controllable
Solution Approach 1:
The patent replaces the traditional liquid polymer impregnation method with a mechanical extrusion process. A solid polymer material is fed into an extruder that melts and deposits the polymer matrix in a controlled manner directly onto the fibers. This mechanical deposition system provides precise control over polymer application rate, fiber distribution, and material composition through extrusion parameters rather than relying on liquid absorption which is difficult to control.
Solution Approach 2:
The patent incorporates sensors and control systems that monitor fiber feed rate, polymer extrusion rate, and resulting composite properties in real-time. This feedback information is used to automatically adjust process parameters to maintain consistent fiber distribution and material quality, enabling precise manufacturing control.
3Manufacturing precision
If fibers are spread and aligned, then fiber orientation is improved, but process complexity increases
Solution Approach 1:
The patent uses a spreading device that opens fibers in the transverse direction (width) rather than attempting to align them longitudinally. By spreading fibers apart laterally before polymer deposition, the process achieves controlled fiber distribution and orientation through a simpler mechanical action that works in perpendicular dimension to the fiber length.
Solution Approach 2:
The patent introduces a polymer matrix as an intermediary substance that binds the spread fibers together in their desired arranged configuration. The extruded polymer acts as a binding medium that fixes the fiber positions established by the spreading device, achieving the final oriented structure through the combined action of mechanical spreading followed by polymer consolidation rather than direct fiber manipulation.
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 process enables the production of fiber-reinforced composite materials with a well-defined fiber structure and improved mechanical properties, including high tensile strength and thermal resistance, while reducing production costs and ensuring reproducibility and controllability of fiber arrangement.
Implementation Method 1
an extruder for melting and depositing polymer material onto the spread rovings
Implementation Method 2
impregnating the at least two rovings brought together with a polymer and/or a polymer precursor
Implementation Method 3
pultruding the at least two impregnated rovings
Data Source
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AI summary
The invention relates to a continuous method for producing a fiber-reinforced composite material consisting of multiple fibers embedded in a polymer matrix, in particular for producing a tension member, said method having the following steps: -providing at least two rovings, -spreading the at least two rovings, -joining the at least two spread rovings such that the at least two joined rovings form fiber layers that are arranged one above the other and/or one next to the other at least in some regions, -impregnating the at least two joined rovings with a polymer and/or a polymer precursor, and -pultruding the at least two impregnated rovings.