Fiber Spreading Apparatus Tension Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing prepregs with uniformly spread continuous multiple filament fiber bundles face challenges in achieving reduced gaps and improved fiber-resin distribution due to high tension, which can lead to fiber damage, decreased permeability, and increased process costs.
Innovation Solution
The use of a tension control module with a series of static bars and driven rollers, where the peripheral surface speed of the driven rollers is operated at least three times the line speed of the fiber bundle, allows for strategic tension control throughout the spreading apparatus, reducing the need for extremely high tensions and improving fiber spreading mechanics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If higher tension is applied to spread fiber bundles, then fiber spread width increases, but fiber permeability decreases and fiber damage increases
Solution Approach 1:
The patent applies dynamic tension control through driven rollers that rotate at varying speeds. The tension control module dynamically adjusts tension levels during the spreading process, using higher differential speeds between rollers to achieve fiber spread while maintaining fiber permeability and preventing damage through controlled tension variation rather than static high tension.
Solution Approach 2:
The patent changes the tension parameter dynamically during the spreading process. By controlling the speed differential between driven rollers, the system varies tension levels to optimize fiber spread at different stages, achieving adequate separation without subjecting fibers to continuously high tension that would reduce permeability and cause damage.
2Shape
If higher tension is applied to spread fiber bundles, then fiber spread width increases, but fiber damage increases
Solution Approach 1:
The patent uses dynamic tension control through driven rollers rotating at varying speeds to spread fibers gradually. This dynamic approach prevents sudden high tension spikes that would cause fiber breaking and fuzz formation, while still achieving adequate fiber spread through controlled tension variation throughout the processing line.
Solution Approach 2:
The tension control module with multiple driven rollers provides progressive tension application and release along the fiber path. This cushioning effect prevents concentrated high tension at any single point, protecting fibers from damage while maintaining spread effectiveness through distributed tension control.
3Shape
If higher tension is applied to spread fiber bundles, then fiber spread width increases, but process costs increase
Solution Approach 1:
The patent replaces static high-tension mechanical systems with dynamic tension control using driven rollers of varying speeds. This reduces the peak forces and torques required in the apparatus while achieving effective fiber spread, as the differential speed control creates tension variations that are more efficient than continuous high-tension mechanical loading.
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 approach results in a superior prepreg product with increased permeability, reduced gaps, and decreased fiber damage, leading to improved uniformity and quality of the final article manufactured.
Implementation Method 1
the peripheral surface speed of the driven rollers is operated at least three times the line speed of the running fiber bundle
Implementation Method 2
strategic use of tension control throughout the spreading apparatus
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Apparatus for producing spread fiber bundles by strategic use of tension control throughout the device and use of higher differential speeds between driven rollers and line speed of the running fiber bundle are provided herein, along with methods for producing spread fibers, prepregs, and articles of manufacture therefrom.