Fiber Switching Textile Join for Continuous Resin Impregnation
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Solution Overview
Problem
Existing methods for producing fiber-reinforced resins face challenges in efficiently connecting reinforcing fibers during switching, leading to production inefficiencies due to complex manual operations or weak connections that can be untied by tension, and require multiple switching apparatuses for lateral arrangement.
Innovation Solution
A production apparatus and method that uses a switching apparatus to connect preceding and following reinforcing fibers by forming a textile with warp and weft threads, ensuring a strong connection and allowing continuous production without stopping the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcing fibers are connected by manual tying method, then connection strength is improved, but device complexity and operation difficulty increase
Solution Approach 1:
The patent replaces the manual mechanical tying operation with an automated air jet system that uses compressed air to entangle and connect fiber ends. This substitution eliminates complex manual manipulation while achieving sufficient connection strength through pneumatic action.
Solution Approach 2:
The patent employs compressed air jets to entangle the ends of preceding and new reinforcing fibers, creating a connection that can withstand subsequent tension during resin impregnation. The pneumatic system provides automated, repeatable connection without mechanical contact or manual intervention.
2Extent of automation
If air jet method is used to connect reinforcing fibers, then automation is improved, but connection strength deteriorates
Solution Approach 1:
The patent applies preliminary tension to the reinforcing fibers before the air jet connection is made. This pre-tensioning ensures that the fiber ends are properly aligned and under sufficient stress to create a strong entanglement when the air jet activates, preventing weak connections during the automated switching process.
Solution Approach 2:
The patent uses dynamic control of the air jet system, activating the compressed air flow at the precise moment when fiber ends are positioned for connection. The timing and duration of the air jet pulse are optimized to create strong entanglement connections while maintaining automated operation.
3Manufacturing precision
If multiple switching apparatuses are used for lateral arrangement, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent designs the switching apparatus to handle multiple reinforcing fibers simultaneously through a single device. The apparatus includes multiple fiber guides and a multi-nozzle air jet system that can connect several fiber bundles in one operation, eliminating the need for separate switching apparatuses for each fiber line.
Solution Approach 2:
The patent combines the functions of multiple individual fiber switching operations into a single integrated switching apparatus. By merging the connection operations for multiple fibers into one device, the system achieves the required manufacturing precision while reducing overall device complexity and space requirements.
4Productivity
If reinforcing fibers are switched during production, then productivity is improved, but connection reliability deteriorates
Solution Approach 1:
The patent enables continuous production by implementing an automated switching system that operates without stopping the resin impregnation process. The air jet connection method allows fiber transitions to occur seamlessly during production, maintaining continuous operation and high productivity while ensuring reliable connections through proper tensioning and pneumatic entanglement.
Data Source
AI summary
The present application provides an apparatus that is for producing a fiber-reinforced resin having reinforcement fibers aligned in one direction and that is capable of, with a relatively simple configuration, connecting a preceding reinforcement fiber and a subsequent reinforcement fiber when switching between the reinforcement fibers. An apparatus according to the present invention is for producing a fiber-reinforced resin having reinforcement fibers aligned in one direction, and comprises: an impregnation part which impregnates a reinforcement fiber with a resin; and a switching device which performs switching of reinforcement fibers on the upstream side of the impregnation part, from a preceding reinforcement fiber to a new reinforcement fiber. During the switching operation, the switching device forms a fabric using the preceding reinforcement fiber and the new reinforcement fiber as warp and other fibers as weft so as to connect the new reinforcement fiber with the preceding reinforcement fiber.