Fiber Tape Electrostatic Resin Coating for Minimal Resin Load
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Solution Overview
Problem
Current methods for treating fibers for tape laying processes either result in excessive resin load or fail to maintain fiber consistency and orientation during automated tape laying, particularly in infusion or RTM-based manufacturing processes.
Innovation Solution
A method involving continuous electrostatic deposition of a first resin with controlled particle size and partial permeable surface coating of a second resin using a swirling or flocking process, combined with heat and pressure application to achieve optimal cohesion and permeability in the treated fiber tapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a resin coating is applied to fibres to improve consistency and orientation during automated tape laying, then fiber consistency is improved, but resin load increases
Solution Approach 1:
The patent applies a partial coating approach where only the outer surface of the fiber bundle is coated with resin, rather than fully impregnating the entire bundle. This creates a permeable surface layer that maintains fiber consistency during handling while leaving the inner fibers resin-free, thus reducing overall resin load while still providing the necessary protective function.
Solution Approach 2:
The resin coating is applied selectively to different regions of the fiber bundle with different properties: the outer surface receives a permeable resin coating that provides consistency and allows resin flow, while the inner fibers remain uncoated to maintain low resin load. This local differentiation resolves the contradiction between needing surface stability and minimizing overall resin quantity.
2Stability of the object's composition
If a resin coating is applied to fibres to maintain orientation during automated tape laying, then orientation stability is improved, but resin load increases
Solution Approach 1:
The patent applies resin coating only partially to the fiber bundle surface, creating just enough orientation stability for automated tape laying without fully impregnating the fibers. This partial action provides the necessary orientation control while minimizing resin consumption and load.
3Quantity of substance
If dry fibres are used to minimize resin load, then resin load is reduced, but fiber cohesion and consistency deteriorate
Solution Approach 1:
The patent creates a local quality distinction where the outer surface of the fiber bundle has resin coating providing cohesion and consistency, while the inner fibers remain dry with minimal resin. This local differentiation allows the bundle to maintain overall cohesion through the surface layer while keeping the total resin load minimal.
Solution Approach 2:
The resin coating is designed to be permeable rather than forming a solid continuous layer. This porous structure provides enough cohesion to maintain bundle integrity and orientation stability, while still allowing resin flow during manufacturing processes and minimizing the total resin quantity required.
4Stability of the object's composition
If preimpregnated fibres are used to improve fiber consistency, then consistency is improved, but handling complexity increases due to curing requirements
Solution Approach 1:
The patent uses partial preimpregnation where only the surface fibers are coated with resin, rather than fully preimpregnating the entire bundle. This reduces the degree of pre-curing needed and simplifies handling, as the inner dry fibers do not require the same level of temperature control and curing management as fully preimpregnated bundles.
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 method achieves fiber tapes with improved mechanical properties and reduced resin load, maintaining fiber integrity and enabling efficient resin flow during subsequent manufacturing processes, while maintaining structural integrity and facilitating infusion or injection processes.
Implementation Method 1
applying a first resin to the bundle of fibres by electrostatic deposition of particles of the first resin
Implementation Method 2
bonding the particles of the first resin to the bundle of fibres by heating, which allows completely or partially melting the particles
Implementation Method 3
applying a partial and permeable surface coating to at least one side of the bundle of fibres by depositing filaments of a second resin
Implementation Method 4
applying a partial and permeable surface coating to at least one side of the bundle of fibres by depositing filaments of a second resin, the thickness of the surface coating preferably being less than 0.2 mm
Implementation Method 5
combined with heat and pressure application to achieve optimal cohesion and permeability in the treated fiber tapes
Data Source
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Figure 3
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AI summary
The invention relates to a method for treating fibres, to an installation for treating fibres and thus obtained tape made of treated fibres. The treatment method comprises the steps of continuously supplying a bundle of fibres (1), applying a first resin (51) to the bundle of fibres (1) by electrostatic deposition of particles of the first resin (51), bonding the particles of the first resin (51) to the bundle of fibres (1) by heating, and applying a surface coating to at least one side of the bundle of fibres (1) by depositing filaments of a second resin (91), such that the thus obtained tape made of fibres has a minimum resin load in relation to the fibre used.