Fiber Tape Resin Deposition for Low-Load Cohesion
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Solution Overview
Problem
Current methods for treating fibers for tape laying processes either result in high resin load or fail to maintain fiber consistency and orientation, limiting their use in automatic tape laying and infusion/RTM-based manufacturing processes.
Innovation Solution
A method involving continuous electrostatic deposition of a first resin and a partial, permeable surface coating of a second resin applied through swirling or flocking, with controlled heating and pressure to achieve optimal resin distribution and fiber cohesion, while maintaining mechanical properties and allowing for infusion or RTM processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If preimpregnated fibres are obtained by hot melt process or solvent immersion process, then the fibres are preimpregnated with the required amount of resin, but the resin load is high and the process complexity increases
Solution Approach 1:
The patent applies partial impregnation by electrostatic deposition, where only a controlled amount of resin (less than 10% of fibre weight) is deposited on the fibre surface, rather than complete impregnation. This partial action reduces resin load while maintaining sufficient cohesion for tape laying processes.
Solution Approach 2:
The patent replaces traditional mechanical impregnation methods (hot melt process, solvent immersion) with electrostatic deposition. This substitution uses electrical fields to deposit resin particles onto fibres, eliminating the need for complex heating, pressing, or solvent evaporation systems.
2Quantity of substance
If dry fibres are used without resin treatment, then the resin load is minimal, but the fibres lack cohesion and consistency for automatic tape laying processes
Solution Approach 1:
The electrostatic deposition process allows resin particles to self-organize and deposit uniformly on fibre surfaces through electrical attraction. The fibres themselves serve as the substrate that attracts and holds the resin particles, eliminating the need for additional coating equipment or complex application mechanisms.
Solution Approach 2:
The patent changes the physical state of resin from liquid (in traditional processes) to charged particles, and controls the deposition through electrical parameters (voltage, charge density). This parameter change enables precise control of resin load while maintaining fibre consistency and orientation.
3Strength
If a thick resin coating is applied to ensure fiber cohesion, then the tape has sufficient consistency for tape laying, but the permeability for infusion or RTM processes is reduced
Solution Approach 1:
The patent applies resin locally on the fibre surface through electrostatic deposition, creating a thin, uniform coating (less than 10% of fibre weight) rather than a thick uniform layer. This local application provides sufficient cohesion at the fibre level while maintaining overall tape permeability for subsequent infusion or RTM processes.
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 a tape with improved cohesion and permeability, maintaining fiber integrity and enabling efficient use in automatic tape laying and infusion/RTM processes with minimal resin load, enhancing the production of composite materials.
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
Data Source
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.