Fibre coating apparatus
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Solution Overview
Problem
Current methods for producing prepreg fiber tapes, such as solvent dip and hot melt processes, result in residual solvent issues, high void content, and fiber weakening during slitting, making them unsuitable for high-end applications like aerospace and energy-intensive.
Innovation Solution
An apparatus with a belt press and matrix application rollers that control the application of a viscous liquid matrix to a fiber tow, reducing process steps and energy consumption by eliminating intermediate paper backing and chilling stages, while ensuring consistent resin-to-fiber ratio through carefully controlled gaps and speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If solvent dip process is used to form prepreg, then resin coating is achieved, but residual solvent remains causing high void content and volatile problems
Solution Approach 1:
The patent removes the solvent from the resin application process entirely, using a solvent-free resin coating method where liquid resin is applied directly to fibers without dissolution in solvent, thereby eliminating residual solvent and void content issues
Solution Approach 2:
The patent changes the physical state and application parameters of resin from solvent-based liquid to pure liquid resin, controlling viscosity and application temperature to achieve proper coating without solvent evaporation and associated harmful effects
2Quantity of substance
If hot melt process with paper backing is used, then resin impregnation is achieved, but multiple process stages and energy consumption are required
Solution Approach 1:
The patent removes the intermediate paper backing sheet and chilling storage stage from the process, applying resin directly to fibers in a single continuous operation without requiring paper support or temperature cycling
Solution Approach 2:
The patent implements continuous resin application and fiber impregnation in a single passing-through operation, eliminating the start-stop nature of multi-stage processes including chilling, storage, and reheating
3Productivity
If wide sheets are used for efficient processing, then productivity is improved, but fiber cutting during slitting weakens the final product
Solution Approach 1:
The patent applies resin coating to individual fiber tows or narrow strips directly as they pass through the apparatus, rather than coating wide sheets and subsequently cutting them, thereby maintaining fiber continuity and eliminating cutting-induced weakness
Solution Approach 2:
The patent transitions from a wide-sheet planar processing approach to a multi-tow parallel processing approach, where multiple narrow fiber bundles are coated and processed simultaneously, achieving both high productivity and fiber integrity
4Manufacturing precision
If multiple process stages are used for prepreg formation, then resin application control is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines resin application, fiber impregnation, and excess resin removal into a single integrated apparatus where liquid resin is applied to fibers passing through a controlled gap, with the belt press simultaneously removing excess resin, eliminating the need for separate coating and pressing stages
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 reduces costs, minimizes fiber weakening, and achieves a consistent resin distribution, enhancing the quality of the prepreg fiber for high-end applications by eliminating residual solvent and void content, and optimizing energy use.
Implementation Method 1
a matrix application roller arranged to receive liquid matrix and transfer it to the fiber tow
Implementation Method 2
transfer the liquid matrix from the matrix application roller to the fiber tow
Implementation Method 3
a belt press arranged to receive the fiber tow and compress it between two moving belts
Implementation Method 4
applying a viscous liquid matrix to a fiber tow... ensuring consistent resin-to-fiber ratio through carefully controlled gaps and speeds
Data Source
AI summary
An apparatus for applying a liquid matrix to a fiber tow includes a belt press arranged to receive the fiber tow and compress it between two moving belts and a matrix application roller arranged to receive liquid matrix and transfer it to the fiber. The apparatus also includes a second matrix application component arranged adjacent to the matrix application roller so as to form a first gap between the component and the matrix application roller. The matrix application roller is positioned adjacent to the belt press so as to form a second gap between the matrix application roller and a belt of the belt press; and wherein the second gap is larger than the first gap.