Fixed carbon fiber bundle and method for producing fixed carbon fiber bundle
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Solution Overview
Problem
Existing methods for producing composite materials with carbon fibers struggle with uniform division and control of filament number, leading to issues like non-uniform bundle width, cracking, and high processing stress, especially when attempting to create narrow-width carbon fiber bundles.
Innovation Solution
A fixed carbon fiber bundle is developed where a thermoplastic resin fixing agent with a specific softening point is applied to at least one side, controlling the bundle's thickness and width to achieve a stable dividing tear load, allowing for precise division and reduced processing stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If heat-fusible yarn is supplied in a meandering shape to fill the surface of the carbon fiber bundle, then the carbon fiber bundle is maintained in a parallel state, but the bundle width becomes non-uniform due to heat shrinkage after melt solidification
Solution Approach 1:
The patent changes the physical state parameters of the fixing agent by controlling its softening point (60-250°C) and applying heat treatment at specific temperatures to achieve desired bonding strength while maintaining bundle width uniformity. The heat treatment temperature and duration are optimized to prevent excessive shrinkage while ensuring proper fixation.
Solution Approach 2:
The fixing agent undergoes phase transition from solid to molten state during heat treatment, then solidifies to bond the carbon fiber bundle. This phase change allows the fixing agent to flow and fill gaps uniformly, then solidify to provide stable fixation without excessive shrinkage that would cause width non-uniformity.
2Stability of the object's composition
If heat-fusible fiber is supplied in a meandering shape, then the surface is filled, but fuzz is easily generated in areas where the fiber is not supplied
Solution Approach 1:
The fixing agent acts as an intermediary material that bonds carbon fibers together. By applying it uniformly across the entire surface including areas where meandering yarn is not supplied, it prevents fuzz generation by securing loose fibers without creating the mixed supplied/not-supplied regions that cause fuzz.
3Ease of manufacture
If the carbon fiber bundle is divided using conventional methods, then the bundle can be separated, but the dividing tear load exceeds 1.00N requiring large apparatus and high processing stress
Solution Approach 1:
The patent extracts the bonding function from mechanical interlocking and conventional high-force division methods, and replaces it with a chemical/adhesive bonding mechanism using the fixing agent. This allows the bundle to be divided with much lower force (0.02-1.00N) while maintaining control over the division process.
4Manufacturing precision
If the average thickness of the carbon fiber bundle is made thin to enable division, then the bundle may crack in the width direction at unintended places
Solution Approach 1:
The fixing agent is applied to the carbon fiber bundle before division to pre-strengthen it. This preliminary bonding action prevents cracking during subsequent thinning and division operations, allowing the bundle to be made thin (180μm or less) without compromising structural integrity.
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 solution enables stable division of carbon fiber bundles with controlled thickness and width, reducing the risk of cracking and processing stress, while maintaining the material's mechanical properties, and facilitating the production of composite materials with improved dimensional stability.
Implementation Method 1
a fixing agent adheres to at least one side of the carbon fiber bundle
Implementation Method 2
an average thickness of the fixed carbon fiber bundle is 180 μm or less, and a dividing tear load of the fixed carbon fiber bundle is 0.02N or more and 1.00N or less
Data Source
AI summary
The present invention provides a fixed carbon fiber bundle to which a fixing agent is adhered, wherein the fixing agent adheres to an area comprising at least 50% of at least one side of a carbon fiber bundle, the average thickness of the fixed carbon fiber bundle is 180 μm or less, and the separated fiber tear load is 0.02N to 1.00N.