Impregnation Section Upstream Surface for Fiber Roving Resin Coating
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Solution Overview
Problem
Current fiber roving impregnation methods using thermoset resins face challenges with bonding characteristics and temperature performance, leading to poor durability and strength in applications such as composite rods and profiles.
Innovation Solution
An impregnation section and method for fiber rovings using a polymer resin, featuring an impregnation zone and gate passage for uniform resin coating, combined with an upstream surface to maintain consistent spacing and enhance resin distribution, along with an extrusion device for thorough fiber impregnation, utilizing thermoplastic polymers with high melting temperatures and suitable viscosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermoset resins are used to achieve desired strength properties, then strength is improved, but bonding characteristics deteriorate and manufacturing difficulty increases
Solution Approach 1:
The patent changes the fundamental parameter of resin type from thermoset to thermoplastic polymers. This parameter change resolves the contradiction by providing materials that offer both desired strength properties and superior bonding characteristics, while also improving ease of manufacture through thermoplastic processing advantages
Solution Approach 2:
The patent employs composite material systems combining fiber rovings with thermoplastic polymer resins. This composite approach achieves the desired strength properties through optimized fiber-resin integration, while the thermoplastic matrix provides excellent bonding characteristics and manufacturability
2Ease of manufacture
If thermoplastic resins are used to improve ease of manufacture, then bonding characteristics improve, but temperature performance deteriorates
Solution Approach 1:
The patent selects thermoplastic polymers with specifically high melting temperatures as a parameter change. This resolves the contradiction by choosing thermoplastic materials that maintain excellent bonding characteristics while achieving the required temperature performance for high-temperature applications
Solution Approach 2:
The patent applies local quality by selecting specific thermoplastic polymer types with tailored properties. Different thermoplastic polymers with appropriate melting temperatures and viscosity characteristics are chosen for specific application requirements, optimizing both bonding characteristics and temperature performance for each use case
3Loss of substance
If inadequate wetting of fibers is used to reduce resin quantity, then loss of substance decreases, but durability and strength deteriorate
Solution Approach 1:
The patent changes the resin viscosity parameter to optimize wetting characteristics. By selecting thermoplastic polymers with suitable viscosity ranges, the system achieves complete and uniform fiber wetting with minimal resin quantity, eliminating dry spots while maintaining durability and strength
Solution Approach 2:
The patent ensures complete resin coverage of all fiber surfaces through optimized flow characteristics. This uniform coating approach, where resin completely impregnates the fiber roving, eliminates inadequate wetting issues and ensures consistent durability and strength throughout the composite structure
4Device complexity
If conventional impregnation methods are used to simplify the process, then device complexity decreases, but impregnation uniformity deteriorates
Solution Approach 1:
The patent incorporates a surface upstream of the impregnation zone that performs preliminary actions on the fiber roving. This surface ensures consistent spacing and proper positioning of fibers before they enter the impregnation zone, achieving uniform impregnation while maintaining process simplicity
Solution Approach 2:
The patent introduces an intermediary surface element between the resin delivery system and the fiber roving. This surface acts as a mediator that distributes the resin uniformly across the fiber bundle and ensures consistent impregnation, achieving manufacturing precision without significantly increasing device complexity
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 achieves improved strength, durability, and temperature performance of fiber-reinforced composites by ensuring consistent and thorough impregnation of polymer resin into fiber rovings, reducing void fractions and enhancing mechanical properties.
Implementation Method 1
a gate passage in fluid communication with the impregnation zone for flowing the resin therethrough such that the resin coats the roving
Implementation Method 2
The impregnation zone is configured to impregnate the roving with the resin... coating the roving with the resin, and traversing the coated roving through an impregnation zone to impregnate the roving with the resin
Data Source
AI summary
An impregnation section of a die (150) and a method for impregnating at least one fiber roving with a polymer resin are disclosed. The impregnation section includes an impregnation zone (250) configured to impregnate the roving (142) with the resin and a gate passage (270) in fluid communication with the impregnation zone for flowing the resin therethrough such that the resin coats the roving. Additionally, the impregnation section includes a surface (253) disposed upstream of the impregnation zone in a run direction of the roving for contacting the roving. The method includes traversing at least one fiber roving over a surface, flowing a polymer resin through a gap (274), the gap being in the range between approximately 0.1 millimeters and approximately 4 millimeters, coating the roving with the resin, and traversing the coated roving through an impregnation zone (250) to impregnate the roving with the resin.