Method and device for impregnating at least one fibre material
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Solution Overview
Problem
Existing impregnation apparatuses for quasi-continuous fiber materials face challenges in preventing molten plastics from rising into the fiber feed channel, leading to leakage and process interruptions, especially when dealing with high-viscosity plastics, and require complex systems to maintain pressure and prevent air inclusions.
Innovation Solution
An impregnation apparatus with a backflow-preventing region featuring an S-shaped fiber feed channel that combines with the plastics feed channel, using the fiber material's tensile stress to prevent plastics from rising, along with a separate plastics feed channel and a heating device for temperature control, and a modular fiber introduction means to facilitate easy installation and prevent plastics from entering the fiber feed channel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plastics material is fed into the mixing chamber under pressure, then impregnation of fiber material is improved, but molten plastic rises into the fiber feed channel causing leakage and process interruptions
Solution Approach 1:
The feed channel is divided into a first feed channel for fiber material and a second feed channel for plastics material that are separate at least in sections. This segmentation prevents the harmful interaction where molten plastic rises into the fiber feed channel, while still allowing both materials to be fed into the mixing chamber under pressure for effective impregnation.
Solution Approach 2:
The feed channels have different local structures optimized for their respective materials. The first feed channel for fiber material has dimensions and characteristics suited for fiber conveyance, while the second feed channel for plastics material is designed for molten plastic flow. This local differentiation allows each material to be fed optimally without interfering with the other.
2Object-generated harmful factors
If positive pressure is applied at the inlet of fiber material feed to prevent plastic rising, then leakage is prevented, but system complexity increases and mobility is limited
Solution Approach 1:
The harmful element (molten plastic) is extracted from the fiber feed channel by providing a separate second feed channel dedicated to plastics material. This eliminates the need for complex positive pressure systems at the fiber material inlet, as the plastic cannot rise into the fiber channel when separate pathways are provided.
Solution Approach 2:
The separate second feed channel acts as an intermediary pathway for plastics material, preventing direct contact between molten plastic and the fiber feed channel. This intermediary structure simplifies the overall system by eliminating the need for additional pressure control mechanisms.
3Object-generated harmful factors
If compressed air is used to prevent plastic rising, then leakage is prevented, but air inclusions form in the matrix material causing defects
Solution Approach 1:
The compressed air system is extracted/replaced by a structural solution where separate feed channels prevent plastic rising without requiring air pressure. This eliminates the source of air inclusions while maintaining effective leakage prevention.
Solution Approach 2:
The separate feed channel structure itself provides the leakage prevention function without requiring external compressed air assistance. The system is self-sufficient in preventing plastic rising through its geometric design rather than relying on external gas pressure.
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
Effectively prevents plastics from rising into the fiber feed channel, ensuring continuous fiber impregnation without interruptions, even at high melt pressures, and allows for controlled temperature management to maintain process efficiency.
Implementation Method 1
a plastics material which has been melted at a process temperature suitable for impregnation
Implementation Method 2
in which the fiber material is subjected to tensile stress in the conveying direction
Data Source
AI summary
The invention relates to an impregnating device for impregnating at least one quasi-endless fibre material with a plastic material which is melted at a corresponding process temperature, having at least one fibre supply channel a having a fibre feed to supply the quasi-endless fibre material to the impregnating device, and at least one plastic supply channel having a plastic feed separate from the fibre feed to supply the plastic material to the impregnating device separately from the fibre material, the at least one fibre supply channel and the at least one plastic supply channel being separate at least in some portions and opening out into a common impregnation cavity to impregnate the quasi-endless fibre material with the supplied and melted plastic material, characterised in that the impregnating device has a backflow-blocking region in which die fibre supply channel has, at least in some portions, an S-shaped profile which is formed by two curves with opposing curve directions, between which the fibre supply channel is joined with the at least one plastic supply channel so that a coalition channel portion is then formed.