Method and device for producing hybrid fibre bundle
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Solution Overview
Problem
Existing methods for producing hybrid fiber bundles result in inhomogeneous mixing of reinforcing and matrix fibers, leading to filament breaks and premature failure of composites due to incomplete matrix encasement, and are uneconomical due to turbulence in the fiber structure.
Innovation Solution
A method involving the use of heatable deflection rods to spread and overlap fiber bundles of different materials, ensuring complete stretching and homogeneous mixing by adjusting the spreading depth and temperature, and guiding the fibers through S-shaped rollers to prevent twists, resulting in a fully stretched and uniformly distributed hybrid fiber bundle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If liquid or gas irradiation is used to spread reinforcing and matrix fibers, then fiber spreading is achieved, but turbulence within the fiber structure occurs making the process uneconomical
Solution Approach 1:
The patent replaces the liquid or gas irradiation system with a purely mechanical spreading system consisting of rollers and deflection bars. The mechanical action of passing fiber bundles over offset deflection bars achieves spreading without causing turbulence, thereby eliminating the economic disadvantages associated with fluid irradiation methods.
Solution Approach 2:
The patent divides the fiber bundle processing into separate levels - reinforcing fibers are spread in a first level while matrix fibers are spread in a second level. This segmentation allows independent control of each fiber type's spreading process, preventing turbulence and enabling economical production while achieving complete encasement.
2Ease of manufacture
If conventional spreading methods are used, then fiber bundles are spread, but inhomogeneous mixing of reinforcing and matrix fibers occurs leading to incomplete matrix encasement
Solution Approach 1:
The patent introduces a vertical dimension by using offset deflection bars that create different spreading levels for reinforcing and matrix fibers. The fibers are spread in separate planes and then merged, ensuring homogeneous mixing and complete encasement of reinforcing fibers by the matrix material, which prevents premature composite failure.
3Device complexity
If fibers are not fully extended during spreading, then processing is simpler, but filament breakage occurs in subsequent steps preventing optimal composite properties
Solution Approach 1:
The patent performs preliminary fiber extension and alignment during the spreading process itself. By passing fibers over deflection bars and through guiding rollers before merging, the fibers are fully extended and positioned correctly in advance, preventing breakage in subsequent processing steps and ensuring optimal composite properties.
4Strength
If high viscosity thermoplastics are used as matrix, then material strength is improved, but homogeneous mixing with reinforcing fibers becomes difficult
Solution Approach 1:
The patent segments the mixing process by spreading reinforcing and matrix fibers in separate levels before merging. This pre-separation approach allows the high viscosity thermoplastic matrix fibers to be uniformly distributed with reinforcing fibers without requiring extensive mixing, overcoming the difficulty posed by high viscosity while maintaining material strength.
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 produces hybrid fiber structures with excellent resilience and homogeneous mixing, preventing filament breaks and ensuring optimal composite properties by ensuring each filament is fully encased in the matrix, thus enhancing the composite's mechanical and thermal properties.
Implementation Method 1
a first fiber bundle with fibers of a first material, preferably a matrix material, and a second fiber bundle with fibers of a second material, preferably a reinforcing material, are each guided over offset, heated deflection bars
Data Source
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AI summary
The disclosure includes a method and an apparatus for producing a hybrid fiber bundle, as well as a hybrid fiber bundle produced according to the invention. In the method, a first fiber bundle (2, 3) with fibers of a first material and a second fiber bundle (2, 3) with fibers of a second material are guided in a first plane over offset, heated deflection bars (10, 8) and thereby separated and spread apart from each other, and subsequently laid on top of each other overlapping, wherein a mixed fiber ribbon formed from the spread and overlapping first and second fiber bundles (2, 3) is guided in an omega shape over at least three feed rollers (12) of a feed unit (11), thereby forming the hybrid fiber bundle.The device comprises at least three first, heatable deflecting bars (10, 8) arranged offset from one another in a first plane and at least three second, heatable deflecting bars (10, 8) arranged offset from one another in a second plane, the second plane being above the first plane. The device also comprises a feed unit (11) with at least three feed unit rollers (12) arranged offset from one another and with an omega-shaped strip guidance direction.