Method for manufacturing a composite fabric
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Solution Overview
Problem
The existing methods for manufacturing composite fabrics with carbon fiber bundles and CNT networks result in a large number of CNT aggregates on the surface, which decrease the strength of carbon fiber-reinforced molded articles and limit designability.
Innovation Solution
A method involving the use of a filter part with a clearance of 100 µm or less to separate the woven fabric from a dispersion containing ultrasonically applied CNTs, preventing aggregate CNTs from adhering to the fabric and forming a network structure with a direct connection between CNTs, reducing aggregation to 25% or less per unit area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the woven fabric is immersed in a dispersion containing CNTs and ultrasonic vibrations are applied, then a CNT network structure is formed on the surface of the woven fabric, but a large number of CNT aggregates adhere to the surface of the woven fabric
Solution Approach 1:
A filter part made of porous glass is introduced as an intermediary between the CNT dispersion and the woven fabric. The filter part with controlled pore size (0.2-10 μm) allows isolated CNTs to pass through and form a network on the fabric surface while blocking larger CNT aggregates from adhering to the fabric, thus resolving the contradiction between forming a CNT network structure and preventing harmful aggregate formation
2Ease of manufacture
If CNT aggregates are present on the surface of the woven fabric, then the composite fabric can be manufactured, but the strength of the carbon fiber-reinforced molded article decreases
Solution Approach 1:
The filter part is positioned in advance during the CNT deposition process to preemptively block aggregates before they can reach and adhere to the woven fabric. This preliminary filtering action ensures that only isolated CNTs deposit on the fabric surface, maintaining both ease of manufacture and high strength of the final molded article by preventing aggregate formation at the source
3Ease of manufacture
If CNT aggregates are present on the surface of the woven fabric, then the composite fabric can be manufactured, but designability is reduced
Solution Approach 1:
The porous glass filter part serves as a mediating element that enables the manufacturing process to proceed easily while simultaneously ensuring a uniform, aggregate-free CNT network structure on the fabric surface. This uniform structure enhances designability by providing consistent surface properties and aesthetic quality, allowing for greater design flexibility in the final molded articles
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 enhances the strength of carbon fiber-reinforced molded articles by minimizing CNT aggregates and improving the uniformity of the composite layer, thereby increasing the adhesion strength and designability of the composite fabric.
Implementation Method 1
holding a surface of a filter part, through which a dispersion solvent and carbon nanotubes dispersed in the dispersion solvent are allowed to pass
Implementation Method 2
immersing the woven fabric on which the filter part is held in a dispersion that contains the dispersion solvent and the dispersed carbon nanotubes and applying ultrasonic vibrations to the dispersion
Implementation Method 3
a structure which is formed on a surface of the woven fabric and includes a plurality of carbon nanotubes, the structure includes a network structure part in which the plurality of carbon nanotubes are connected directly to one another
Data Source
Figure 1~2
Figure 3A~3B
Figure 4A~4B
AI summary
Provided are a method for manufacturing a composite fabric capable of further improving the strength of a carbon fiber-reinforced molded article, a composite fabric, and a carbon fiber-reinforced molded article. The method includes a step of holding a surface of a filter part (22A), through which a dispersion solvent and carbon nanotubes dispersed in the dispersion solvent are allowed to pass, in contact with at least one surface of a woven fabric (12A) including a carbon fiber bundle as weaving yarn, a step of immersing the woven fabric (12A) on which the filter part (22A) is held in a dispersion that comprises the dispersion solvent and the dispersed carbon nanotubes and applying ultrasonic vibrations to the dispersion, and a step of extracting the woven fabric (12A) on which the filter part (22A) is held from the dispersion and removing the filter part (22A) from the woven fabric (12A).