Multi-Component Fibre and Production Method
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Solution Overview
Problem
Existing methods for producing thermoplastic, semifinished, continuous fiber reinforced products, such as organosheets, result in nonuniform fiber distribution, low fiber volume content, and inefficient use of matrix materials, leading to diminished mechanical properties and increased costs.
Innovation Solution
A method involving in situ polymerization of thermoplastic monomers or oligomers onto the surface of fiber cores during filament production, forming a multicomponent fiber with a core and thermoplastic sheath, allowing for uniform wetting and high-throughput production, eliminating the need for additional binder application and reducing the number of production steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If film stacking method is used to produce organosheets, then production can be performed in continuous operation, but fiber distribution becomes nonuniform and fiber volume content remains low (30-60 vol %)
Solution Approach 1:
The patent applies preliminary action by pre-coating individual glass fibers with thermoplastic material before they are woven into fabrics. This pre-impregnation ensures uniform fiber distribution and adequate plastic coverage before the consolidation step, eliminating the nonuniform fiber distribution problem associated with film stacking while maintaining continuous production capability.
2Ease of manufacture
If film stacking method is used, then organosheets can be produced, but fiber volume content is limited to 30-60 vol % and mechanical load-bearing capacity is below theoretical limit
Solution Approach 1:
The patent applies local quality by selectively applying thermoplastic coating only to the surface of individual glass fibers where needed, rather than using a blanket film stacking approach. This localized application allows for higher fiber volume content (up to 80 vol %) while ensuring each fiber is adequately surrounded by plastic, thereby achieving both ease of manufacture and high fiber content.
3Adaptability or versatility
If commingling method is used to mix matrix and reinforcing fibers, then hybrid yarns can be produced, but sufficient comixing is not achieved and distribution remains nonuniform
Solution Approach 1:
The patent applies segmentation by treating each glass fiber individually with thermoplastic coating before bundling them into yarns. This segment-by-segment approach ensures that every fiber is uniformly coated and distributed, eliminating the nonuniform distribution problems associated with bulk commingling methods while maintaining the versatility of hybrid yarn production.
4Reliability
If size is applied as binder between fiber and plastic in film stacking, then fiber-matrix bonding can be achieved, but production cost increases
Solution Approach 1:
The patent merges the functions of thermoplastic matrix and binder by using the thermoplastic material itself as both the matrix and the bonding agent. The thermoplastic coating applied to fibers during extrusion serves dual purposes: it acts as the matrix material and simultaneously provides the bonding function traditionally requiring separate size application. This eliminates the need for additional expensive size materials while maintaining reliable fiber-matrix bonding.
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 achieves fiber volume contents up to 91% and uniform distribution, improving mechanical properties and reducing material and energy consumption, while enabling high-speed industrial production of organosheets with enhanced mechanical performance.
Implementation Method 1
the sheath is generated during the production of the filaments by in situ polymerization of monomers or oligomers of the thermoplastic on the surface of the core
Data Source
AI summary
The disclosure relates to a method for producing a multicomponent fiber, wherein the fiber is formed from a plurality of filaments, where the filaments each have a core and a thermoplastic sheath, and where the sheath is generated during the production of the filaments by in situ polymerization of monomers or oligomers of the thermoplastic on the surface of the core, and also to multicomponent fibers produced accordingly and to organosheets produced therefrom.