Electrospun Nanofibrous Resin Penetration in Split Fiber Composites
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Solution Overview
Problem
Conventional techniques for producing fiber composite materials using nanofibrous resin and split fibers result in the resin being primarily surface-bound, lacking strength and stability due to random orientation and inability to penetrate inner parts of the fibers.
Innovation Solution
A process involving continuous spinning of nanofibrous resin onto split fibers using electrospinning, where an air stream aligns the resin direction with the fiber conveyance route, followed by heating and cooling to ensure resin penetration and bonding within the fiber structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If nanofibrous resin is continuously spun by electrospinning and stacked on split fibers, then the production efficiency is improved, but the resin is not introduced into inner parts of the fibers and merely functions as a bridge between monofilaments
Solution Approach 1:
The patent applies preliminary action by performing fiber splitting immediately before resin spinning, ensuring the fiber bundle is separated into individual monofilaments at the optimal moment. This timing allows the nanofibrous resin to be introduced into the freshly separated fiber structure, enabling deep penetration into inner parts rather than just surface bonding.
Solution Approach 2:
The patent utilizes pneumatic principles by controlling the electrospinning process with electric fields and potentially using gas flows to direct and accelerate the nanofibrous resin toward the split fibers. This pneumatic/electric assistance enables the resin to penetrate deep into the fiber inner parts while maintaining continuous production.
2Ease of manufacture
If nanofibrous resin is spun with random orientation, then the spinning process is simple, but the resin lacks strength and stability
Solution Approach 1:
The patent applies dynamics by transitioning from static random orientation to dynamic controlled orientation. The nanofibrous resin is spun with random orientation initially, then guided and aligned along the fiber direction through the electrospinning process and subsequent handling, combining the simplicity of random spinning with the strength benefits of aligned structure.
3Ease of manufacture
If fiber bundle is split into monofilaments with multiple layers stacked, then the fiber processing is feasible, but the resin cannot penetrate into inner parts of the fibers
Solution Approach 1:
The patent applies segmentation by dividing the fiber bundle into individual monofilaments through splitting, creating a structure where resin can access and penetrate between and into the separated fibers. This segmentation transforms the dense bundled structure into a more open configuration that allows deep resin penetration while maintaining the layered arrangement for structural integrity.
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 method effectively introduces nanofibrous resin into the inner parts of fibers, enhancing the strength and stability of the resulting fiber composite material.
Implementation Method 1
The electrospinning is a method of discharging a polymer dissolved in a solvent or a molten polymer into an electric field to which a high voltage is applied, thereby extending the polymer by Coulomb force to form a nanofibrous polymer.
Implementation Method 2
a direction in which the nanofibrous resin proceeds is made to be the same as a conveying direction of the split fiber by blowing an air stream on the nanofibrous resin
Implementation Method 3
a step of heating a composite of the split fiber and the nanofibrous resin, obtained by the resin-spinning step, to a given temperature
Implementation Method 4
a cooling step of cooling the composite heated in the heating step to a given temperature
Data Source
AI summary
A technique with which a nanofibrous resin spun by electrospinning can be introduced into inner parts of fibers. The process for fiber composite material production is a process which comprises spinning a nanofibrous resin toward split fibers continuously conveyed along a given conveyance route and thereby combining the split fibers with the resin to produce a fiber composite material. The process involves a resin spinning step in which the nanofibrous resin spun with an electrospinning device is flown toward the split fibers. In the resin spinning step, the direction in which the nanofibrous resin proceeds is made to be the same as the conveying direction of the split fibers by blowing an air stream from a blower on the nanofibrous resin.