Partial Split-Fiber Bundle Manufacturing via Piercing Protrusions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing partial split-fiber fiber bundles face challenges in continuous slitting without causing yarn breakage, especially when dealing with fiber bundles that are twisted or have a large number of single fibers, and they often require frequent blade exchanges.
Innovation Solution
A method and device that uses a fiber splitting means with protruding parts to create split-fiber processed parts while detecting pressing forces and twists, allowing for continuous slitting by adjusting the fiber splitting mechanism's position and timing to prevent yarn breakage and extend blade life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a fiber bundle with a large number of single fibers is used, then flowability at the time of molding is improved, but mechanical properties of the molded article deteriorate
Solution Approach 1:
The fiber bundle is segmented into multiple sub-bundles through the slitting process. The slitting device divides the large tow into several smaller bundles, each maintaining adequate flowability while collectively providing improved mechanical properties through better fiber distribution and consolidation in the molded article.
2Adaptability or versatility
If the number of single fibers in a fiber bundle is adjusted to an arbitrary number, then both flowability and mechanical properties can be satisfied, but the adjustment range is limited when using pre-wound fiber bundle winding bodies
Solution Approach 1:
The slitting device employs adjustable slitting positions and variable pitch configurations that can be dynamically modified during operation. This allows continuous adjustment of the number of single fibers in the output bundle without requiring multiple pre-configured winding bodies, providing versatile adaptation while maintaining operational simplicity.
3Adaptability or versatility
If a fiber bundle is longitudinally slitted over the entire length, then the number of single fibers can be adjusted, but the yarn becomes difficult to handle such as winding on a bobbin or unwinding from the bobbin
Solution Approach 1:
The slitting operation is applied partially rather than continuously along the entire fiber bundle length. By controlling the slitting device to create localized slits at specific intervals, the fiber bundle maintains sufficient structural integrity for handling and winding operations while still achieving the desired reduction in the number of single fibers in the processed portions.
4Ease of operation
If a split-fiber cutter with longitudinal blade and lateral blade is used, then handling property is improved by eliminating the need to wind and transport the fiber bundle, but the entire blade has to be exchanged when one blade reaches cutting life
Solution Approach 1:
The cutting function is segmented into separate longitudinal and lateral cutting components that can be independently maintained. The longitudinal slitting function and lateral cutting function are separated into distinct刀 components, allowing the lateral blade to be replaced independently without discarding the longitudinal slitting blade, thus extending overall system productivity.
5Manufacturing precision
If a fiber bundle with twist is processed through longitudinal slitting, then the fiber bundle may be cut at small length before and after the longitudinal slitting, but continuous longitudinal slitting cannot be performed
Solution Approach 1:
The slitting device incorporates detection mechanisms that monitor the fiber bundle's twist state and positioning in real-time. Based on this feedback, the control system adjusts the slitting timing and position to avoid cutting through twisted sections, enabling continuous operation without interruption while maintaining precise control over the cut length and preventing yarn breakage.
Data Source
Figure 1
Figure 2(A)~2(B)
Figure 3~4(B)
AI summary
Provided are a method for manufacturing and a device for manufacturing a partial split-fiber fiber bundle and a partial split-fiber fiber bundle obtained using these method and device, said method being characterized by piercing a fiber splitting means provided with a plurality of protruding parts into a fiber bundle formed from a plurality of single fibers while making the fiber bundle travel along the longitudinal direction thereof and creating a split-fiber processed part, forming entangled parts where single fibers are interlaced at contact parts with the protruding parts in at least one split-fiber processed part, thereafter pulling the fiber splitting means out of the fiber bundle, and after passing through an entanglement accumulation part including the entangled parts, once again piercing the fiber splitting means into the fiber bundle. Thus, the present invention can provide a method for manufacturing and a manufacturing device for a partial split-fiber fiber bundle that can continuously and stably slit a fiber bundle. Specifically, the present invention can provide a method for manufacturing and a manufacturing device for a partial split-fiber fiber bundle that make continuous slit processing possible without having to worry about the exchange life of rotary blades even if the fiber bundle includes twists or the fiber bundle is a large tow having a large number of single fibers, as well as a partial split-fiber fiber bundle obtained using these method for manufacturing and manufacturing device.