Partially Separated Fiber Bundle Production Method
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Solution Overview
Problem
Existing methods for producing partially separated fiber bundles struggle to achieve optimal separation while maintaining mechanical properties and flowability, often resulting in reaggregation and handling issues during molding, which affects the quality and productivity of fiber-reinforced resin molding materials.
Innovation Solution
A method involving partial separation processing using a separation means with projected parts to create alternately formed separation-processed and not-separation-processed sections, accompanied by timely application of a sizing agent to prevent reaggregation and maintain optimal form, allowing for continuous and efficient slitting of fiber bundles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
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 with different numbers of single fibers. This segmentation allows the composite material to exhibit both good flowability (from finer sub-bundles) and high mechanical properties (from coarser sub-bundles) simultaneously, resolving the contradiction between ease of operation and strength.
2Manufacturing precision
If separation processing is performed using pre-wound fiber bundle winding bodies, then the number of single fibers can be adjusted, but the adjustment range is limited
Solution Approach 1:
The invention introduces a dynamic separation means that can be adjusted during the slitting process, allowing the number of single fibers to be continuously varied. This dynamic adjustment capability overcomes the limited adjustment range of fixed pre-wound winding bodies while maintaining precise control over the fiber bundle composition.
3Manufacturing precision
If a fiber bundle is longitudinally slit to adjust the number of single fibers, then the desired fiber count can be achieved, but the yarn becomes difficult to handle and wind on bobbins
Solution Approach 1:
The slitting is performed only in specific local regions of the fiber bundle rather than along the entire length. This creates a partially separated structure where some sections maintain bundle integrity for easy handling and winding, while other sections provide the desired fiber count adjustment, thus resolving the contradiction between manufacturing precision and ease of operation.
4Productivity
If a separation cutter with longitudinal and lateral blades is used, then cutting and slitting can be performed simultaneously, but the entire blade must be exchanged when one blade reaches cutting life
Solution Approach 1:
The blade system is segmented into independent replaceable components. Instead of a single integrated blade assembly where one blade failure requires complete replacement, the cutting and slitting functions are separated into independently replaceable blade elements, reducing device complexity and maintenance downtime while maintaining simultaneous cutting and slitting capability.
5Ease of manufacture
If a roll with projections is used to partially separate fiber bundles, then separation can be achieved, but the lengths of separated and not-separated sections cannot be controlled
Solution Approach 1:
The separation means is designed with dynamic control capabilities, allowing the lengths of separated and not-separated sections to be adjusted during operation. This dynamic control mechanism enables precise management of section lengths while maintaining the ease of manufacture benefits from roll-based separation, resolving the contradiction between ease of manufacture and manufacturing precision.
Data Source
AI summary
A method of producing a partially separated fiber bundle includes a partial separation processing step for alternately forming separation-processed sections, each divided into a plurality of bundles, and not-separation-processed sections along the lengthwise direction of a fiber bundle, wherein a separation means provided with a plurality of projected parts is penetrated into the fiber bundle to create separation-processed parts, the separation means is removed from the fiber bundle, and the separation means is penetrated into the fiber bundle again, characterized in that a sizing agent is applied at an arbitrary timing during the production process of the partially separated fiber bundle. A partially separated fiber bundle is obtained by the production method, a fiber-reinforced resin molding material uses the partially separated fiber bundle, and a production method makes the fiber-reinforced resin molding material.