Particle-containing fiber bundle production method and particle-containing fiber bundle

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Solution Overview

Problem

Existing methods for producing carbon fiber pellets from recycled fibers face challenges in achieving sufficient feed efficiency and uniformity.

Innovation Solution

A production method involving mixing shortened fibers, particles with a median diameter of 100 μm or less, an organic binder, and a liquid to form a particle-containing fiber bundle with a prolate spheroidal or strand shape, utilizing specific ratios and conditions to enhance feed efficiency and uniformity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If recycled fibers are used as carbon fiber raw material, then cost and sustainability are improved, but feed efficiency and uniformity deteriorate

Engineering Contradiction:

Improveuse of recycled fibersVSAvoidfeed efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The invention changes the physical and chemical parameters of recycled fibers through thermal treatment (heating to 100-200°C) and chemical treatment (oxidation in oxygenated atmosphere) to improve their surface properties and compatibility with binding agents, thereby achieving sufficient feed efficiency and uniformity while maintaining the use of recycled fibers

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite structure by combining treated recycled carbon fibers with binding agents and optional additives to form a unified material system with improved feed properties, while maintaining the recycled fiber content for cost and sustainability benefits

Inventive Principle:

Principle #40Composite materials

2Reliability

If thermal decomposition is performed before cutting or crushing, then fiber treatment is improved, but process complexity increases

Engineering Contradiction:

Improvefiber treatment qualityVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention performs thermal decomposition and oxidation treatments as preliminary steps before cutting or crushing the carbon fibers, which prepares the fibers for subsequent processing and improves overall treatment quality, while the sequential arrangement keeps the process manageable

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If carbon fiber pellets are produced by mixing with sizing agent solution, then feed stability is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvefeed stabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The invention optimizes the concentration and composition parameters of the sizing agent solution and binding agents to achieve stable feed properties, while controlling the mixing ratios and processing conditions to manage manufacturing complexity

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20250353993A1Particle-containing fiber bundle production method and particle-containing fiber bundle

Publication Date: 2025.11.20 MITSUBISHI CHEM CORP

AI summary

A particle-containing fiber bundle having high uniformity and further improved feed efficiency, and a production method of the same are provided. The particle-containing fiber bundle production method of the present invention is for producing a particle-containing fiber bundle having a prolate spheroidal shape or a strand shape, the production method including a step of mixing a plurality of shortened fibers, particles having a median diameter of 100 μm or less, an organic binder, and a liquid, in which the fibers include carbon fibers, and the particles are used in an amount of 10 parts by mass or more with respect to 100 parts by mass of the fibers.