Pressurizing Pre-impregnating Die Head for Uniform Fiber Impregnation
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Solution Overview
Problem
The existing production process of fiber-reinforced plastic sheets faces challenges in controlling deformation, achieving uniform melting, and meeting strength requirements due to short fibers and inadequate impregnation of molten plastic, leading to suboptimal composite material properties.
Innovation Solution
A pressurizing pre-impregnating die head special for a fiber reinforced plastic sheet machine, featuring a die head body with longitudinal fiber channels, compression rollers, and a heat flow channel, ensures uniform distribution and impregnation of thermoplastic base materials around fiber yarns, facilitated by a rotatable pressurizing screw rod and flow dividing chambers, enhancing the extrusion and impregnation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If long fiber filaments are twisted and broken by screw rod in extruder, then fiber reinforced plastic sheet can be produced, but the fiber length becomes short and the strength of composite material product is not enhanced obviously
Solution Approach 1:
The patent applies preliminary action by pre-impregnating the fiber yarn with molten thermoplastic base material before the main extrusion process. The fiber yarn is fed into the die head body and impregnated with molten material in advance, so that when the composite sheet is formed, the fibers maintain their length and strength without being broken by the screw rod, while still achieving high production efficiency
2Productivity
If molten plastic is paved on fiber yarns and extrusion forming is performed by compression roller, then composite sheet can be produced, but the melting effect is not good and flow is not uniform
Solution Approach 1:
The patent applies segmentation by dividing the die head body into multiple channels: a fiber channel for fiber yarn conveyance and multiple heat flow channels for molten material distribution. This segmented structure ensures uniform flow and melting of the thermoplastic base material across all fiber yarns, achieving both high production efficiency and precise melting uniformity
Solution Approach 2:
The patent applies local quality by providing dedicated heat flow channels that deliver molten thermoplastic base material locally and uniformly to each fiber yarn position in the die head body. This ensures consistent impregnation quality at each location, improving both production efficiency and melting uniformity
3Strength
If thermoplastic base material is extruded to pave on fiber yarn surfaces, then impregnation can be achieved, but the distribution uniformity and combination effect are insufficient
Solution Approach 1:
The patent applies universality by designing the die head body to simultaneously perform multiple functions: conveying fiber yarn through the fiber channel, delivering molten thermoplastic base material through heat flow channels, and enabling uniform impregnation of the fiber yarn surfaces. This integrated multi-functional design achieves both high impregnation quality and distribution uniformity
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 design achieves high-efficiency production with uniform distribution of fiber yarns and thermoplastic materials, improving the strength and quality of composite sheets, suitable for larger thicknesses and cost-effective large-scale production.
Implementation Method 1
a rotatable pressurizing screw rod is arranged in the pressurizing chamber, one end of the pressurizing screw rod extends out of the die head body and is connected to a driving device, and the driving device is used to drive the pressurizing screw rod to rotate and convey the thermoplastic base materials
Implementation Method 2
the fiber yarn and the thermoplastic base materials on the two sides of the fiber yarn are extruded by the compression rollers
Implementation Method 3
A heat flow channel for conveying the thermoplastic base materials is formed in the die head body, and one end of the heat flow channel communicates with the feeding port and the other end of the heat flow channel communicates with the discharging ports
Data Source
AI summary
A pressurizing pre-impregnating die head for a fiber reinforced plastic sheet machine is provided. The die head includes a body; at least one group of fiber channels arranged in a longitudinal hole-through manner in a middle of the body, and a fiber yarn conveyed in the fiber channel. The body includes a feeding port and discharging ports, which communicate with each other. The discharging ports are located in outer sides of the fiber channel. Thermoplastic base materials in a molten state are paved on two sides of the fiber yarn. The thermoplastic base materials may be paved on surfaces of the two sides of the fiber yarn when being extruded.