Precursor Fiber Bundle Interlacing for High-Strength Carbon Fiber Bundles
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Solution Overview
Problem
Existing methods for manufacturing carbon fiber bundles face challenges in achieving high-strength and high-grade carbon fibers with sufficient convergence properties and productivity, often resulting in filament breakage and fuzzy fibers due to excessive opening or interference during processing.
Innovation Solution
A method involving spinning a spinning solution through a spinneret to produce a coagulated fiber bundle, followed by interlacing with a fluid under controlled pressure and moisture content, tension, and specific processing conditions to create a precursor fiber bundle with improved convergence properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If high-pressure fluid is used for interlacing the precursor fiber bundle, then the convergence properties are improved, but the precursor fiber bundle is damaged and filament breakage occurs
Solution Approach 1:
The patent applies parameter changes by precisely controlling the fluid pressure within a specific range (0.01 to 0.05 MPa), moisture content (25 to 50%), and tension (0.02 g/dtex or less) during the interlacing process. This optimization resolves the contradiction by finding the optimal parameter combination that achieves sufficient convergence without causing fiber damage or filament breakage.
2Strength
If low-pressure fluid is used for interlacing the precursor fiber bundle, then the fiber damage is reduced, but the convergence properties become insufficient
Solution Approach 1:
The patent resolves this contradiction by optimizing the fluid pressure parameter to a specific range (0.01 to 0.05 MPa) rather than using simply low pressure. This controlled low-pressure range is sufficient to achieve the required convergence properties for bundles with large numbers of filaments while avoiding the fiber damage associated with higher pressures.
3Stability of the object's composition
If the precursor fiber bundle is processed to achieve high convergence properties, then the fiber bundle stability is improved, but the productivity is reduced due to excessive processing time
Solution Approach 1:
The patent applies continuity of useful action by implementing a continuous interlacing process where fluid is continuously applied to the coagulated fiber bundle as it moves through the processing system. This continuous approach, combined with optimized parameters, achieves high convergence properties without requiring excessive processing time or multiple discrete operations, thereby maintaining productivity.
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
The method produces high-strength carbon fiber bundles with reduced yarn bundle divides, enabling high productivity and higher-performance composite materials with minimal filament breakage and fuzzy fibers.
Implementation Method 1
interlacing the coagulated fiber bundle by applying a fluid onto the coagulated fiber bundle. The interlacing includes applying the fluid under a pressure in a range of 0.01 to 0.05 MPa onto the coagulated fiber bundle
Implementation Method 2
spinning by extruding a spinning solution through a spinneret to produce a coagulated fiber bundle
Implementation Method 3
applying the fluid under a pressure in a range of 0.01 to 0.05 MPa onto the coagulated fiber bundle with a moisture content in a range of 25 to 50% under a tension of 0.02 g/dtex or less
Data Source
AI summary
A method for manufacturing a precursor fiber bundle provides precursor fiber bundles used in manufacturing carbon fiber bundles allowing high productivity and having high tensile strength with less yarn bundle divides in the fiber bundles. The method for manufacturing a precursor fiber bundle includes spinning by extruding a spinning solution through a spinneret to produce a coagulated fiber bundle, and interlacing the coagulated fiber bundle by applying a fluid onto the coagulated fiber bundle. The interlacing includes applying the fluid (18) under a pressure in a range of 0.01 to 0.05 MPa onto the coagulated fiber bundle (14) with a moisture content in a range of 25 to 50% under a tension of 0.02 g/dtex or less.