Prepreg Fiber Bundle Impregnation with Tension-Stabilized Wiping Wheel
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Solution Overview
Problem
Current pre-preg manufacturing methods face issues with incomplete resin impregnation due to synchronization problems between the wiping wheel and winding roller, leading to unstable resin adhesion and fiber tension, which results in uneven resin distribution and increased hairiness and ear-folding.
Innovation Solution
A method and apparatus utilizing a tension controller to stabilize fiber bundle tension and rollers with smooth surfaces to flatten and widen the fiber bundle, ensuring consistent impregnation and reducing resin content variation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the fiber bundle is wound via the action between the fiber bundle, the wiping wheel, and the winding roller, then the pre-preg is formed, but the synchronization between the wiping wheel and winding roller is not precise during start and termination actions, resulting in incomplete impregnation
Solution Approach 1:
A tension controller is introduced as an intermediary device between the fiber bundle roll and the winding roller. This tension controller actively regulates the tension of the fiber bundle during winding operations, ensuring consistent tension transmission to the wiping wheel and preventing synchronization issues during start and termination actions, thereby achieving complete and uniform impregnation.
2Manufacturing precision
If the fiber bundle is squeezed by extrusion wheels to remove excess resin, then the resin content is controlled, but the resin adhesion amount becomes unstable due to yarn tension changes
Solution Approach 1:
The tension controller serves as a mediator that stabilizes yarn tension before the fiber bundle reaches the extrusion wheels. By maintaining constant tension, the fiber bundle is fed uniformly to the extrusion wheels, ensuring stable resin adhesion amount and consistent resin content control without the instability caused by tension variations.
3Device complexity
If the fiber bundle is transferred directly without tension control, then the process is simple, but the tension of the fiber bundle is affected by start and stop of the winding roller, causing incomplete impregnation
Solution Approach 1:
The tension controller is positioned as an intermediary component in the fiber bundle transmission path. It actively compensates for tension fluctuations caused by the start and stop actions of the winding roller, ensuring uniform tension throughout the process. This maintains impregnation uniformity while adding minimal complexity to the overall system.
4Productivity
If the fiber bundle is not flattened before impregnation, then the process is faster, but ear-folding occurs and the impregnation effect is reduced
Solution Approach 1:
The fiber bundle is flattened in advance using a flattening roller before entering the impregnation zone. This preliminary action opens up the fiber structure and removes ear-folding, creating an optimal state for resin impregnation. The flattening occurs before the fiber bundle contacts the wiping wheel, ensuring complete resin penetration without compromising processing speed.
Data Source
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AI summary
A method and an apparatus for manufacturing pre-preg are described. In this method, a fiber bundle of a fiber bundle roll is transferred to a wiping wheel and is flattened by several rollers. These rollers are arranged in sequence between the fiber bundle roll and the wiping wheel and are separated from each other. The fiber bundle is transferred by using the wiping wheel to impregnate the fiber bundle with a resin on a wheel surface of the wiping wheel. A tension of the fiber bundle on the rollers and the wiping wheel is controlled by using a tension controller during the transfer of the fiber bundle by the roller and the wiping wheel. The fiber bundle impregnated with the resin is wound by using a winding roller.