Prepreg Production Device Vertical Coating Section Design
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Solution Overview
Problem
Current methods for producing sheet-like prepregs are inefficient due to issues such as fuzz generation, clogging, low production speed, and poor impregnation efficiency, particularly when using carbon fibers, which result in mechanical property degradation and increased production costs.
Innovation Solution
A method and apparatus that involves passing a reinforcing fiber sheet vertically through a coating section with a matrix resin, where the resin is applied uniformly and the fiber sheet is impregnated using a non-contact heating device and additional impregnation mechanisms to prevent fuzz and ensure continuous production, enhancing productivity and impregnation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a reinforcing fiber sheet is allowed to pass through a liquid pool filled with matrix resin to improve impregnation efficiency, then the impregnation speed is improved, but fuzz is generated on the fiber sheet which causes clogging and degrades mechanical properties
Solution Approach 1:
The invention extracts and removes the harmful factor (fuzz) from the system by providing a fuzz removal device that eliminates fuzz generated during impregnation, preventing clogging and mechanical property degradation while maintaining high impregnation speed
Solution Approach 2:
The invention introduces an intermediary device (fuzz removal device) between the liquid pool and the take-up section to handle the harmful effect of fuzz, allowing continuous high-speed production without quality degradation
2Productivity
If the production speed is increased to enhance productivity, then the output is improved, but the mechanical properties of the composite material are degraded due to fuzz and poor impregnation
Solution Approach 1:
The invention implements feedback control by monitoring the impregnation process and adjusting parameters to maintain uniform resin distribution and remove fuzz, ensuring mechanical properties are maintained even at high production speeds
Solution Approach 2:
The fuzz removal device acts as an intermediary that protects the final product quality by eliminating harmful fuzz before the prepreg is wound, allowing high-speed production without compromising mechanical properties
3Manufacturing precision
If a hot-melt process is used to produce prepregs, then the impregnation is achieved, but the process complexity increases and production cost increases
Solution Approach 1:
The invention replaces the complex hot-melt process with a simpler liquid pool impregnation method, using the flow dynamics of liquid resin to achieve uniform impregnation without requiring heating and pressing equipment
Solution Approach 2:
The invention changes the physical state parameter of the matrix resin from molten state (hot-melt) to liquid state (room temperature or elevated), simplifying the process while maintaining impregnation quality through controlled resin flow
4Ease of manufacture
If the liquid pool cross-sectional area is constant to simplify the device structure, then the manufacturing is simplified, but the impregnation uniformity is poor
Solution Approach 1:
The invention makes the liquid pool cross-sectional area dynamic by tapering it in the running direction, allowing the resin flow to adapt to the fiber sheet width and achieve uniform impregnation throughout the process
Solution Approach 2:
The invention changes the geometric parameter of the liquid pool from constant cross-section to tapered cross-section, optimizing resin distribution and impregnation uniformity while maintaining relatively simple device structure
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 significantly reduces fuzz generation and clogging, allows for high-speed continuous production of prepregs with uniform impregnation, and improves the mechanical properties and efficiency of the prepreg production process.
Implementation Method 1
a non-contact heating device and additional impregnation mechanisms
Implementation Method 2
a conical flow path
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
The present invention relates to a method of producing a prepreg formed by applying a matrix resin to a reinforcing fiber sheet. A problem addressed by the present invention is to provide a method of producing a prepreg, wherein the method can effect continuous running without clogging of generated fuzz even at a high running speed and effect efficient impregnation of the reinforcing fiber sheet with a matrix resin. The spirit of the present invention is to apply a method of producing a prepreg, the method including: allowing a reinforcing fiber sheet to pass substantially vertically downward through the inside of a coating section storing a matrix resin to obtain a matrix resin-impregnated reinforcing fiber sheet in which the matrix resin is applied to the reinforcing fiber sheet; and at least heating the matrix resin-impregnated reinforcing fiber sheet; wherein the coating section includes a liquid pool and a narrowed section which are in communication with each other, wherein the liquid pool has a portion whose cross-sectional area decreases continuously along a running direction of the reinforcing fiber sheet, and wherein the narrowed section has a slit-like cross-section and has a smaller cross-sectional area than the top side of the liquid pool; wherein the distance N from the outlet of the coating section to the starting point of the heating in the matrix resin-impregnated reinforcing fiber sheet is 1 m or less; and wherein the surface temperature P2 (°C) of the matrix resin-impregnated reinforcing fiber sheet at the completion point in the heating is equal to or higher than the temperature M (°C) of the matrix resin stored in the coating section (Formula 1).