Process of making a sized and resin-coated fiber
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Solution Overview
Problem
The manufacturing process of fiber reinforced composites is complex and costly due to the multiple steps involved in producing sized and resin-coated fibers, including impregnation and molding, which increases overall production expenses.
Innovation Solution
A method is developed to create sized and resin-coated fiber tows by stabilizing, carbonizing, and graphitizing carbon fibers, then contacting them with a sizing slurry comprising a sizing agent and matrix-resin powder, followed by drying below the melting point of the resin, allowing for direct molding without additional resin impregnation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional multiple steps (impregnation and molding) are used to produce sized and resin-coated fibers, then manufacturing precision and fiber protection are improved, but device complexity and production cost increase
Solution Approach 1:
The patent combines the sizing agent application and matrix-resin coating into a single simultaneous step by using a sizing slurry that contains both the sizing agent and matrix-resin powder. This merging eliminates the need for separate impregnation and molding steps, reducing process complexity while maintaining the protective and bonding functions that traditional multi-step processes provide.
Solution Approach 2:
The sizing slurry serves multiple functions simultaneously: it acts as both the sizing agent solution and the matrix-resin source for composite formation. This multi-functionality allows the single step to achieve what traditionally required multiple specialized steps, simplifying the overall manufacturing process while preserving manufacturing precision.
2Reliability
If traditional multiple steps are used for fiber processing, then fiber quality and composite performance are improved, but productivity decreases due to more process steps
Solution Approach 1:
By merging the sizing and resin-coating operations into one simultaneous step using a sizing slurry containing both sizing agent and matrix-resin powder, the patent reduces the number of process steps. This increases productivity by eliminating intermediate handling and processing time, while the slurry formulation ensures that fiber quality and composite performance are maintained through proper adhesion and protection.
3Productivity
If high solid content sizing slurry is used (>30 wt.%), then resin coating efficiency is improved, but drying complexity and energy consumption increase
Solution Approach 1:
The patent optimizes the solid content of the sizing slurry to be greater than 30 wt.%, which improves coating efficiency by reducing the volume of solvent that needs to be evaporated. While this increases the energy required per unit of solvent removed, the overall energy consumption is reduced because fewer total evaporation steps are needed due to the elimination of separate impregnation and molding operations.
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 method reduces the number of manufacturing steps and costs by ensuring efficient bonding between fibers and matrix-resin, enhancing mechanical properties and weight reduction in fiber reinforced composites while simplifying the production process.
Implementation Method 1
contacting at least a portion of the fiber with a sizing slurry to form a sized and resin-coated fiber
Implementation Method 2
drying the sized and resin-coated fiber at a temperature below the melting point of the matrix-resin powder
Data Source
AI summary
A method of making a sized and resin-coated fiber tow for use in a fiber reinforced composite. the method comprising the steps of providing a fiber, contacting at least a portion of the fiber with a sizing slurry to form a sized and resin-coated fiber, the sizing slurry comprising 0.1-25% by weight of a sizing agent and 20-80% by weight of a matrix-resin powder in a solvent, based on the total weight of the sizing slurry. wherein the total solid content, including the sizing agent and the matrix-resin powder, of the sizing slurry is greater than 30 wt. %. The method further comprising drying the sized and resin-coated fiber at a temperature below the melting point of the matrix-resin powder, thereby forming a dried sized and resin-coated fiber and winding the dried sized and resin-coated fiber onto a spool.