Reinforcing fiber bundle
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Solution Overview
Problem
Existing fiber-reinforced thermoplastic resin forming materials face challenges in achieving a balance between mechanical properties and fluidity during the forming process, with a need for improved continuous productivity and formability to produce complex shapes.
Innovation Solution
A continuous reinforcing fiber bundle is developed, comprising regions with specific characteristics such as fiber density, drape level, and hardness, and treated with sizing agents to enhance mechanical properties and fluidity, using interlaced sections formed by fiber separation and sizing agent application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If fiber bundles consisting of many single yarns are used to improve fluidity during forming process, then fluidity is improved, but mechanical properties of shaped product deteriorate
Solution Approach 1:
The fiber bundle is designed with non-uniform structure: regions near terminals have fewer single yarns (1,600 fibers/mm or less) to improve fluidity and drapability, while central regions have more single yarns (600-1,600 fibers/mm) to maintain mechanical strength. This local variation in fiber distribution resolves the contradiction between fluidity and mechanical properties.
Solution Approach 2:
The fiber bundle is segmented into different regions along its length: terminal regions (150mm from ends) with lower single yarn density for better flow, and central regions with higher single yarn density for strength. This segmentation allows different parts of the same fiber bundle to serve different functional requirements.
2Productivity
If continuous production of intermediate base materials is implemented to improve productivity, then productivity is improved, but quality consistency becomes difficult to maintain
Solution Approach 1:
Sizing agents are applied to the fiber bundle in advance during continuous production, and interlaced sections are formed beforehand through controlled fiber separation. This preliminary treatment ensures that quality requirements are met during continuous manufacturing, maintaining consistency without requiring post-production adjustments.
Solution Approach 2:
The invention specifies precise parameter ranges (single yarn number per unit width of 1,600 fibers/mm or less in terminal regions, drape level of 120-240mm, bundle hardness of 39-200g) that can be controlled during continuous production. By maintaining these parameters within defined ranges, quality consistency is achieved throughout continuous manufacturing.
3Strength
If fiber bundle structure is optimized to improve mechanical properties, then mechanical properties are improved, but fluidity during forming deteriorates
Solution Approach 1:
Different regions of the fiber bundle have different structural characteristics: terminal regions have sparser single yarn distribution (1,600 fibers/mm or less) for better fluidity, while central regions have denser distribution (600-1,600 fibers/mm) for mechanical strength. This local differentiation resolves the contradiction between strength and fluidity.
Solution Approach 2:
The fiber bundle combines regions with different structural properties (low-density terminal regions and high-density central regions) into a single composite structure. This composite approach allows the material to exhibit both good fluidity (from terminal regions) and high mechanical strength (from central regions).
Data Source
Figure 1(I)~3
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AI summary
This reinforcing fiber bundle is a continuous reinforcing fiber bundle that has a length of at least 1 m and is characterized by the number of monofilaments per unit width being at most 1,600/mm and the average number of fibers in the bundle being at most 1,000 in a region (I) described below, and the drape level found in a region (II) being 120 - 240 mm. In addition, this continuous reinforcing fiber bundle has a length of at least 1 m and is characterized by the adhesion amount of a sizing agent (I) in the region (I) described below being 0.5 - 10% by weight and the drape level found in the region (II) being 120 - 240 mm. Provided is a continuous reinforcing fiber bundle with superior mechanical properties, formability into complex shapes, and continuous producibility. Region (I): region up to 150 mm from terminal Region (II): region other than region (I)