Fiber-Reinforced Resin Impregnation via Symmetric Inlet Segmentation
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Solution Overview
Problem
Current methods for producing fiber-reinforced resin compositions face challenges in achieving uniform resin pressure and impregnation, leading to poor outward appearance and limited application in products requiring high aesthetic quality, due to issues like unspread glass fibers and coloration.
Innovation Solution
The method involves supplying a plurality of fiber bundles into an impregnation chamber with multiple resin flow inlets symmetrically arranged relative to the fiber bundle progress direction to regulate resin flow and maintain uniform resin pressure, ensuring consistent impregnation and improved outward appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the number of fiber bundles introduced into one impregnation chamber is increased to increase production volume, then productivity is improved, but resin pressure becomes non-uniform and impregnation quality deteriorates
Solution Approach 1:
The impregnation chamber is divided into multiple resin supply zones with separate inlets, allowing independent pressure control for different fiber bundle groups. This segmentation enables uniform resin pressure distribution even when processing a large number of fiber bundles simultaneously, resolving the contradiction between high productivity and pressure uniformity.
Solution Approach 2:
Different regions of the impregnation chamber are provided with locally optimized resin supply conditions through multiple inlets positioned at specific locations. Each inlet supplies resin to a specific zone, ensuring that local pressure and flow conditions are optimized for the number and arrangement of fiber bundles in that zone, thereby maintaining overall uniformity across the entire chamber.
2Quantity of substance
If resin pressure is increased to prevent insufficient resin supply, then impregnation completeness is improved, but gas removal becomes difficult and impregnation properties deteriorate
Solution Approach 1:
The resin supply system is segmented into multiple independent inlet zones, each capable of maintaining appropriate pressure levels without requiring excessive overall pressure. This allows sufficient resin supply to all fiber bundles while avoiding the high pressure that would trap gas, thus preventing deterioration of impregnation properties.
3Productivity
If the size of the impregnation chamber is increased to accommodate more fiber bundles, then productivity is improved, but resin flow becomes non-uniform and residence time increases causing coloration
Solution Approach 1:
The large impregnation chamber is functionally segmented into multiple smaller supply zones through multiple resin inlets. Each zone has a dedicated inlet that supplies resin directly to the local fiber bundles, shortening the resin flow path and reducing residence time in each zone. This prevents coloration and deterioration while maintaining the capability to process a large number of fiber bundles.
Solution Approach 2:
Instead of increasing chamber size in a single dimension, the patent distributes resin supply across multiple spatial dimensions by adding multiple inlets at different positions. This multi-dimensional approach reduces the maximum resin travel distance and ensures uniform residence time across all fiber bundles, preventing coloration even in large-scale production.
4Device complexity
If resin is supplied from one point on one side of the die, then device complexity is reduced, but flow rate and pressure differ significantly between positions
Solution Approach 1:
The single-point resin supply is segmented into multiple inlet points distributed across the impregnation chamber. This segmentation of the supply system maintains relative simplicity while achieving uniform flow rate and pressure distribution to all fiber bundles, resolving the contradiction between device simplicity and flow uniformity.
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 approach enables mass production of fiber-reinforced resin compositions with excellent outward appearance, reducing unspread fibers and coloration issues, thus expanding their application in high-quality product manufacturing.
Implementation Method 1
supplying a molten thermoplastic resin from a resin flow inlet into the impregnation chamber so that the amount of the resin flow is almost the same or, each side the direction perpendicular to the fiber bundle progress direction
Implementation Method 2
supplying a molten thermoplastic resin... to contact with the fiber bundles to impregnate the fiber bundles with the molten thermoplastic resin
Data Source
AI summary
A method for producing a fiber-reinforced resin composition including supplying a plurality of fiber bundles (1) into an impregnation chamber (10); supplying a molten thermoplastic resin from a resin flow inlet (4) into the impregnation chamber (10) so that the amount of the resin flow is almost the same on on each side the direction perpendicular to the fiber bundle (1) progress direction; contacting the molten thermoplastic resin with the fiber bundles (1) to impregnate the fiber bundles (1) with the molten thermoplastic resin; and withdrawing the fiber bundles (1) impregnated with the molten thermoplastic resin from the impregnation chamber (10).