Resin-Impregnated Roving Alignment for Fiber-Reinforced Components
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Solution Overview
Problem
Existing methods for producing fiber-reinforced components using resin-impregnated fiber materials often result in structural irregularities and visually unappealing surface areas due to high-speed processing, leading to increased scrap rates and undesirable reflections.
Innovation Solution
A method involving the alignment of rovings by stretching them in their longitudinal direction, combined with controlled heating and friction, to ensure proper resin impregnation and minimize surface irregularities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the fiber material is processed at high speed through the impregnation station, then productivity is improved, but structural irregularities and surface quality deteriorate
Solution Approach 1:
The patent applies preliminary action by stretching the fiber material before the impregnation process. This preliminary stretching alignment of rovings in the longitudinal direction prevents structural irregularities from forming during high-speed processing, enabling both high productivity and high surface quality without compromise
2Manufacturing precision
If the fiber material is stretched to align rovings, then surface quality and force transmission are improved, but processing time increases
Solution Approach 1:
The stretching alignment is performed as a preliminary action before impregnation, so that when the material is subsequently processed at high speed, the rovings are already aligned and cannot form structural irregularities. This eliminates the need for post-processing corrections and reduces overall processing time despite the initial stretching step
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 reduces or eliminates undesirable reflections and improves surface quality, enhancing force transmission and appearance by aligning rovings, thereby minimizing scrap and improving the overall quality of fiber-reinforced components.
Implementation Method 1
the fiber material is stretched in such a way that the rovings align themselves in their longitudinal direction
Implementation Method 2
the fiber material is heated at least before and/or during the drawing process, whereby the resin with which the fiber material is impregnated is at least partially softened
Implementation Method 3
the protruding ends of the rovings extending side by side in one direction are stretched by means of friction
Data Source
Figure 1a~1b
Figure 2~3
Figure 4
AI summary
The present invention relates to a method for producing a fiber-reinforced component, comprising the step of providing a fiber material (2) impregnated with resin, having rovings (4) extending alongside one another at least in one direction. The object of the present invention is to provide a method, with which irregularities in the fiber material impregnated with resin can be reduced or even eliminated. The method is characterized by a step of stretching the fiber material (2), so that the rovings (4) align in their longitudinal direction. Furthermore, the invention relates to a device for carrying out the method according to the invention and to a fiber-reinforced component.