Separated Fiber Bundle Production via Partial Separation and Cutting
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Solution Overview
Problem
Existing methods for producing separated fiber bundles struggle with achieving optimal fiber adjustment for molding materials, leading to issues with flowability and mechanical properties, and often result in process instability and high blade exchange frequencies during longitudinal slitting.
Innovation Solution
A method involving partial separation and subsequent cutting of a fiber bundle to create alternately formed separation-processed and not-separation-processed parts, followed by complete division into separate bundles, which reduces cutting processing and minimizes blade exchange frequency, while maintaining high bundle shape retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a fiber bundle is longitudinally slitted over the entire length to adjust the number of single fibers, then the number of single fibers can be adjusted, but the yarn loses convergence property and becomes difficult to handle
Solution Approach 1:
The fiber bundle separation is divided into two stages: first performing partial separation to create a partially separated state with improved handling, then performing complete separation to achieve the desired number of single fibers. This segmentation of the separation process allows the fiber bundle to maintain sufficient convergence for handling while ultimately achieving the target fiber count.
Solution Approach 2:
The partial separation is performed as a preliminary action before complete separation. This preliminary partial separation creates intermediate states that maintain yarn convergence and handling properties, while preparing the fiber bundle for subsequent complete separation to achieve the final desired fiber count.
2Ease of operation
If a separation cutter with longitudinal and lateral blades is used for cutting and slitting, then handling property is improved, but blade exchange frequency increases when one blade reaches cutting life
Solution Approach 1:
The lateral blade function is extracted and replaced by a cutting unit that operates independently after the longitudinal slit is created. This allows the longitudinal blade to continue being used until its cutting life expires, while the cutting unit performs the cutting function, thereby reducing blade exchange frequency and maintaining productivity.
3Quantity of substance
If a large tow with large number of single fibers is used, then cost is reduced, but separation without yarn breakage is not expected
Solution Approach 1:
The separation of large tow is segmented into partial separation and complete separation stages. The partial separation stage prepares the fiber structure to reduce stress concentration points, enabling subsequent complete separation to proceed with minimal yarn breakage even when processing large numbers of single fibers.
Solution Approach 2:
Partial separation is performed as a preliminary action before complete separation of large tow. This preliminary processing reduces the complexity and stress on the fiber bundle, enabling reliable complete separation with reduced yarn breakage risk despite the large number of single fibers being processed.
4Quantity of substance
If fiber bundle is conveyed after longitudinal slitting, then separation is achieved, but split end-like fiber bundle may wrap around guide rolls
Solution Approach 1:
The separation process is segmented into partial separation followed by complete separation. The partial separation stage maintains sufficient yarn convergence to prevent wrapping around guide rolls during conveyance, while the subsequent complete separation achieves the desired separation completeness without causing conveyance issues.
Data Source
AI summary
A production method for a separated fiber bundle includes at least: [A] a partial separation step for obtaining a partially separated fiber bundle in which separation-processed parts, each separated into a plurality of bundles, and not-separation-processed parts are alternately formed along the lengthwise direction of a fiber bundle comprising a plurality of single fibers; and [B] a cutting step for cutting the not-separation-processed parts of the partially separated fiber bundle formed in the step [A] along the lengthwise direction of the fiber bundle. A separated fiber bundle produced by the method, a fiber-reinforced resin molding material that uses the separated fiber bundle, and a production method for the fiber-reinforced resin molding material.