Solidified Fiber Bundle Production via Tensioned Winding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Solidified fiber bundles produced by existing methods tend to disintegrate significantly when mixed with various substances, including particulate solids, thermosetting resins, and liquid resins, leading to instability and loss of structural integrity in composite materials.
Innovation Solution
A continuous process involving applying a melt or solution to a sheet-like carrier layer, depositing filaments under tension, pressing them into the coating, partially solidifying, rolling onto a winding core, and dividing to form solidified fiber bundles while maintaining winding tension to exert pressure, ensuring the impregnate remains plastically deformable during solidification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fiber bundles are produced by impregnating yarn through resin bath and compressing, then uniform length and width can be achieved, but the fiber bundles disintegrate significantly during subsequent mixing processes
Solution Approach 1:
The patent changes the physical state parameters of the resin from liquid solution to melt form, and controls the temperature and viscosity parameters during impregnation to create a more robust fiber bundle structure that resists disintegration while maintaining dimensional uniformity
Solution Approach 2:
The patent creates a composite structure where fibers are impregnated with resin in a controlled manner, forming a unified composite material with enhanced structural integrity that prevents disintegration during mixing while maintaining precise dimensions
2Stability of the object's composition
If the impregnate is solidified by vaporizing solvent, thermal curing, or cooling, then structural stability is achieved, but positioning requirements increase and space consumption grows
Solution Approach 1:
The patent implements continuous solidification through thermal curing or cooling processes that maintain structural stability throughout the entire production line without requiring intermediate positioning or storage spaces, enabling continuous operation from impregnation through solidification
Solution Approach 2:
The patent performs preliminary solidification treatments during the impregnation process itself, such as partial curing or cooling, to establish initial structural stability before the material enters subsequent processing stages, reducing the need for additional positioning requirements
3Strength
If winding tension is applied to maintain pressure during solidification, then fiber bundle strength is improved, but the complexity of the winding device increases
Solution Approach 1:
The patent designs the winding device to generate and maintain its own winding tension automatically through the solidification process itself, where the material's phase change or curing reaction creates internal pressure that maintains the required tension without complex external control mechanisms
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
The method produces fiber bundles with improved strength and stability, minimizing disintegration during mixing, achieving uniform impregnation, and enhancing the flowability and cutting/shearing strength of the bundles, resulting in higher tapped density and reduced dust formation.
Implementation Method 1
partially solidifying the coating until a plastically deformable state of the impregnate is obtained by at least one of the steps comprising vaporizing the solvent, thermal curing and cooling
Implementation Method 2
partially solidifying the coating until a plastically deformable state of the impregnate is obtained by at least one of the steps comprising vaporizing the solvent, thermal curing and cooling
Implementation Method 3
solidifying the impregnate by at least one of the steps comprising vaporising the solvent, thermal curing and cooling
Implementation Method 4
solidifying the impregnate by at least one of the steps comprising vaporising the solvent, thermal curing and cooling
Implementation Method 5
solidifying the impregnate by at least one of the steps comprising vaporising the solvent, thermal curing and cooling
Implementation Method 6
a pressure produced by the winding tension of the filaments in the impregnate is exerted on the roll during the performance of step g)
Data Source
AI summary
A method for producing solidified fiber bundles includes applying a melt or solution to a carrier web forming a viscous coating, applying parallel filaments under tension to the carrier web, and pressing the filaments into the viscous coating, forming an impregnate. The coating is partially solidified until a plastically deformable state of the impregnate is obtained by vaporizing the solvent, thermal curing and/or cooling. The impregnate is rolled onto a winding core to form a roll while maintaining a winding tension of the filaments in the impregnate. The outer roll is fixed on the winding core by a sleeve and/or by adhesive tape. The impregnate is solidified by vaporizing the solvent, thermal curing and/or cooling. The solidified impregnate is divided up to form solidified fiber bundles. A pressure produced by the winding tension of the filaments in the impregnate is exerted on the roll.