Thermoplastic Continuous Fiber Hybrid Composite Zigzag Folding
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Solution Overview
Problem
Existing methods for preparing continuous fiber-reinforced thermoplastics face challenges in achieving flexibility, uniform impregnation, and ease of weaving, particularly due to difficulties in controlling resin content and maintaining mechanical properties during hot pressing and pultrusion processes.
Innovation Solution
A method involving the uniform stretching and heating of glass fibers, binding with thermoplastics in a tape shape, forming a multi-layered structure by alternately stacking continuous fibers and thermoplastics, and folding the material in a zigzag shape before hot melt impregnation to enhance flexibility and uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pultrusion method is used to impregnate thermoplastic resin in continuous fibers, then degree of impregnation is increased, but flexibility is degraded and weaving becomes difficult
Solution Approach 1:
The patent applies preliminary action by pre-forming the continuous fibers into a bundled structure before impregnation, and pre-heating the thermoplastic resin to facilitate controlled impregnation. This preliminary preparation allows the fibers to maintain flexibility during handling and weaving while ensuring proper resin distribution during subsequent processing.
Solution Approach 2:
The patent utilizes parameter changes by controlling the temperature of the thermoplastic resin during impregnation. By heating the resin to specific temperature ranges, the viscosity is reduced enabling better penetration into the fiber bundle while maintaining fiber flexibility. The controlled temperature parameters ensure adequate impregnation without degrading fiber properties or excessive resin uptake.
2Ease of operation
If hot pressing method with commingle is used to mix continuous fibers and thermoplastic resin, then flexibility is maintained and weaving is easy, but uniformity of impregnation is degraded
Solution Approach 1:
The patent applies segmentation by dividing the impregnation process into distinct stages: pre-forming the fiber bundle, pre-heating the resin, controlled impregnation, and final hot pressing. This segmented approach ensures uniform resin distribution throughout the fiber bundle while maintaining the flexibility needed for weaving. Each stage is optimized independently to achieve both uniformity and workability.
Solution Approach 2:
The patent maintains continuity of useful action by ensuring continuous contact between the heated resin and the fiber bundle throughout the impregnation process. The resin is applied continuously and distributed uniformly through the bundled fibers, followed by continuous hot pressing to ensure complete and uniform impregnation. This continuous process prevents localized variations in resin content.
3Ease of operation
If thermoplastic resin is randomly mixed in continuous fibers, then flexibility is maintained, but sufficient impregnation does not occur and uniformity of physical properties is degraded
Solution Approach 1:
The patent applies preliminary action by pre-forming the continuous fibers into a tightly bundled structure before resin impregnation. This pre-bundling ensures that the resin will distribute uniformly throughout the fiber assembly during subsequent heating and pressing stages, while the bundled structure maintains flexibility for handling and weaving operations.
Solution Approach 2:
The patent creates a composite material structure by combining continuous fibers with thermoplastic resin in a controlled manner. The resin is applied to the fiber bundle and then uniformly distributed through heating and pressing, creating a homogeneous composite where both components are evenly distributed. This composite structure maintains fiber flexibility while achieving uniform impregnation and consistent physical properties.
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 results in a thermoplastics-continuous fiber hybrid composite that is easily woven and exhibits excellent impregnation and mechanical properties, such as flexural strength and modulus, while allowing for control over resin content and maintaining flexibility.
Implementation Method 1
heating the stretched glass fibers
Implementation Method 2
binding the heated glass fiber with thermoplastics
Implementation Method 3
pressing the multi-layered thermoplastics-continuous fiber bonding material
Data Source
Figure 1
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AI summary
Provided is a method of preparing thermoplastics-continuous fiber hybrid composite, which is easily woven and has excellent uniformity and impregnation at the time of hot melt impregnation after the weaving, including: a) widely and uniformly stretching a bundle of glass fibers; b) heating the stretched glass fibers; c) preparing a thermoplastics-continuous fiber bonding material by binding the heated glass fiber with thermoplastics; d) preparing a multi-layered thermoplastics-continuous fiber bonding material by folding the bonding material in a shape of zigzag; and e) pressing the multi-layered thermoplastics-continuous fiber bonding material.