Continuous Fiber-Reinforced Thermoplastic Sheets via Infrared Drying
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Solution Overview
Problem
Conventional processes for producing continuous fiber-reinforced thermoplastic resin sheets are inefficient and require large-scale equipment, limiting production efficiency.
Innovation Solution
A method involving impregnation of continuous fibers with a thermoplastic resin solution containing a halogen-containing organic solvent, followed by solvent removal using infrared irradiation with specific distance and temperature settings, to efficiently produce continuous fiber-reinforced thermoplastic resin sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional solvent removal methods are used, then equipment complexity is reduced, but production efficiency deteriorates
Solution Approach 1:
The patent replaces conventional thermal drying equipment with an infrared irradiation system. The infrared heater directly irradiates the continuous fiber impregnated with thermoplastic resin solution, enabling rapid solvent removal without complex mechanical drying systems. This substitution of mechanical thermal processing with optical energy delivery achieves high production efficiency while maintaining equipment simplicity.
Solution Approach 2:
The patent optimizes specific parameters of the infrared irradiation process: the distance between the infrared heater and the continuous fiber is controlled at 50mm or less, and the irradiation time is limited to 1 second or less. These parameter changes enable efficient solvent removal that improves production speed without requiring complex equipment modifications.
2Productivity
If infrared irradiation is used for solvent removal, then production efficiency improves, but energy consumption increases
Solution Approach 1:
The patent applies partial action by limiting the infrared irradiation to a very short duration (1 second or less) and a specific distance (50mm or less). This concentrated, brief energy input is sufficient for solvent removal without excessive energy consumption, achieving high production efficiency while controlling energy usage.
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
Improves production efficiency by effectively removing solvents from intermediate materials, enhancing the overall production rate of fiber-reinforced thermoplastic resin sheets.
Implementation Method 1
a solvent removal step for removing, by means of infrared irradiation, the halogen-containing organic solvent from the continuous fiber
Implementation Method 2
removing, by means of infrared irradiation, the halogen-containing organic solvent
Data Source
AI summary
Provided are, inter alia, a manufacturing method that can be carried out using simple equipment and that makes it possible to efficiently manufacture many continuous fiber-reinforced thermoplastic resin sheets in a short period of time. The above problem is overcome by a method for manufacturing a continuous fiber-reinforced thermoplastic resin sheet comprising: an impregnation step for impregnating continuous fiber with a thermoplastic resin solution containing a halogen-containing organic solvent and a thermoplastic resin containing at least one resin from among polycarbonate resins and polyarylate resins; and a solvent removal step for removing, under exposure to IR radiation, the halogen-containing organic solvent from the continuous fiber impregnated with the thermoplastic resin solution. In the solvent removal step, the distance between a heater for emitting the IR radiation and the continuous fiber is 400 mm or less, and the temperature of a heating element for radiating the IR radiation in the heater is 260°C or higher.