Through-Hole Plate Layout for Uniform Long Fiber Resin Impregnation
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Solution Overview
Problem
Existing methods for manufacturing long fiber composite materials face challenges in uniformly impregnating resin onto fiber bundles, especially with high viscosity resins, leading to poor dispersibility and irregular pores, which affect mechanical and physical properties, and require complex zigzag arrangements and high-temperature processing.
Innovation Solution
A manufacturing apparatus with adjustable through-hole plates and movable second through-hole plates that allow for controlled tension and uniform resin impregnation, enabling easy zigzag arrangement of fiber bundles and reducing processing time and risk, while accommodating various fiber and resin types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fiber bundles are arranged in a zigzag manner to apply tension for resin impregnation, then resin coating uniformity is improved, but device complexity and processing time increase
Solution Approach 1:
The apparatus divides the fiber bundle processing into multiple stages using separate through-hole plates (first through-hole plate, second through-hole plate, third through-hole plate) arranged in sequence. Each plate applies tension and impregnation independently, transforming the complex zigzag arrangement into a simplified linear multi-stage process that maintains coating uniformity while reducing operational complexity
Solution Approach 2:
The through-hole plates are designed with adjustable positions and movable structures that allow dynamic control of fiber bundle tension during processing. The plates can be positioned at different locations and the fiber bundles can be moved through them in sequence, providing flexible tension control without requiring fixed complex zigzag routing
2Productivity
If fiber bundles are continuously drawn at high speed, then productivity is improved, but resin coating quality deteriorates
Solution Approach 1:
The apparatus applies preliminary tension and impregnation actions through the first through-hole plate before the fiber bundles enter the main impregnation die. This preliminary preparation ensures that the fiber bundles are properly positioned and tensioned, enabling high-speed continuous processing while maintaining coating quality through pre-conditioning the material
Solution Approach 2:
The multi-plate arrangement enables continuous impregnation action throughout the entire processing path. Fiber bundles pass through multiple through-hole plates in sequence with continuous resin application, eliminating interruptions and maintaining both high speed and consistent coating quality through uninterrupted processing
3Strength
If high viscosity resin is used for impregnation, then mechanical strength is improved, but resin permeation and coating difficulty increase
Solution Approach 1:
The through-hole plates create preliminary channels and pathways through which high viscosity resin can be forced to permeate the fiber bundles before entering the main impregnation die. This preliminary action opens up the fiber structure and creates routes for resin flow, enabling effective impregnation with high viscosity resins that would otherwise be difficult to coat
Solution Approach 2:
The adjustable and movable through-hole plates allow dynamic control of the impregnation process parameters. The plate positions and spacing can be optimized for different resin viscosities, enabling the system to adapt to high viscosity resins by adjusting the tension and flow characteristics throughout the processing path
4Manufacturing precision
If zigzag arrangement is implemented for tension application, then resin impregnation effectiveness is improved, but work hazard and processing time increase
Solution Approach 1:
The processing path is segmented into multiple linear stages through the sequence of through-hole plates, eliminating the need for time-consuming zigzag repositioning. Each plate performs a specific function in sequence, maintaining impregnation effectiveness through staged processing while reducing total processing time through linear material flow
Data Source
AI summary
A manufacturing apparatus of a long fiber composite material according to an exemplary embodiment of the present invention includes: a main body where an inlet through which a plurality of fiber bundles are penetrated is formed at one side and an outlet through the fiber bundles are discharged is formed at the other side; a plurality of first through-hole plates that are arranged in parallel with each other along a first direction in the main body and having a plurality of through-holes through which the plurality of fiber bundles are penetrated formed therein; and a second through-hole plate that is disposed between a pair of first through-hole plates that are adjacent to each other among the plurality of first through-hole plates, and through which the plurality of fiber bundles penetrated through the first through-hole plates are penetrated.