Towpreg Production Basis Weight Control via Fiber Sorting
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Solution Overview
Problem
Existing methods for producing tape-shaped unidirectional prepregs face challenges in maintaining consistent basis weight, leading to variations in the final fiber-reinforced plastic (FRP) products, especially when using the filament winding or automatic lamination methods, which can result in uneven thickness and weight deviations.
Innovation Solution
A method involving the measurement and prediction of fiber basis weight for multiple fiber bundles before impregnation, sorting, and strategically combining them to achieve a target basis weight range, thereby minimizing deviations and ensuring reproducibility in the production of towpregs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single fiber bundle is impregnated with resin to produce a tape-shaped unidirectional prepreg, then the production process is simple, but the basis weight variations are large
Solution Approach 1:
The invention divides the single fiber bundle into multiple sub-bundles, and each sub-bundle is impregnated with resin separately. This segmentation allows better control of resin distribution and reduces basis weight variations in the final prepreg product.
Solution Approach 2:
The invention combines multiple impregnated sub-bundles to form the final tape-shaped unidirectional prepreg. By merging multiple controlled sub-bundles, the overall basis weight consistency is improved while maintaining production efficiency.
2Manufacturing precision
If multiple fiber bundles are combined to form a towpreg, then the basis weight consistency is improved, but the production process becomes more complex
Solution Approach 1:
The invention performs preliminary measurement of basis weight for each fiber bundle before impregnation. This preliminary action allows selective combination of fiber bundles to achieve target basis weight ranges, improving consistency without excessive complexity.
Solution Approach 2:
The invention implements a feedback mechanism where basis weight measurements are used to predict and control the final towpreg basis weight. This feedback loop enables precise control while streamlining the production process through systematic decision-making.
3Manufacturing precision
If fiber bundles are sorted and strategically combined based on measured basis weight, then the towpreg basis weight variation is reduced, but the measurement and sorting time increases
Solution Approach 1:
The invention applies partial sorting by grouping fiber bundles into categories (first group, second group, third group) based on basis weight ranges rather than exhaustive sorting. This partial action achieves sufficient uniformity while minimizing time loss.
Solution Approach 2:
The invention changes the parameter basis weight into a controllable variable by measuring and categorizing fiber bundles. By setting target basis weight ranges and combining bundles strategically, the process transforms an uncontrolled parameter into a controlled one, achieving uniformity efficiently.
Data Source
AI summary
The present invention relates to a method for producing a towpreg by impregnating a plurality of fiber bundles with a resin to form a single towpreg, characterized in that the method comprises providing a stock of fiber bundles for preparing a towpreg; measuring a basis weight for each of the fiber bundles of said stock before impregnation by a resin; defining groups of fiber bundles from said stock based of the fiber basis weight, thereby providing determined fiber bundles; predicting a fiber basis weight of a towpreg when the plurality of fiber bundles is combined to form the towpreg, thereby providing a predicted fiber basis weight of a towpreg; and producing the towpreg using a combination of fiber bundles from all groups of determined fiber bundles in which the predicted fiber basis weight of the towpreg is in a range determined from a target value of a basis weight of a towpreg.