UHMWPE Fiber Prepreg Continuous Process Friction Reduction
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Solution Overview
Problem
The preparation of ultra high molecular weight polyethylene fiber prepregs is hindered by friction-induced abrasion during the winding process, leading to reduced uniformity and performance of the final weft-free fabric.
Innovation Solution
A continuous method involving multistage drafting and immersion of semi-finished ultra high molecular weight polyethylene fibers in a liquid matrix, followed by orthogonal alignment and lamination of prepregs to minimize friction and ensure uniform fiber distribution, using a drafting device with rotating rollers and a controlled matrix application system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ultra high molecular weight polyethylene fibers are wound on a fabric reel and pulled out continuously, then production efficiency is improved, but friction between fibers causes abrasion and reduces uniformity
Solution Approach 1:
The patent segments the fiber processing into distinct stages: spinning semi-finished fibers, laying them in layers, immersing in liquid matrix, and solidifying. This segmentation eliminates continuous winding and pulling operations that cause friction, allowing each stage to be optimized independently while maintaining high production efficiency through continuous processing where applicable.
Solution Approach 2:
The patent introduces a liquid matrix as an intermediary medium between the ultra high molecular weight polyethylene fibers and the environment. The fibers are immersed in this liquid matrix during the laying process, which acts as a lubricant and protective medium, reducing friction and abrasion between fibers while enabling continuous processing.
2Speed
If fibers are laid and bonded continuously to form fabric, then production speed is improved, but friction-induced damage reduces final product quality
Solution Approach 1:
The patent applies preliminary action by immersing the fiber layers in liquid matrix before the bonding/pressing stage. This pre-treatment protects the fibers during the high-speed laying process, reducing friction damage before the fibers are bonded together, thereby maintaining both production speed and fiber strength.
Solution Approach 2:
The patent changes the physical state parameters of the matrix material, using it in liquid form during the laying and immersion processes, then allowing it to solidify during bonding. This parameter change enables high-speed processing in liquid form while achieving strong bonding in solid form, maintaining both production speed and product reliability.
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
This approach reduces fiber damage from friction, resulting in improved uniformity and strength of the final weft-free fabric, with enhanced resistance to abrasion and impact.
Implementation Method 1
the ultra high molecular weight polyethylene fiber layer is immersed in a liquid matrix
Implementation Method 2
a matrix on an ultra high molecular weight polyethylene fiber layer is solidified to form an ultra high molecular weight polyethylene fiber prepreg
Data Source
AI summary
The present application relates to a process for preparing a prepreg by a continuous method, including the following steps: S1: preparing a raw material; S2: heating and stirring the raw material, and spinning in a spinning box to form a semi-finished ultra high molecular weight polyethylene fiber; S3: uniformly laying the semi-finished ultra high molecular weight polyethylene fiber into a layer, performing multistage drafting on the layer while immersing in a liquid matrix; S4: solidifying the matrix on the layer of ultra high molecular weight polyethylene fiber to form an ultra high molecular weight polyethylene fiber prepreg; S5: orthogonally aligning two sheets of the ultra high molecular weight polyethylene fiber prepregs with each other in warp and weft directions, and then performing lamination to form a weft-free fabric; and in step S3, performing multistage drafting by using a drafting device, and immersing by using an immersing device.