Production method and coating device for coating-liquid-impregnated sheet-like reinforcing-fiber bundle and sheet-like integrated object
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Solution Overview
Problem
Current methods for producing sheet-like prepregs with unidirectionally arranged reinforcing fibers face challenges such as fuzz generation, clogging, and low production speed due to inefficient impregnation processes, particularly with carbon fibers, which degrade the quality and mechanical properties of the final composite materials.
Innovation Solution
A method and device that involves passing a unidirectionally arranged sheet-like reinforcing fiber bundle vertically through a coating section with a liquid pool and a narrowed slit-like section, where the cross-sectional area decreases continuously, to efficiently impregnate the fibers with a coating liquid, preventing fuzz clogging and enabling high-speed continuous production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional impregnation methods are used for sheet-like reinforcing fiber bundles, then the fibers can be impregnated with coating liquid, but fuzz generation occurs and production speed is limited
Solution Approach 1:
The invention changes the impregnation approach from horizontal passing through a die to vertical passing through a liquid pool. This dimensional change allows gravity to assist the coating liquid to penetrate the fiber bundle from top to bottom, achieving both high-speed continuous production and effective fuzz suppression through the vertical flow direction
2Productivity
If hot-melt process is used to produce prepregs, then matrix resin can be applied onto fiber bundles, but the process has many steps and production speed cannot be increased
Solution Approach 1:
The invention enables continuous impregnation by passing the fiber bundle vertically through the liquid pool in a continuous manner. The coating liquid continuously penetrates the fiber bundle during movement, eliminating the need for discrete steps such as melting, applying, and separate impregnation operations required in conventional hot-melt processes
Solution Approach 2:
The invention uses hydraulic principles by utilizing a liquid pool where the coating liquid flows vertically under gravity and pressure to impregnate the fiber bundle. This fluid-based approach replaces the mechanical heating and melting processes, simplifying the overall process and enabling continuous operation
3Adaptability or versatility
If liquid pool with conical flow path is used for impregnation, then production efficiency can be enhanced, but the method is not applicable to sheet-like reinforcing fiber bundles
Solution Approach 1:
The invention introduces a narrowed section at the bottom of the liquid pool with a smaller cross-sectional area to create localized high velocity and pressure zones. This local modification of the flow path geometry ensures effective impregnation of sheet-like fiber bundles while maintaining the overall vertical flow structure suitable for high-speed production
4Productivity
If horizontal type pultrusion method is used, then strip-like reinforcing fiber bundles can be impregnated with thermoplastic resin, but fuzz clogging occurs and production speed is limited
Solution Approach 1:
The invention inverts the conventional horizontal impregnation approach by using vertical passing through the liquid pool. This inversion changes the flow direction and pressure distribution, allowing the coating liquid to effectively penetrate and carry fuzz particles downward, preventing clogging and enabling continuous high-speed production
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 effectively suppresses fuzz generation, allows for continuous high-speed production of prepregs with uniform impregnation, enhancing productivity and the mechanical properties of the resulting fiber-reinforced composite materials.
Implementation Method 1
the liquid pool has a portion whose cross-sectional area decreases continuously along a running direction of the sheet-like reinforcing fiber bundle
Implementation Method 2
the sheet-like reinforcing fiber bundle is allowed to pass substantially vertically downward through the inside of a coating section storing a coating liquid, whereby the sheet-like reinforcing fiber bundle is provided with the coating liquid
Data Source
AI summary
The present invention relates to a method of producing a coating liquid impregnated sheet-like reinforcing fiber bundle formed by applying a coating liquid to a sheet-like reinforcing fiber bundle that is unidirectionally arranged continuous reinforcing fibers long in one direction. The present invention provides a production method and a coating device of a coating liquid impregnated sheet-like reinforcing fiber bundle, wherein the method and device can effect continuous running without clogging of generated fuzz even at a high running speed and effect efficient impregnation of a coating liquid into the sheet-like reinforcing fiber bundle. The present invention relates to a method of producing a coating liquid impregnated sheet-like reinforcing fiber bundle, including allowing a sheet-like reinforcing fiber bundle, which is unidirectionally arranged reinforcing fibers, to pass substantially vertically downward through the inside of a coating section storing a coating liquid, whereby the method provides the sheet-like reinforcing fiber bundle with the coating liquid; wherein the coating section includes a liquid pool and a narrowed section which are in communication with each other; wherein the liquid pool has a portion whose cross-sectional area decreases continuously along a running direction of the sheet-like reinforcing fiber bundle, and wherein the narrowed section has a slit-like cross-section and has a smaller cross-sectional area than the top side of the liquid pool.