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US20170037545A1 - Method and device for spreading fiber strands - Google Patents

Method and device for spreading fiber strands Download PDF

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Publication number
US20170037545A1
US20170037545A1 US15/304,109 US201515304109A US2017037545A1 US 20170037545 A1 US20170037545 A1 US 20170037545A1 US 201515304109 A US201515304109 A US 201515304109A US 2017037545 A1 US2017037545 A1 US 2017037545A1
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US
United States
Prior art keywords
fiber strand
fiber
spreading
spreader
strand
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US15/304,109
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English (en)
Inventor
Jürgen Keppel
Andy Rakovac
Thomas Holtmann
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
C Cramer Weberei Heek-Nienborg & Co KG GmbH
C Cramer Weberei Heek- Nienborg & Co KG GmbH
Original Assignee
C Cramer Weberei Heek- Nienborg & Co KG GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by C Cramer Weberei Heek- Nienborg & Co KG GmbH filed Critical C Cramer Weberei Heek- Nienborg & Co KG GmbH
Publication of US20170037545A1 publication Critical patent/US20170037545A1/en
Assigned to C. CRAMER, WEBEREI, HEEK-NIENBORG, GMBH & CO. KG reassignment C. CRAMER, WEBEREI, HEEK-NIENBORG, GMBH & CO. KG ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HOLTMANN, THOMAS, RAKOVAC, ANDY
Abandoned legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02J—FINISHING OR DRESSING OF FILAMENTS, YARNS, THREADS, CORDS, ROPES OR THE LIKE
    • D02J1/00—Modifying the structure or properties resulting from a particular structure; Modifying, retaining, or restoring the physical form or cross-sectional shape, e.g. by use of dies or squeeze rollers
    • D02J1/18—Separating or spreading

Definitions

  • the invention relates to a method and a device for spreading of a fiber strand, which features an initial width and an initial thickness, to a strip-type fiber strand with greater final width and with smaller final thickness, wherein the fiber strand consists of continuous multifilament fibers.
  • the spreading of fiber strands has long been known and is employed on fiber strands made of polymer fibers to improve physical properties, since due to the spreading, twisting of the filaments in the fiber strand, for example, can be eliminated and a fiber strand with filaments positioned in the same direction are obtained.
  • the spreading causes in particular a lower surface weight of the fabric or textile produced from these fiber strands.
  • Fabric or textile produced in this manner can be used, in particular for composites.
  • a composite material is formed, by pressing a fiber fabric or fiber textile or another textile structure made of reinforcing filaments, such as carbon fibers, with a thermoplastic matrix and compressing it into a pre-product (prepreg).
  • fiber strands with the smallest possible thickness and consistent, good mechanical properties, such as tensile strength, for example, are used.
  • a reduction in thickness and a broadening of the fiber strand is obtained by spreading of the fiber strand.
  • the fiber strand is spread apart in different ways.
  • One possibility is to charge the fiber strand in an electric field, such that the filaments mutually repel each other and separate in this way.
  • This kind of spreading method is energy-intensive and can only be used on fiber strands that are electrically conductive and can thus be electrically charged.
  • Fiberglas or textile fibers, for instance, have to be impregnated before application of this kind of spreading method.
  • vibrations are introduced into the fiber strand for spreading.
  • the two documents U.S. Pat. No. 5,042,111 and U.S. Pat. No. 3,704,485 describe a method wherein sound waves are produced by a loudspeaker and a vibrating air cushion spreads a fiber strand.
  • a method of this kind is very difficult to control and results in irregular final widths of the fiber strand.
  • a better transfer of the vibrations to a fiber strand is obtained when the sound is introduced into a liquid, like water for example.
  • This is described in documents U.S. Pat. No. 5,511,395 and EP 1,652,978 B1.
  • the disadvantage of this method is that the release agent surrounding the filaments changes in the water bath.
  • the object of the present invention is to provide a lower-cost method for spreading of fiber strands, which can be used on fiber strands of different character, and in particular which does not affect the ratio of release agent to fiber in the fiber strand.
  • the method according to the invention is used for spreading of a fiber strand which features an initial width (extension in the y-direction) and an initial thickness (extension in the z-direction) into a strip-type fiber strand with a greater final width and with a smaller final thickness, that is, a broadening of the fiber strand transverse to its longitudinal direction (x-direction).
  • the method can be used on all fiber strands made of a continuous multifilament fiber, that is, on fibers made of ceramic, such as, for example, silicate, basalt, glass, silicon carbide, metals like steel, aluminum, titanium, aramid, such as Kevlar, but also on polymer fibers.
  • Multifilament fibers with a different number of filaments can be used, such as 1K-fibers which contain 1000 filaments, but also for example, 50K fibers with 50,000 filaments.
  • the fiber strand to be spread is moved, proceeding from an unwinding roll, in the fiber longitudinal direction, through a spreader station, where a spreading takes place, and then the spread, strip-type fiber strand is wound up or is immediately passed on to a subsequent manufacturing process.
  • the fiber strand in the spreader station is exposed to vibrations without the use of a fluid, such as for example, an air cushion or a liquid.
  • ultrasound waves are used which are transmitted from a sonotrode.
  • the sonotrode contacts the fiber strand from above or from below.
  • the mechanical vibrations are introduced in the z-direction, that is, perpendicular to the longitudinal direction (x-direction) of the fiber strand, so that the strand widens in the transverse direction (y-direction).
  • the used vibrations here have a frequency of 15 to 80 kHz, preferably between 20 and 40 kHz. At frequencies of less than 20 kHz, very large sonotrodes should be used which cause the overall apparatus to be much larger and more expensive. When using frequencies greater than 40 kHz, the sonotrode does indeed become smaller, but the process tolerance is reduced to the same extent.
  • the ultrasound vibrators are equipped with replaceable sonotrodes which introduce the high-frequency mechanical vibrations (ultrasound) from their front surfaces into the fiber strand.
  • One or a plurality of sonotrodes can be used in the spreader station. When the fiber strands pass through the spreader station, the fiber strands can loop around the sonotrodes so that the working angle to the contact surface of the sonotrode is variable.
  • the individual filaments in a fiber strand are surrounded by a release agent.
  • the composition of the release agent will differ, according to the manufacturer of the fibers.
  • Release agents based on epoxy are known. This kind of release agent promotes the processing of the fiber strands.
  • carbon fibers display a high tensile strength in the longitudinal direction, but can break very easily transverse to the fiber longitudinal direction.
  • the release agent acts in an adverse manner in that the fibers adhere together, which impedes a spreading of the fiber strand.
  • the release agent on the filaments of the fiber strand does not change in the spreader station. Firstly, no chemical change occurs, since the release agent does not come into contact with any medium. Secondly, the quantity ratio of fiber to release agent does not change in the overall process.
  • the vibrations emitted by the sonotrode cause friction in the fiber strand, which generates heat and causes a softening of the release agent and promotes spreading of the fiber strand.
  • Conductive fibers such as carbon fibers for example, additionally contribute to the heat conduction. Since this softening of the release agent occurs only in the region of the contact surface of the sonotrode, and immediately thereafter a cooling of the fiber strand begins again, the release agent/fiber quantity ratio does not change.
  • the fiber strand Upon passage through the spreader station, the fiber strand is maintained in a tensioned state.
  • This tensioned state is adjustable and is preferably the same throughout the entire method in order to obtain the best possible, uniform spreading.
  • the attainable spread width here is dependent on this tensioned state. The greater the tension, that is, the more tightly the fiber strand is held, the smaller is the spread width.
  • the tensioned state is held constant and at a constant vibration frequency, the spread width can be changed via a change in the vibration amplitude.
  • fiber strands can be moved and uniformly spread at a high speed, preferably of at least 20 m/min. Due to this method, a fiber strand can be spread out in a process-reliable manner into a strip-type fiber strand with at least twice the final width, and preferably the final width will change by at least 5-fold. For example, a 12K carbon fiber strand with a width of 2 mm is spread at a frequency of 30 kHz to obtain a uniformly consistent, strip-type 12 mm-wide fiber strand. By means of an appropriate bandwidth limiter, the final width can be adjusted to a specified, final width value.
  • the method according to the invention represents a low-cost method since the fiber strand is processed when dry, no energy is required for dewatering, heating or drying of the fiber strand. Moreover, the nature of the fiber strand does not change with respect to its composition, namely the quantity ratio of multifilament fibers and release agent in the method. A strip-type fiber strand with consistent and larger final width, and with a lesser final thickness is obtained according to the desired specification, which leads to the desired, low surface weight and, when using the fiber strand for fabric or textile, results in lighter composites with consistently good mechanical properties, such as tensile strength, for instance.
  • a device for this method which comprises an unwinding unit for the fiber strand to be spread, a spreader station for spreading of the used fiber strand into a strip-type fiber strand, a controllable tensioning device for consistent tensioning of the fiber strand during its movement through the spreader station, and a winding device for the spread, strip-type fiber strand.
  • the spreader station contains at least one sonotrode for contacting and spreading of the fiber strand, wherein the sonotrode introduces vibrations at a frequency of between 15 kHz and 80 kHz from its contact surface from above and/or from below (z-direction) into the fiber strand, which causes a spreading of the fiber strand in the y-direction.
  • the ultrasound vibrators are equipped preferably with replaceable sonotrodes which feature on their front side, contact surfaces for contacting of the fiber strand. These contact surfaces can be planar, concave or arched in the direction of motion of the fiber strand, that is, in the fiber longitudinal direction.
  • the width of the contact surfaces that is, the extension of the contact surface transverse to the motion of the fiber strand, is chosen so that in every case it is greater than the final width of the strip-type fiber strand to be obtained by the spreading.
  • two neighboring sonotrodes are arranged at a predetermined spacing. This spacing is determined according to the nature of the fiber strand material.
  • neighboring sonotrodes can be arranged with respect to each other, preferably at a different alignment, so that for example, a first sonotrode contacts the fiber strand from above, and the second sonotrode contacts the fiber strand from below. This results in more consistent process results.
  • the contact surfaces of the sonotrodes in this case are located preferably in a plane. But in the case of high tensile strength fiber strands, such as carbon fiber strands, for example, a looping around the sonotrodes is desirable.
  • the contact surfaces are arranged preferably at different heights with respect to the transiting fiber strand, so that this fiber strand is guided preferably in a zig-zag-line through the spreader station.
  • diverter rollers can be arranged in front of and behind the spreader station.
  • an additional bandwidth limiter can be installed behind the spreader station in order to obtain a consistent final width of the spread, strip-type fiber strand.
  • FIG. 1 Basic sketch of an apparatus according to the invention
  • FIGS. 2 a , 2 b , 2 c Different designs of the sonotrodes
  • FIGS. 3 a , 3 b , 3 c Different arrangements of sonotrodes
  • FIG. 4 Basic sketch of another apparatus according to the invention.
  • the invention is not restricted to these exemplary embodiments.
  • the basic sketch in FIG. 1 depicts the fundamental passage of a fiber strand 2 to be spread, through the spreader station 5 , proceeding from the unwinding unit 1 , out to the winding unit 8 .
  • the fiber strand 2 in this case pertains to a 12K fiber strand, that is, the fiber strand consists of 12,000 filaments, which are arranged continuously in the fiber strands 2 , side by side, and each one surrounded by a release agent. This release agent prevents the fiber strand 2 from being damaged during its movement.
  • the employed fiber strand 2 is delivered on a spool of the unwinding unit 1 and is unwound from this spool.
  • the unwinding position of the fiber strand 2 can be determined by a sensor and the unwinding spool can be displaced in accordance with the desired unwinding position.
  • the fiber strand 2 then arrives in the front dancing unit 3 , which operates together with the rear dancing unit 7 as tensioning devices, wherein the front dancing unit 3 is disposed in the direction of motion of the fiber strand 2 , 2 ′ in front of the spreader station 5 , and the rear dancing unit 7 is disposed in the direction of motion of the fiber strand 2 , 2 ′ behind the spreader station 5 .
  • the effect is that the fiber strand 2 , 2 ′ is consistently tensioned in the spreader station 5 during the entire process.
  • the dancing units 3 , 7 can counteract changing conditions which affect the tension on the fiber strand 2 , 2 ′.
  • the dancing units 3 , 7 each comprise three rollers. But two rollers would also suffice for a uniform tensioning of the fiber strand 2 , 2 ′.
  • a third roller of the dancing unit 3 can act as additional diverter roller for the fiber strand 2 .
  • Additional diverter rollers 4 in front of the spreader unit 5 and/or additional diverter rollers 6 behind the spreader station 5 can be supplied, in particular for adjusting a particular working angle of the fiber strand 2 upon its entry into the spreader station.
  • the spreader station 5 comprises three ultrasound vibrators 51 .
  • Each ultrasound vibrator 51 features a replaceable sonotrode 52 with a front-side contact surface 53 .
  • the vibrations are generated in one ultrasound generator (not depicted) and the vibrations are directed by the sonotrodes 52 via their contact surface 53 into the fiber strand 2 from above and/or from below, that is, in the z-direction.
  • the three sonotrodes 52 are arranged in sequence in the direction of motion of the fiber strand 2 , 2 ′, wherein neighboring sonotrodes 52 are provided at different alignments in the spreader station 5 , and specifically so that the contact surfaces 53 of the first and third sonotrode 52 direct their vibrations from top to bottom into the fiber strand 2 , and the second sonotrode 52 arranged therebetween, directs the vibrations from the contact surface 53 from bottom to top into the fiber strand 2 .
  • mechanical vibrations are introduced from the sonotrodes 52 at a frequency of 30 kHz into the fiber strand 2 , 2 ′.
  • a spreading of the employed fiber strand 2 occurs right at the first sonotrode 52 , that is, a spreading of the fiber strand in a lateral direction (y-direction) occurs. This spreading is enhanced in transit of the fiber strand 2 upon contact with the following sonotrodes 52 .
  • the passage of the fiber strand 2 , 2 ′ through the spreader station 5 takes place horizontally in the illustrated example, that is, with no upward or downward deflection. A progression of this kind is selected, in particular, for sensitive or elastic fiber strands.
  • the spread, strip-type fiber strand 2 ′ emerging from the spreader station 5 is guided over the rear dancing unit 7 of the winding unit 8 , where the spread fiber strand 2 ′ is wound up onto a spool with a corresponding winding tension.
  • the spool in the winding unit 8 can be designed as a torque-controlled winding spool.
  • FIGS. 2 a , 2 b , 2 c depict different sonotrodes 52 ′, 52 ′′, 52 ′′′.
  • the particular contact surfaces 53 ′, 53 ′′, 53 ′′′ can have a radius in the direction of motion of the fiber strand 2 , for example, like the arched contact surface 53 ′′ in FIG. 2 b . This makes possible an easier looping around this sonotrode 52 ′′ during the spreading process, without the fiber strand 2 being damaged during such looping; see FIG. 3 b .
  • the sonotrode 52 ′′′ according to FIG.
  • FIG. 2 a features an arched contact surface 53 ′′′, which has the added advantage that such sonotrodes 52 ′′′ can be arranged inside each other in one spreader device 5 , as depicted in FIG. 3 a .
  • FIG. 2 c additionally shows a sonotrode 52 ′ which likewise features a radius at the outer edge 54 of the contact surface 53 ′ and in the middle, a back-set plane 55 .
  • the fiber strand 2 is tensioned across the edge 54 and when the vibrations are applied, will have a free space for vibrating due to the back-set plane 55 .
  • FIG. 3 c shows one possible arrangement of several such sonotrodes 52 ′.
  • a looping around the sonotrodes 52 is preferred for carbon fiber strands.
  • the fiber strand 2 is supplied at a steep working angle to the contact surface 53 ′, 53 ′′, 53 ′′′ of the sonotrodes 52 ′, 52 ′′, 52 ′′′. This is also possible when the first and third sonotrodes 52 are lowered with respect to the second sonotrode 52 , as in the example of FIG. 1 , so that the contact surfaces 53 are no longer arranged at the same height, but rather the first and third contact surfaces 53 are positioned lower in comparison to the second contact surface 53 .
  • FIG. 4 depicts another exemplary embodiment.
  • several fiber strands 2 are spread simultaneously, that is, several fiber strands 2 are guided side by side through the spreader device 5 , and several spread fiber strands 2 ′, that is, fiber strands widened in the y-direction, leave the spreader unit 5 .
  • the individually spread fiber strands 2 ′ are sent to a supply unit 9 which collects the fiber strands 2 ′ into a common fiber strand 2 ′′.
  • it may pass through an additional spreader device 5 ′. Wide fiber strands 2 ′′′ produced in this way can be used advantageously for the production of knitted fabrics or textiles.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
  • Treatment Of Fiber Materials (AREA)
US15/304,109 2014-04-16 2015-03-18 Method and device for spreading fiber strands Abandoned US20170037545A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE102014105464.4A DE102014105464A1 (de) 2014-04-16 2014-04-16 Verfahren und Vorrichtung zum Spreizen eines Faserstrangs
DE102014105464.4 2014-04-16
PCT/EP2015/055689 WO2015158483A1 (de) 2014-04-16 2015-03-18 Verfahren und vorrichtung zum spreizen eines faserstrangs

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US20170037545A1 true US20170037545A1 (en) 2017-02-09

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US15/304,109 Abandoned US20170037545A1 (en) 2014-04-16 2015-03-18 Method and device for spreading fiber strands

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US (1) US20170037545A1 (de)
EP (1) EP3132074B1 (de)
JP (1) JP2017528606A (de)
DE (1) DE102014105464A1 (de)
WO (1) WO2015158483A1 (de)

Cited By (7)

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Publication number Priority date Publication date Assignee Title
CN107723872A (zh) * 2017-11-14 2018-02-23 无锡市鼎麒新材料科技有限公司 一种干式超声波多股纤维展宽设备及其方法
US10570536B1 (en) * 2016-11-14 2020-02-25 CFA Mills, Inc. Filament count reduction for carbon fiber tow
US20210156054A1 (en) * 2019-11-22 2021-05-27 Industrial Technology Research Institute Fiber spreading apparatus
CN115074887A (zh) * 2022-08-22 2022-09-20 常州市新创智能科技有限公司 一种碳纤维定宽展纤系统及方法
CN115418762A (zh) * 2022-09-13 2022-12-02 东华大学 棘轮式强化展丝辊表面振动而增加展丝功效的装置及用途
CN115896995A (zh) * 2022-09-13 2023-04-04 东华大学 一种复丝碰撞频率可调的展丝装置与方法及用途
US20230193525A1 (en) * 2021-12-20 2023-06-22 Raytheon Technologies Corporation Fabric structure control using ultrasonic probe

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Publication number Priority date Publication date Assignee Title
CN106894139B (zh) * 2015-12-17 2019-02-26 聚合兴企业有限公司 碳纤维多轴向震动的展纱装置
DE102016203603B3 (de) * 2016-03-04 2017-08-03 M & A - Dieterle GmbH Maschinen- und Apparatebau Vorrichtung und Verfahren zum Herstellen eines Rovingbands und/oder zum Herstellen eines faserverstärkten Verbundwerkstoffes
EP4585316A1 (de) 2022-09-08 2025-07-16 Toray Industries, Inc. Vorrichtung zur herstellung einer mit schlamm imprägnierten folie

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US4959895A (en) * 1989-10-13 1990-10-02 Branson Ultrasonics Corporation Method and apparatus for separating monofilaments forming a strand
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Publication number Priority date Publication date Assignee Title
US10570536B1 (en) * 2016-11-14 2020-02-25 CFA Mills, Inc. Filament count reduction for carbon fiber tow
CN107723872A (zh) * 2017-11-14 2018-02-23 无锡市鼎麒新材料科技有限公司 一种干式超声波多股纤维展宽设备及其方法
US20210156054A1 (en) * 2019-11-22 2021-05-27 Industrial Technology Research Institute Fiber spreading apparatus
US11519107B2 (en) * 2019-11-22 2022-12-06 Industrial Technology Research Institute Fiber spreading apparatus
US20230193525A1 (en) * 2021-12-20 2023-06-22 Raytheon Technologies Corporation Fabric structure control using ultrasonic probe
US12173431B2 (en) * 2021-12-20 2024-12-24 Rtx Corporation Fabric structure control using ultrasonic probe
CN115074887A (zh) * 2022-08-22 2022-09-20 常州市新创智能科技有限公司 一种碳纤维定宽展纤系统及方法
CN115418762A (zh) * 2022-09-13 2022-12-02 东华大学 棘轮式强化展丝辊表面振动而增加展丝功效的装置及用途
CN115896995A (zh) * 2022-09-13 2023-04-04 东华大学 一种复丝碰撞频率可调的展丝装置与方法及用途

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Publication number Publication date
WO2015158483A1 (de) 2015-10-22
JP2017528606A (ja) 2017-09-28
EP3132074B1 (de) 2018-11-14
DE102014105464A1 (de) 2015-10-22
EP3132074A1 (de) 2017-02-22

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