Method and Apparatus for Making a Fiber Reinforced Article

Abstract

A method and apparatus for producing an article. The method includes providing a fiber material, splitting the fiber material with a splitting roller having a set of grooves that extend continuously around a circumference of the splitting roller, and cutting the fiber material to a desired length.

What is claimed: 
     
         1 . A method of producing an article, comprising:
 providing a fiber material configured as a ribbon that includes a plurality of fibers;   splitting the fiber material with a splitting roller having a set of grooves that extend continuously around a circumference of the splitting roller such that the splitting roller engages the ribbon and separates the ribbon into bundles without cutting the fiber material; and   cutting the fiber material to a desired length.   
     
     
         2 . The method of  claim 1  wherein the plurality of fibers of the fiber material are arranged generally parallel to each other and wherein at least some of the fibers are discontinuous with respect to each other. 
     
     
         3 . The method of  claim 1  wherein members of the set of grooves are disposed substantially parallel to each other. 
     
     
         4 . The method of  claim 1  wherein each member of the set of grooves extends substantially perpendicular to an axis of rotation of the splitting roller. 
     
     
         5 . The method of  claim 1  wherein a tooth is disposed between adjacent members of the set of grooves, wherein a tip of the tooth is provided with a continuous curved surface. 
     
     
         6 . The method of  claim 1  wherein the splitting roller does not rotate against a feed direction of the fiber material. 
     
     
         7 . The method of  claim 1  wherein a drive roller engages an exterior surface of the splitting roller to rotate the splitting roller. 
     
     
         8 . The method of  claim 7  wherein the drive roller engages and rotates a cutting roller that is spaced apart from the splitting roller. 
     
     
         9 . The method of  claim 1  wherein the fiber material is carbon fiber. 
     
     
         10 . An apparatus for producing a fiber reinforced article, comprising:
 a splitting roller configured to rotate about a first axis, the splitting roller having a set of grooves that extend around a circumference of the splitting roller in a substantially parallel relationship, wherein the splitting roller engages and separates a ribbon of fiber material into bundles of fibers without cutting the fibers;   a cutting roller spaced apart from the splitting roller and configured to rotate about a second axis; and   a drive roller configured to rotate the splitting and cutting rollers about the first and second axes.   
     
     
         11 . The apparatus of  claim 10  wherein the first and second axes are disposed substantially parallel to each other. 
     
     
         12 . The apparatus of  claim 10  wherein a depth of each groove is greater than a width of each groove. 
     
     
         13 . The apparatus of  claim 10  wherein each groove includes a bottom surface having a constant radius of curvature. 
     
     
         14 . The apparatus of  claim 10  wherein each member of the set of grooves is separated from an adjacent member of the set of grooves by a tooth that extends continuously around the circumference of the splitting roller. 
     
     
         15 . The apparatus of  claim 14  wherein the tooth includes a tip having a constant radius of curvature. 
     
     
         16 . The apparatus of  claim 14  wherein each groove includes a bottom surface having a flat portion disposed adjacent to a radius of curvature disposed at a base of the tooth. 
     
     
         17 . An apparatus for producing an article, comprising:
 a splitting roller having a set of grooves that extend around a circumference of the splitting roller in a substantially parallel relationship; and   a fiber material that is configured as a ribbon, wherein fibers of the fiber material are separated into bundles that are received in the set of grooves when the ribbon engages the splitting roller.   
     
     
         18 . The apparatus of  claim 17  wherein each member of the set of grooves extends substantially perpendicular to an axis of rotation of the splitting roller and a tooth having a tip with a curved surface is disposed between adjacent members of the set of grooves. 
     
     
         19 . The apparatus of  claim 18  wherein the tip engages the ribbon to separate the fibers. 
     
     
         20 . The apparatus of  claim 19  wherein the tooth extends completely around the circumference of the splitting roller.