Solidified fiber bundles

Abstract

A method for producing solidified fiber bundles includes applying a melt or solution to a carrier web forming a viscous coating, applying parallel filaments under tension to the carrier web, and pressing the filaments into the viscous coating, forming an impregnate. The coating is partially solidified until a plastically deformable state of the impregnate is obtained by vaporizing the solvent, thermal curing and/or cooling. The impregnate is rolled onto a winding core to form a roll while maintaining a winding tension of the filaments in the impregnate. The outer roll is fixed on the winding core by a sleeve and/or by adhesive tape. The impregnate is solidified by vaporizing the solvent, thermal curing and/or cooling. The solidified impregnate is divided up to form solidified fiber bundles. A pressure produced by the winding tension of the filaments in the impregnate is exerted on the roll.

1 - 16 . (canceled) 
     
     
         17 . A method for producing solidified fiber bundles, which comprises the steps of:
 a) applying a melt or solution to a sheet-shaped carrier layer, thereby forming a viscous coating;   b) applying parallel filaments under tension to the sheet-shaped carrier layer having the viscous coating;   c) pressing the filaments into the viscous coating, thereby forming an impregnate;   d) rolling the impregnate onto a winding core to form a roll while maintaining a winding tension of the filaments in the impregnate;   e) solidifying the impregnate by at least one of vaporizing a solvent, thermal curing and cooling resulting in a solidified impregnate, wherein a pressure produced by the winding tension of the filaments in the impregnate is exerted on the roll during a performance of step e); and   f) dividing up the solidified impregnate for forming the solidified fiber bundles.   
     
     
         18 . The method according to  claim 17 , wherein the melt is a melt of a thermoplastic plastic, a thermosetting synthetic resin, a pitch and/or a sugar. 
     
     
         19 . The method according to  claim 17 , wherein the solution is a solution of a thermoplastic plastic, a thermosetting synthetic resin, a phenolic resin, a pitch and/or a sugar. 
     
     
         20 . The method according to  claim 17 , which further comprises dividing the impregnate into strips before performing the rolling step by cutting parallel to a filament direction with a cutting device. 
     
     
         21 . The method according to  claim 17 , which further comprises dividing the solidified impregnate into sub-rolls by cutting parallel to a filament direction with a cutting device before performing step f). 
     
     
         22 . The method according to  claim 17 , which further comprises covering the impregnate with a top cover immediately after performing step c). 
     
     
         23 . The method according to  claim 17 , wherein the filaments contain carbon filaments. 
     
     
         24 . The method according to  claim 17 , which further comprises:
 providing the solution or the melt as a solution or melt of an organic substance in step a); and   treating the solidified fiber bundles at a temperature from 750° C. to 1300° C. in an absence of oxidizing agents after step f), thereby converting at least some of the organic substance into carbon.   
     
     
         25 . The method according to  claim 17 , which further comprises:
 partially solidifying the viscous coating after step c) until a plastically deformable state of the impregnate is obtained by vaporizing the solvent, thermal curing and/or cooling, wherein the vaporizing, the thermal curing and/or the cooling are only performed to an extent that a plastically deformable state is maintained, wherein a force is exerted directly or indirectly on the impregnate by a pressure application device during or after solidification of the viscous coating;   fixing the roll on the winding core after step d) by at least one sleeve and/or at least one adhesive tape;   dividing up the solidified impregnate in step f) in parallel and perpendicularly to the direction of the filaments for forming the solidified fiber bundles.   
     
     
         26 . A solidified fiber bundle, comprising:
 a solid matrix being a solidified viscous coating formed from a melt or a solution; and   parallel filaments under tension disposed and pressed in said viscous coating thereby forming an impregnate, said impregnate rolled onto a winding core forming a roll while maintaining a winding tension of said filaments in said impregnate, said impregnate being solidified by at least one of vaporizing a solvent, thermal curing or cooling resulting in a solidified impregnate, wherein a pressure produced by the winding tension of said filaments in said impregnate is exerted on said roll, said solidified impregnate being divided up and forming the solidified fiber bundles.   
     
     
         27 . The solidified fiber bundle according to  claim 26 , wherein the solidified fiber bundle has a width, measured as an average of a larger spatial extension in each case of the solidified fiber bundle perpendicular to an average vector in a direction of a lengthwise extension of the solidified fiber bundle between 0.1 mm and 20 mm, and a length of the solidified fiber bundle, measured as an average of a spatial extension of the solidified fiber bundle parallel to an average vector in a direction of longitudinal extension of the filaments in the solidified fiber bundle is between 2 mm and 50 mm. 
     
     
         28 . The solidified fiber bundle according to  claim 26 , wherein the solidified fiber bundle has a thickness, measured as an average of a respective smaller spatial extension of the solidified fiber bundle perpendicular to an average vector in a longitudinal direction of an alignment of said filaments in the solidified fiber bundle is between 0.05 mm and 2 mm. 
     
     
         29 . The solidified fiber bundle according to  claim 27 , wherein:
 said width is between 0.5 mm and 3 mm; and   said length is between 3 mm and 20 mm.   
     
     
         30 . The solidified fiber bundle according to  claim 28 , wherein said thickness is between 0.1 mm and 0.5 mm. 
     
     
         31 . A method for producing reinforced synthetic resins, which comprises the steps of:
 producing solidified fiber bundles by the sub-steps of:
 applying a melt or solution to a sheet-shaped carrier layer, thereby forming a viscous coating; 
 applying parallel filaments under tension to the sheet-shaped carrier layer having the viscous coating; 
 pressing the filaments into the viscous coating, thereby forming an impregnate; 
 rolling the impregnate onto a winding core to form a roll while maintaining a winding tension of the filaments in the impregnate; 
 solidifying the impregnate by at least one of vaporizing the solvent, thermal curing or cooling resulting in a solidified impregnate, wherein a pressure produced by the winding tension of the filaments in the impregnate is exerted on the roll during a performance of the solidifying step); and 
 dividing up the solidified impregnate for forming the solidified fiber bundles; 
   providing the solidified fiber bundles as a reinforcing agent for a synthetic resin selected from the group consisting of thermoplastic synthetic resins and thermosetting synthetic resins.   
     
     
         32 . The method according to  claim 31 , which further comprises treating the synthetic resin reinforced with the solidified fiber bundles at a temperature from 750° C. to 1300° C. in an absence of oxidizing agents, wherein at least some of the synthetic resin is converted into carbon by carbonization. 
     
     
         33 . A molded body, comprising:
 solidified fiber bundles each containing a solid matrix being a solidified viscous coating formed from a melt or a solution and parallel filaments under tension disposed and pressed in said viscous coating thereby forming an impregnate, said impregnate rolled onto a winding core forming a roll while maintaining a winding tension of said filaments in said impregnate, said impregnate being solidified by vaporizing a solvent, thermal curing and/or cooling resulting in a solidified impregnate, wherein a pressure produced by the winding tension of said filaments in said impregnate is exerted on said roll, said solidified impregnate being divided up and forming said solidified fiber bundles; and   a synthetic resin, selected from the group consisting of thermoplastics synthetic resins and thermosetting synthetic resins, and reinforced with said solidified fiber bundles, the molded body being treated to a temperature of 750° C. to 1300° C. in an absence of oxidizing agents, wherein at least some of said synthetic resin being converted into carbon by carbonization resulting in a carbonized molded body, and by infiltrating said carbonized molded body with liquid or gaseous carbide-forming elements, above a melting or vaporization temperature thereof, thereby forming carbides of said carbide-forming elements.   
     
     
         34 . A production process, which comprises the steps of:
 providing solidified fiber bundles each containing a solid matrix being a solidified viscous coating formed from a melt or a solution and parallel carbon filaments under tension disposed and pressed in the viscous coating thereby forming an impregnate, the impregnate being rolled onto a winding core forming a roll while maintaining a winding tension of the carbon filaments in the impregnate, the impregnate being solidified by vaporizing the solvent, thermal curing and/or cooling resulting in a solidified impregnate, wherein a pressure produced by the winding tension of the carbon filaments in the impregnate is exerted on the roll, the solidified impregnate being divided up and forming the solidified fiber bundles; and   providing the solidified fiber bundles as a reinforcing agent in mixtures having thermosetting resins with at least one additional ingredient selected from the group consisting of pitches and particulate carbon.   
     
     
         35 . The process according to  claim 34 , which further comprises:
 processing the mixtures provided with the reinforcing agent to form molded bodies; and   treating the molded bodies at a temperature from 750° C. to 1300° C. in an absence of oxidizing agents, wherein at least some of the thermosetting resins and the pitches is converted into carbon by carbonization.