Apparatus, system, and method for splicing carbon fiber tow

Abstract

An entanglement apparatus includes a controller and a nozzle rotatably mounted for rotation about a nozzle axis. An entanglement section is coupled to a fluid supply and defines openings positionable to face overlapped ends of the fiber tows. At least one of the openings extends along an angled direction relative to the nozzle axis to create adjacent or overlapping fluid distribution paths, and two or more of which are disposed in irregular intervals along the entanglement section and relative to another two or more of the paths. The controller regulates a preselected property of the fluid supply, including a rotation characteristic of the nozzle to randomize the paths. The apparatus directs the fluid through the openings and along the paths toward the overlapped ends of the fiber tows while the nozzle is rotating about the nozzle axis and while the fiber tows, other than their overlapped ends, are maintained stationary.

1 . An entanglement apparatus configured for entangling overlapped ends of fiber tows, the apparatus comprising:
 a nozzle rotatably mounted for rotation about a nozzle axis, the nozzle comprising
 an entanglement section defining openings positionable to face the overlapped ends of the fiber tows, the entanglement section being configured to be coupled to a fluid supply for receiving a fluid, 
 wherein at least one of the openings extends along a direction at an angle relative to the nozzle axis such that the openings are configured to create adjacent or overlapping fluid distribution paths, and 
 wherein two or more of the adjacent or overlapping fluid distribution paths are disposed in irregular intervals along the entanglement section and relative to another two or more of the adjacent or overlapping fluid distribution paths; and 
   a controller configured to regulate a preselected property of the fluid supply, the preselected property of the fluid supply determining a rotation characteristic of the nozzle to randomize the adjacent or overlapping fluid distribution paths;   wherein the entanglement apparatus is configured to direct the fluid through the openings and along the adjacent or overlapping fluid distribution paths toward the overlapped ends of the fiber tows while the nozzle is rotating about the nozzle axis and while the fiber tows, other than their overlapped ends, are maintained stationary.   
     
     
         2 . The entanglement apparatus of  claim 1 , wherein the nozzle comprises a first nozzle and a second nozzle, the second nozzle being spaced apart from the first nozzle along the nozzle axis and oriented opposite of the first nozzle. 
     
     
         3 . The entanglement apparatus of  claim 1 , wherein the entanglement section comprises an upstream area and a downstream area, and the openings comprise upstream openings disposed in the upstream area of the entanglement section and downstream openings disposed in the downstream area of the entanglement section. 
     
     
         4 . The entanglement apparatus of  claim 1 , further comprising a gear assembly comprising at least one wheel configured to rotate about the nozzle axis. 
     
     
         5 . The entanglement apparatus of  claim 4 , wherein the nozzle is rotatably mounted to the at least one wheel. 
     
     
         6 . The entanglement apparatus of  claim 5 , wherein the nozzle is configured to rotate about the nozzle axis in response to rotation of the at least one wheel. 
     
     
         7 . The entanglement apparatus of  claim 4 , wherein a first end section of the nozzle is rotatably mounted to a first wheel. 
     
     
         8 . The entanglement apparatus of  claim 7 , wherein a second end section of the nozzle is rotatably mounted to a second wheel, and the second end section of the nozzle is opposite the first end section of the nozzle. 
     
     
         9 . The entanglement apparatus of  claim 7 , wherein the first wheel is coupled to a first joint for delivering a first fluid stream supply to the nozzle. 
     
     
         10 . The entanglement apparatus of  claim 8 , wherein the second wheel is coupled to a second joint for delivering a second fluid stream supply to the nozzle. 
     
     
         11 . The entanglement apparatus of  claim 4 , further comprising a motor configured to cause rotation of the wheel of the gear assembly. 
     
     
         12 . The entanglement apparatus of  claim 11 , wherein the gear assembly is coupled directly or indirectly to the motor. 
     
     
         13 . The entanglement apparatus of  claim 11 , wherein the motor is a pneumatic motor. 
     
     
         14 . The entanglement apparatus of  claim 11 , wherein the at least one wheel is configured to rotate about a wheel axis in response to activation of the motor. 
     
     
         15 . The entanglement apparatus of  claim 11 , the gear assembly further comprising at least one gear interposed between the at least one wheel and the motor, the at least one gear being configured to be driven by the motor. 
     
     
         16 . The entanglement apparatus of  claim 1 , wherein the rotation characteristic of the nozzle comprises a predetermined range of rotational speed. 
     
     
         17 . The entanglement apparatus of  claim 13 , wherein the preselected property of the fluid supply comprises a predetermined range of air pressure supplied to an inlet of the pneumatic motor. 
     
     
         18 . The entanglement apparatus of  claim 1 , wherein the openings include at least a first opening having a first diameter, and at least a second opening having a second diameter, the first diameter being different from the second diameter. 
     
     
         19 . The entanglement apparatus of  claim 1 , wherein the apparatus is configured to produce fiber tows comprising:
 a first carbon fiber tow having a terminal end and a starting end;   a second carbon fiber tow having a terminal end and a starting end; and   a splice joint comprising joined portions of the first carbon fiber tow and the second carbon fiber tow;   wherein the density of the spliced carbon fiber tow is substantially increased from the starting end of the first carbon fiber tow to the terminal end of the second carbon fiber tow.   
     
     
         20 . The entanglement apparatus of  claim 19 , wherein the first and second carbon fiber tows are each made up of about 50,000 or more filament fibers. 
     
     
         21 . The entanglement apparatus of  claim 19 , wherein a dry splice joint is able to withstand a tension force of at least 40 kg. 
     
     
         22 . The entanglement apparatus of  claim 19 , wherein a dry splice joint is able to withstand a tension force of at least 60 kg. 
     
     
         23 . The entanglement apparatus of  claim 19 , wherein the splice joint, impregnated with uncured epoxy resin, is able to withstand a tension force of at least 28 kg. 
     
     
         24 . The entanglement apparatus of  claim 19 , wherein the splice joint, impregnated with uncured epoxy resin, is able to withstand a tension force of at least 50 kg. 
     
     
         25 .- 37 . (canceled) 
     
     
         38 . A system for entangling overlapped ends of fiber tows to form spliced carbon fiber tows, the system comprising:
 the entanglement apparatus of  claim 1 ; and   a source for delivering the fiber tows to the entanglement apparatus.   
     
     
         39 . The system of  claim 38 , the source comprising a creel containing the fiber tows including a first reel having a coiled portion of a first carbon fiber tow and a second reel having a coiled portion of a second carbon fiber tow. 
     
     
         40 . The system of  claim 39 , wherein the entanglement apparatus is mounted to an assembly moveable to one or more positions for operative engagement with the creel. 
     
     
         41 . The system of  claim 39 , wherein the first and second carbon fiber tows are each made up of about 50,000 or more filament fibers. 
     
     
         42 . The system of  claim 41 , wherein a dry splice joint of the fiber tows is able to withstand a tension force of at least 40 kg. 
     
     
         43 . The system of  claim 41 , wherein a dry splice joint of the fiber tows is able to withstand a tension force of at least 60 kg. 
     
     
         44 . The system of  claim 41 , wherein a splice joint of the fiber tows, impregnated with uncured epoxy resin, is able to withstand a tension force of at least 28 kg. 
     
     
         45 . The system of  claim 41 , wherein a splice joint of the fiber tows, impregnated with uncured epoxy resin, is able to withstand a tension force of at least 50 kg.