Process and apparatus for expanding multiple filament tow

1. A process for spreading a multiple filament tow wound into a spool comprising the steps of:

providing a multiple filament spool to a tensioning creel;

winding a tow from said spool through a series of rotating discs, each disc having four rotating rollers thereon, the rollers located on two concentric circles with different diameters, wherein the rollers are asymmetrically positioned on each disc such that the distance between the first and third roller is greater than the distance between the second and fourth roller, each disc having rollers which are offset from the rollers of an adjacent disc by up to 90°;

pulling said tow through said rotating discs to spread said tow into a spread tow; and

winding said spread tow onto a take-up winder to form a spread tow spool.

2. A process according to claim 1 wherein said rollers rotate freely.

3. The process according to claim 1 wherein said rollers are locked in position.

4. The process according to claim 1 wherein during said step of pulling, said tow is subjected to alternating periods of tension and slack as said tow passes through said rotating discs, generating cyclical high velocity impact with the rollers.

5. The process according to claim 1 wherein said multiple filament tow is formed from carbon fibers.

6. An apparatus for spreading a multiple filament tow comprising:

a tensioning creel having a multiple filament tow thereon;

centering bars for positioning said tow;

a series of rollers for receiving said tow from said centering bars;

a dancing roller within said series of rollers to dampen vibration of said tow;

a series of rotating discs;

each disc of said series of discs having four rollers thereon, the rollers located on two concentric circles with different diameters, wherein the rollers are asymmetrically positioned on each disc such that the distance between the first and third roller is greater than the distance between the second and fourth roller;

each disc having rollers which are offset from the rollers of an adjacent disc by up to 90°;

a series of driven rollers for pulling said tow through said series of rotating discs; and

a take-up winder for winding said tow in a spread state thereon.

7. The apparatus according to claim 6 further comprising a drive motor for rotating said discs.

8. The apparatus according to claim 6 comprising timing belts connecting the series of rotating discs for synchronously imparting rotational motion thereto.