Fiber-Reinforced Angle Plate Forming to Reduce Fiber Rupture
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for forming angle plates with fibers face challenges such as friction-induced displacement and rupture of fibers during compression molding, leading to inefficiencies in the process.
Innovation Solution
A method involving the positioning of preforms with free ends in a mold, where the ends are inclined towards a mold surface, and compression forms buckling portions and padding against curved portions using fillers, along with a mold system featuring actuators and guiding rails to control the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If compression molding is applied to form angle plates with fibers, then the angle plate structure is formed, but fiber displacement and rupture occur due to friction
Solution Approach 1:
The patent introduces a mold design with a specific geometry that acts as an intermediary between the compression force and the fiber preform. The mold includes a cavity with controlled friction characteristics and geometric features that guide fiber flow, reducing direct friction between the preform and molding surfaces while still enabling effective compression to form the angle plate structure.
Solution Approach 2:
The patent modifies the friction parameter by designing the mold surface with specific geometric features and material characteristics that reduce the coefficient of friction between the mold and fiber preform. This parameter change allows compression molding to proceed without causing fiber rupture, while still achieving the desired angle plate formation.
2Ease of manufacture
If traditional compression molding is used, then the molding process is simple, but fiber displacement occurs leading to reduced quality
Solution Approach 1:
The patent applies preliminary action by pre-positioning the fiber preform in a specific orientation and configuration within the mold cavity before compression begins. The mold design includes features that guide the preform into the correct position, ensuring proper fiber alignment is established before the compression force is applied, thereby preventing fiber displacement during molding.
3Productivity
If the free end of preform is compressed directly, then compression efficiency is high, but fiber rupture occurs due to concentrated stress
Solution Approach 1:
The patent employs curvature by designing the mold cavity with rounded surfaces and gradual transitions instead of sharp angles. The curved geometry distributes the compression force more evenly across the preform, preventing stress concentration at the free end while maintaining compression efficiency. This allows the forming process to proceed without causing fiber rupture.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces fiber displacement and rupture, enhancing the efficiency and quality of fiber-reinforced angle plate formation by controlling the compression process.
Implementation Method 1
compressing, by translating at least a first surface of the mold in at least a -Z-direction, the free first end of one or more of the first preforms
Implementation Method 2
the compressing forms: a buckling portion in the first preform from a buckling reference elevation
Data Source
AI summary
A method for forming a molded device comprising an angle plate, comprising: positioning in a mold ore or more first preform comprising a free first end and wherein the first preform comprises a first thermoplastic material and a plurality of elongated fibers; and positioning in the mold one or more filler comprising a second thermoplastic material; and compressing, by translating at least a first surface of the mold in at least a −Z-direction, the free first end of one or more of the first preform from a first position of the first end to a second position of the first end.