Arc-Shaped FRP Molding via Intermittent Radial Pressing
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Solution Overview
Problem
Molding large arc-shaped FRP components requires complex and large molds, and existing methods are inefficient for achieving homogeneous pressing in a radial direction, leading to suboptimal results.
Innovation Solution
An FRP molding system utilizing an arc-shaped inner and outer jig plate with a partial pressing device to intermittently compress and transfer the FRP material, allowing for the production of homogeneous arc-shaped components without the need for large or complicated molds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a large mold and large press machine are used to mold large arc-shaped FRP components, then the component size can be achieved, but the device complexity and size requirements increase significantly
Solution Approach 1:
The molding process is segmented into multiple sequential pressing operations. Instead of pressing the entire large FRP component simultaneously with a large mold, the component is divided into multiple zones that are pressed sequentially. The pressing device presses only a portion of the FRP material at each step, then transfers to press the next portion, repeating this process until the entire component is molded. This segmentation allows using a smaller, simpler pressing device to achieve large component molding.
Solution Approach 2:
The invention introduces the dimension of time and sequence to the molding process. By pressing portions sequentially in different time steps rather than all at once, the system transforms a spatial problem (requiring a large mold to cover the entire component area) into a temporal process (pressing different areas at different times). This allows a smaller pressing device to mold a large component through repeated sequential operations.
2Manufacturing precision
If the FRP component is pressed in a radial direction orthogonal to the arc for homogeneity, then the molding quality improves, but the mold structure becomes more complicated
Solution Approach 1:
The pressing device is designed to be movable rather than fixed, allowing it to dynamically reposition between different pressing operations. The device can move along the arc of the FRP component to press different portions sequentially. This dynamic capability enables the system to achieve radial pressing for homogeneity without requiring a complex fixed mold structure that would be needed to provide radial pressing from all directions simultaneously.
Solution Approach 2:
The pressing device acts as an intermediary that can be repositioned between pressing operations. Instead of having a complex mold structure that provides radial pressing from multiple fixed positions, a single pressing device serves as a mobile intermediary that delivers the pressing force at different locations sequentially. This simplifies the overall mold structure while maintaining the ability to press in the required radial direction for each portion.
3Device complexity
If a compact mold is used to avoid complexity, then the device size is reduced, but the ability to mold large arc-shaped components is compromised
Solution Approach 1:
The molding process uses periodic action through repeated cycles of pressing and transferring. The compact pressing device performs a periodic sequence: press a portion of the FRP material, transfer to the next position, press the next portion, transfer again, and repeat. This periodic repetition allows a compact device to accumulate the total pressing work needed for large components over multiple cycles, effectively compensating for the device's small size while maintaining molding capability for large components.
Solution Approach 2:
The system maintains continuity of useful action through the transfer mechanism that moves the pressed portion and positions the pressing device for the next operation. The pressing action is continuous in the sense that work is continuously being performed on different portions of the FRP component without idle time. The transfer step quickly repositions the system so that the compact pressing device can continuously apply pressing force throughout the entire component area over time, achieving complete molding despite the device's compact size.
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
Enables the production of large, homogeneous arc-shaped FRP components by intermittently compressing and transferring the integrated jig plate, reducing the complexity and size of the mold required, while ensuring uniformity and efficiency in the molding process.
Implementation Method 1
a partial pressing device configured to intermittently compress a part of an integrated jig plate in which the FRP material is interposed between the inner jig plate and the outer jig plate, in a radial direction orthogonal to the arc of the FRP component to partially mold the FRP component
Data Source
AI summary
A fiber reinforced plastic (FRP) molding system in which FRP material, having stacked prepregs, is molded to manufacture an arc-shaped FRP component. The FRP molding system comprises inner and outer jig plates, a partial pressing device, and transfer devices. The jig plates are arc-shaped members having outer and inner surfaces that respectively fit with inner and outer surface shapes of the FRP component. The FRP material is sandwiched between the jig plates to form an integrated jig plate. The partial pressing device intermittently compresses a portion of the integrated jig plate in a radial direction orthogonal to an arc of the FRP component so that the FRP component is partially molded. The transfer devices intermittently move the compressed portion of the integrated jig plate by the partial pressing device. By repeating the partial pressing and the transport, the entire integrated jig plate is compressed to form the FRP component.