Braided Composite Tube Molding with Internal Pressure for Resin Adhesion
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Solution Overview
Problem
Existing methods face challenges in achieving adequate adhesion between carbon fiber and thermoplastic resin, particularly due to high viscosity and difficulty in impregnation, and limit the shape freedom in molding composite molded bodies.
Innovation Solution
A molding system that combines braiding with warm pressure molding, using an elastic insertion member to apply internal pressure and maintain adhesion between carbon fiber and thermoplastic resin, allowing for various shapes and improved integration of overlapped portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermoplastic resin is used to impregnate carbon fiber, then adhesion can be improved, but high viscosity makes sufficient impregnation difficult
Solution Approach 1:
The patent applies parameter changes by controlling the temperature of the thermoplastic resin during the impregnation process. By heating the resin to a specific temperature range (above melting point but below degradation point), its viscosity is reduced to enable sufficient impregnation into carbon fiber bundles, then cooled to maintain adhesion. This temperature parameter control resolves the contradiction between achieving good adhesion and enabling sufficient impregnation.
Solution Approach 2:
The patent employs preliminary action by pre-heating the thermoplastic resin before the impregnation process. The resin is heated to the appropriate temperature in advance to ensure it has optimal viscosity for impregnation, then applied to the carbon fiber. This preliminary temperature treatment enables the resin to flow properly and penetrate the carbon fiber structure effectively.
2Ease of manufacture
If thermosetting resin is used to impregnate carbon fiber, then impregnation is easy due to low viscosity, but curing time is long and subsequent molding is difficult
Solution Approach 1:
The patent changes the resin type parameter from thermosetting to thermoplastic, which fundamentally alters the curing behavior. Thermoplastic resins do not require chemical curing and can be shaped by temperature control alone, eliminating the long curing time associated with thermosetting resins while maintaining easy impregnation characteristics.
Solution Approach 2:
The patent replaces the chemical curing mechanism of thermosetting resins with a thermal processing mechanism for thermoplastic resins. Instead of relying on chemical cross-linking reactions that take time, the thermoplastic resin is shaped through temperature control (heating for molding, cooling for solidification), which is a faster physical process that enables rapid production.
3Reliability
If carbon fiber is braided with thermoplastic resin, then adhesion can be achieved, but applying sufficient pressure during drawing is difficult
Solution Approach 1:
The patent changes the processing temperature parameter during the drawing operation. By heating the thermoplastic resin to a temperature where it is soft or melted, its viscosity is reduced, allowing sufficient pressure to be applied during drawing without causing resin degradation or poor adhesion. The temperature control enables the resin to flow and bond properly under the required drawing pressure.
Solution Approach 2:
The patent applies dynamics by making the resin's physical state changeable during the process. The resin transitions from a solid state during braiding to a soft/melt state during drawing, then back to solid after cooling. This dynamic state change allows the system to adapt to different process requirements (adhesion during braiding, flow during drawing) without being constrained by fixed material properties.
4Shape
If spiral winding of tape is used to form tubular body, then some shapes can be achieved, but adhesion of overlapped portion is insufficient and shape freedom is limited
Solution Approach 1:
The patent applies parameter changes by controlling temperature during the forming process. The thermoplastic resin is heated to a temperature where it is soft or melted, enabling it to flow and bond properly at overlapped portions during spiral winding. This temperature control ensures strong adhesion at overlaps while allowing flexibility in achieving various tubular shapes.
Solution Approach 2:
The patent uses composite materials by combining carbon fiber with thermoplastic resin in a braided structure. This composite approach allows the carbon fiber to provide structural strength and the thermoplastic resin to provide adhesion and shape flexibility, creating a material system that overcomes the limitations of using either material alone.
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
The system enhances adhesion and flexibility in shaping composite molded bodies, enabling high strength and diverse design possibilities.
Implementation Method 1
a thermoplastic resin can be melted by being heated to a predetermined temperature
Implementation Method 2
when pressured relatively from both ends of the cylindrical material, the elastic insertion member expands in the lateral direction to pressure the inner peripheral surface of the cylindrical material
Data Source
Figure 1A~1B
Figure 2~3C
Figure 4~5
AI summary
An object of the invention is to provide a molding system and a production method for a composite molded body having excellent adhesion between carbon fiber and a thermoplastic resin and having a high degree of freedom in molding. The molding system includes: braiding means that braids a cylindrical material made of a composite material of carbon fiber and a thermoplastic resin; and warm pressure means that warm molds the braided cylindrical material into the composite molded body while pressuring the cylindrical material from the inside.