C-Frame Membrane Press for Composite Forming
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Solution Overview
Problem
Existing methods for producing lightweight components from fiber composite materials are not suitable for large-scale production due to complexity and instability, particularly in creating components with complex structures and small radii.
Innovation Solution
A C-frame membrane press design with a heatable C-frame structure, utilizing a silicone membrane and differential pressures to form thermoplastic semi-finished products into complex shapes without the need for liquid resins, allowing for the production of stable and high-quality components with varying thickness and edge geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional membrane press methods are used with rigid frames and liquid resin injection, then the process can handle small to medium components, but the complexity and instability increase for large-scale production
Solution Approach 1:
The press frame is divided into modular C-frame sections that can be assembled together, allowing the press to handle large components while maintaining manageable structural complexity through standardized repeating units
Solution Approach 2:
A flexible membrane replaces the traditional rigid upper press plate, allowing the press to adapt to complex component geometries and large surfaces without requiring a complex rigid frame structure, thereby reducing overall press complexity while maintaining productivity
2Shape
If conventional methods with liquid resins are used, then the process can produce components with simple structures, but it cannot achieve complex structures with small radii
Solution Approach 1:
The flexible membrane acts as a conformable tooling surface that can be stretched over complex mold geometries with small radii, enabling the formation of intricate shapes without requiring complex rigid mold structures or liquid resin injection processes
Solution Approach 2:
The process uses controlled application of vacuum pressure and heat to the thermoplastic organo sheet, changing its physical state and mechanical properties to enable forming of complex shapes with small radii that would be impossible with conventional rigid mold methods
3Manufacturing precision
If high pressures are applied to ensure proper forming and venting, then components with excellent surface quality and accuracy are produced, but the energy consumption increases
Solution Approach 1:
Vacuum pressure is applied through the flexible membrane to draw the thermoplastic organo sheet onto the mold surface, providing uniform pressure distribution that ensures excellent surface quality and accuracy while consuming less energy compared to conventional high-pressure mechanical pressing methods
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 high-stability, lightweight components with complex structures and small radii, such as aircraft parts, by using consolidated organo sheets and applying high pressures to ensure proper forming and venting, resulting in components with excellent surface quality and accuracy.
Implementation Method 1
a vacuum pump (12) is provided, which is connected to the lower part (3) of the press
Implementation Method 2
applying a vacuum to the membrane (11) on the side facing the mold (4)
Implementation Method 3
applying an overpressure to the side facing away from the mold (4) using an overpressure pump (13)
Implementation Method 4
the semi-finished product/organic sheet is preferably heated before it is placed in the press (1)
Implementation Method 5
an elastically stretchable membrane (11) which can be stretched over the mold (4)
Data Source
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AI summary
The invention relates to a press for producing a component from a fibre-composite material, which is designed as a membrane press, comprising a press frame (15), a press lower part (3) on which a mould (4) is arranged, a press upper part (5) having a pressure chamber (6) that can be sealed against the press lower part (3), one or more press cylinders (9) which are supported on the press frame and act on the press upper part (5) and/or the press lower part (3), a membrane (11) that can be tensioned over the mould (4), a vacuum pump (12) with which a vacuum can be generated on a side of the membrane (11), for example on the underside, characterised in that the press frame is designed as a C-frame with an upper horizontal C-arm, a lower horizontal C-frame and a vertical C-base.