CFRP Molding Guide Member Thermal Conductivity Design
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Solution Overview
Problem
The existing molding techniques for CFRP (Carbon Fiber Reinforced Plastic) materials face issues with smooth operation due to the melting and adhesion of resin to the guide member's inner walls during transportation, leading to defective products and reduced material supply.
Innovation Solution
A molding apparatus with a guide member having a thermal conductivity of at least 10 W/m·k, equipped with a cooling structure such as a cooling fin or water supply, and a heat insulation structure like a gap or heat dissipation structure to prevent heat transfer from the heating device, ensuring the CFRP material does not melt during transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a heating device is used to melt resin at the nozzle port, then the resin can be supplied smoothly to the stage, but the resin melts and adheres to the guide member's inner wall during transportation
Solution Approach 1:
The guide member is designed with non-uniform thermal conductivity along its length. The first guide portion (near the nozzle) has low thermal conductivity to prevent heat transfer and resin adhesion, while the second guide portion (farther from nozzle) has high thermal conductivity to facilitate resin flow. This local differentiation resolves the contradiction by allowing heat retention only where needed.
Solution Approach 2:
The guide member is divided into two distinct guide portions with different thermal properties. The first guide portion uses a material with thermal conductivity of 0.1-10 W/m·k, while the second guide portion uses a material with thermal conductivity of 10-300 W/m·k. This segmentation allows each portion to perform its specific function independently, preventing adhesion in the heated zone while maintaining flow in the transport zone.
2Productivity
If the guide member has high thermal conductivity to facilitate resin flow, then resin can be transported efficiently, but heat from the heating device transfers to the guide member causing resin melting and adhesion
Solution Approach 1:
The guide member exhibits spatially varying thermal conductivity, with the first guide portion having low thermal conductivity (0.1-10 W/m·k) to block heat transfer from the heating device, and the second guide portion having high thermal conductivity (10-300 W/m·k) to enable efficient resin transportation. This local quality differentiation directly addresses the contradiction by controlling heat transfer only where necessary.
3Reliability
If the resin is prevented from melting during transportation, then adhesion to the guide member is avoided, but the operation complexity increases due to additional cooling structures
Solution Approach 1:
The guide member's thermal conductivity parameter is changed along its length, transitioning from low (0.1-10 W/m·k) in the first guide portion to high (10-300 W/m·k) in the second guide portion. This parameter change approach prevents resin melting during transport without requiring active cooling systems, thereby maintaining operational simplicity while ensuring resin integrity.
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 solution allows for smooth operation and reduced production of defective products, maintaining the integrity of the CFRP wiring by preventing resin melting and adhesion, resulting in minimal deviation in dimensions and consistent electrical resistance.
Implementation Method 1
a guide member having a thermal conductivity of not less than 10 W/m·k, equipped with a cooling structure such as a cooling fin or water supply
Implementation Method 2
a heat insulation structure like a gap or heat dissipation structure to prevent heat transfer from the heating device
Implementation Method 3
The heater 105 is built into the metal injection nozzle 104. The heat from the heater 105 is efficiently transmitted through the metal injection nozzle 104. As a result, the resin in the CFRP 100 at the nozzle port 104A position melts (fuses).
Data Source
AI summary
Provided is a molding technique with which a molding operation is performed smoothly, preventing the production of defective products. Also provided is a molding apparatus including a nozzle, a guide member guiding a molding material to the nozzle, and a heating device, the molding apparatus being further provided with a prevention structure configured to prevent the molding material from melting during transportation through the guide member.