Injection-Molded Composite Blank and Guide for Lightweight Strength
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Solution Overview
Problem
Current methods for manufacturing lightweight yet high-strength plastic components, such as aircraft seat frames, are inefficient due to the use of thermoset composites which are time-consuming and costly, often resulting in increased weight and overdesigned strength where it is not needed.
Innovation Solution
A structural blank with oriented fiber plies in a thermoplastic matrix is combined with a guide made of randomly dispersed fibers in a thermoplastic matrix, using injection molding techniques to create a lightweight and strong article with reduced weight and increased strength in stress-prone areas, eliminating the need for adhesive layers and optimizing fiber distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermoset composites reinforced with fibers are used to manufacture seat frames, then strength is improved, but processing time increases and weight increases
Solution Approach 1:
The patent changes the material state from thermoset to thermoplastic, enabling injection molding processing. This parameter change allows the use of oriented fibers in a thermoplastic matrix that can be quickly processed while maintaining strength, resolving the contradiction between strength and processing time
Solution Approach 2:
The patent uses composite materials consisting of oriented fibers embedded in a thermoplastic matrix. This composite structure provides the necessary strength while allowing for efficient injection molding processing, avoiding the time-consuming processing of thermoset composites
2Strength
If thermoset composites reinforced with fibers are used to manufacture seat frames, then strength is improved, but weight increases
Solution Approach 1:
The patent changes the material from thermoset to thermoplastic, which has a lower density. This parameter change reduces the weight of the seat frame while maintaining strength through the use of oriented fibers in the thermoplastic matrix
Solution Approach 2:
The patent employs composite materials with oriented fibers in a thermoplastic matrix, creating a lightweight yet strong structure. The oriented fiber arrangement provides maximum strength-to-weight ratio, resolving the contradiction between strength and weight
3Strength
If oriented fibers are used in thermoplastic matrix, then strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent replaces complex mechanical fiber alignment processes with injection molding technology. The injection molding process automatically orients fibers during material injection, simplifying manufacturing while maintaining the strength benefits of oriented fibers
Solution Approach 2:
The patent changes the processing method to injection molding of thermoplastic materials, which simplifies the manufacturing process compared to traditional thermoset composite processing. This parameter change reduces manufacturing complexity while preserving oriented fiber strength
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 results in a lightweight, high-strength article that maintains structural integrity while reducing production time and costs, making it suitable for applications like aircraft interiors where weight and strength are critical.
Implementation Method 1
the guide is affixed to at least a portion of the structural blank top side with the guide thermoplastic matrix surrounding the structural blank guide hole
Implementation Method 2
injection molding techniques to create a lightweight and strong article
Data Source
AI summary
This specification discloses an article of manufacture. The article of manufacture has at least one structural blank and at least one guide. The structural blank has a plurality of oriented fiber plies in a thermoplastic matrix. The guide has a plurality of random dispersed fibers in a thermoplastic matrix. The guide is affixed to the structural blank by injection molding and over molding the guide onto the structural blank. The article of manufacture can take a number of forms for use in industries such as aircraft, automobiles, motorcycles, bicycles, trains or watercraft.