Composite Corner Forming via Segmented Through-Hole Integration
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Solution Overview
Problem
Conventional methods for forming composite materials with corners often result in wrinkling, spacing, or unintended overlap, leading to quality issues in shape and strength due to the bending and lamination process.
Innovation Solution
A method where the corner and surrounding portion are formed separately and integrated, allowing for independent shaping and stabilization, with the corner being formed without being affected by the surrounding portion, using a process that includes preparing surrounding and corner members, placing them in a mold, and integrating them with thermosetting resin in a hardened state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the corner piece is bent around the periphery to form the corner, then the corner can be formed, but the corner piece becomes wrinkled or spaced from, or overlaps with surrounding members, resulting in poor lamination quality
Solution Approach 1:
The invention divides the corner formation process into two independent segments: the surrounding portion is formed first, and then the corner is formed separately by closing the through-hole. This segmentation allows each part to be formed without interfering with the other, eliminating the wrinkling and overlap problems that occur when bending a single corner piece around the periphery.
Solution Approach 2:
The surrounding portion is formed in advance before the corner is formed. By preparing the surrounding portion first with its through-hole, the subsequent corner formation can be performed independently without causing deformation to the surrounding structure, thus ensuring high lamination quality.
2Shape
If the corner is formed by bending and lamination of a single piece, then the corner structure can be created, but the process causes wrinkles and spacing issues that compromise shape and strength quality
Solution Approach 1:
The corner structure is segmented into the surrounding portion and the corner part formed separately. The surrounding portion is formed first, then the corner is formed by closing the through-hole with resin and fibers. This separate formation eliminates the mechanical deformation (wrinkles and spacing) that would compromise strength.
Solution Approach 2:
Resin and reinforcing fibers act as intermediaries to form the corner by closing the through-hole. This intermediary material fills the hole and bonds the surrounding portions, creating a strong corner structure without the need for bending and lamination of a single piece.
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 improves the quality of the corner by preventing wrinkling and overlap, enhancing the shape and strength of both the corner and surrounding portion, resulting in a high-quality composite material.
Implementation Method 1
obtained by impregnating reinforced fibers with thermosetting resin, wherein the thermosetting resin takes a softened state, a hardened state, and a semi-hardened state
Implementation Method 2
impregnating reinforced fibers with thermosetting resin
Data Source
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AI summary
Provided are a composite material forming method and a composite material with which a good quality corner can be suitably formed. A method of forming a composite material 10 including a corner 12 includes a surrounding portion formation step, a corner formation step, and an integration step. In the surrounding portion formation step, the state of the corner 12 before the corner 12 is formed is a through-hole state, and a surrounding portion 14 that surrounds the through-hole is formed. In the corner formation step, the through-hole is closed and the corner 12 is formed. In the integration step, the surround portion 14 and the corner 12 are integrated.