Composite Laminate Vacuum Forming for Wrinkle-Free Joggle Molding
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Solution Overview
Problem
Molding defects, such as wrinkles, often occur in composite materials with shape-changing portions due to the formation of laminates around these areas during the molding process.
Innovation Solution
A composite material molding method and apparatus that utilizes a molding die with specific surfaces and recesses to draw in a part of the laminate, applying a tensile load to prevent wrinkling, and includes a covering member and suction device to hermetically seal and shape the laminate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a laminate is shaped around a shape-changing portion (joggle portion) during molding, then the composite material can be formed with complex geometry, but wrinkles may be formed around the shape-changing portion resulting in molding defects
Solution Approach 1:
The recess is formed in advance on the molding die at the position corresponding to the shape-changing portion. This preliminary structural preparation allows the laminate to be properly positioned and drawn into the recess during vacuum shaping, preventing wrinkles from forming around the joggle portion while enabling complex geometry to be achieved
2Shape
If vacuum suction is applied to draw in the laminate, then the laminate can be shaped properly around complex geometries, but the suction force may cause excessive tension or damage to the laminate
Solution Approach 1:
The recess is localized at the specific position corresponding to the shape-changing portion rather than applying vacuum suction uniformly across the entire laminate. This localized approach concentrates the drawing force only where needed to form the joggle portion, preventing excessive tension and damage to other areas of the laminate while still achieving proper shaping
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 method and apparatus effectively suppress the occurrence of molding defects by shaping the laminate with a tensile load, ensuring the composite material is molded without wrinkles.
Implementation Method 1
sucking atmosphere in the space between the covering member and the molding die to draw in the part of the laminate into the recess
Implementation Method 2
sucking atmosphere in the space between the covering member and the molding die to draw in the part of the laminate into the recess and to shape the laminate
Data Source
AI summary
A method for molding a composite material includes arranging a laminate of fiber sheets on a molding die with a part of the laminate facing a recess of the molding die; covering the laminate with a covering member to hermetically seal a space between the covering member and the molding die; sucking atmosphere in the space between the covering member and the molding die to draw in the part of the laminate into the recess and to shape the laminate; and molding the composite material including the product portion and the excess portion by curing the laminate after shaping.