Composite Laminate Molding With Tensioned Recess Shaping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The thickness change of composite materials with bent portions during curing leads to circumferential length differences, causing wrinkles and molding defects.
Innovation Solution
A composite material molding method and apparatus that uses a molding die with a recess and a tension generating member to apply tension to the laminate, hermetically sealing it with a covering member and sucking atmosphere to draw the tension member into the recess, shaping and curing the laminate to suppress defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the laminate is shaped into a bent portion during molding, then the composite material can achieve the desired bent shape, but the thickness change during curing causes circumferential length difference and wrinkles
Solution Approach 1:
The tension generating member is disposed on the laminate before the curing process, and tension is applied in advance during the shaping stage. This preliminary application of tension prevents the circumferential length difference from causing wrinkles during the subsequent curing process, where the resin would otherwise contract and create defects.
Solution Approach 2:
The patent changes the physical state of the laminate by applying tension through the tension generating member during shaping, and maintains this tensioned state during curing. This parameter change (application of tensile stress) prevents the natural contraction of the resin during curing from causing circumferential length differences and wrinkles in the bent portion.
2Manufacturing precision
If tension is applied to the laminate during shaping, then circumferential length difference is suppressed, but the molding process becomes more complex
Solution Approach 1:
The tension generating member is implemented as a flexible film or sheet that can be easily disposed on the laminate and sealed with the covering member. This flexible film approach simplifies the overall system compared to rigid mechanical tensioning devices, while still effectively applying the necessary tension to suppress circumferential length differences during shaping and curing.
3Shape
If the tension generating member is drawn into the recess, then the laminate is effectively shaped, but the sealing requirement becomes more stringent
Solution Approach 1:
The tension generating member is nested within the sealing system formed by the covering member and molding die. As the tension generating member is drawn into the recess during suction, it remains contained within the hermetic seal, allowing the sealing system to maintain its integrity while still achieving the desired laminate shaping through the recess mechanism.
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
Suppresses the occurrence of molding defects by applying a tensile load to the laminate, effectively eliminating slack and preventing wrinkles around bent portions.
Implementation Method 1
sucking atmosphere between the covering member and the molding die to draw in a part of the tension generating member into the recess
Implementation Method 2
covering the laminate covered with the tension generating member with a covering member to hermetically seal between the covering member and the molding die
Implementation Method 3
covering the laminate with a tension generating member that generates tension in the laminate at a time of shaping
Implementation Method 4
curing a resin impregnated into the fiber sheets
Data Source
AI summary
A method for molding a composite material by shaping, by using a molding die, a laminate of fiber sheets including a bent portion, and curing a resin impregnated into the fiber sheets. The molding die has a molding surface and a recess other than the molding surface. The composite material molding method includes: disposing the laminate on the molding surface; covering the laminate with a tension generating member that generates tension in the laminate at shaping, and disposing a part of the tension generating member to face the recess; covering the laminate with a covering member to hermetically seal between the covering member and the molding die; sucking atmosphere between the covering member and the molding die to draw in a part of the tension generating member into the recess to shape the laminate; and curing the laminate after shaping to mold the composite material.