Composite Mold Gap Spacing to Prevent Resin-Rich Fiber Ends
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Solution Overview
Problem
In resin transfer molding, the formation of resin-rich parts without fiber material at the ends of the composite material is likely, leading to increased manufacturing costs and potential damage due to cracking.
Innovation Solution
A method and apparatus that involves measuring and adjusting the gap between molds using spacers to ensure even distribution of resin, incorporating a movable second mold with a contact surface and a spacer to seal the fiber base material, and injecting resin into a tightly closed space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the clearance between the die and the molding jig is adjusted to compress the fiber base material, then the fiber base material can be sufficiently pressed and compressed, but a gap may be generated at the end portion of the fiber base material causing resin-rich parts to form
Solution Approach 1:
The invention introduces a preliminary positioning action where the die is positioned to contact the first end portion of the fiber base material before compression. This preliminary action ensures that the fiber base material is properly located and prevents gap formation at the ends during subsequent compression, eliminating resin-rich parts while maintaining compression uniformity.
Solution Approach 2:
The invention uses the first end portion of the fiber base material as an intermediary element to mediate between the die and the molding process. By having the die contact this specific end portion, the system creates a reference point that prevents gap formation and ensures uniform compression throughout the material.
2Ease of manufacture
If resin transfer molding is applied using pressure difference, then the fiber base material can be impregnated with resin material, but resin material may be injected into gaps forming resin-only parts
Solution Approach 1:
The invention implements a preliminary positioning action where the die contacts the first end portion of the fiber base material before resin injection. This preliminary action eliminates gaps at the ends, ensuring that resin material is distributed uniformly throughout the fiber base material during impregnation, preventing resin-only parts from forming.
3Length of moving object
If the clearance is adjusted for plate thickness, then the desired thickness can be achieved, but gaps at end portions lead to increased manufacturing cost due to removal operations
Solution Approach 1:
The invention performs a preliminary positioning action where the die contacts the first end portion of the fiber base material before the molding process. This preliminary action prevents gap formation at the ends, eliminating the need for subsequent removal operations of resin-rich parts, thereby reducing manufacturing cost while maintaining the desired plate thickness.
4Length of moving object
If the clearance is adjusted for plate thickness, then the desired thickness can be achieved, but gaps at end portions cause cracking and potential damage
Solution Approach 1:
The invention implements a preliminary positioning action where the die contacts the first end portion of the fiber base material before compression and resin injection. This preliminary action prevents gap formation at the ends, eliminating the root cause of cracking and ensuring structural integrity of the molded composite material while achieving the desired plate thickness.
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
Prevents the formation of resin-only parts at the ends of the composite material, reducing manufacturing costs and preventing damage by ensuring uniform integration of resin with fiber material.
Implementation Method 1
resin transfer molding (RTM) of impregnating the fiber base material with the resin material using a pressure difference between a vacuum pressure and an atmospheric pressure
Implementation Method 2
resin transfer molding (RTM) of impregnating the fiber base material with the resin material using a pressure difference between a vacuum pressure and an atmospheric pressure
Data Source
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AI summary
Provided is a fiber reinforced composite material (200) molding method including: a disposing process S102 of disposing a second mold (20) in a first mold (10) such that a contact surface (20b) of the second mold (20) is brought into contact with a molding surface (10a, 10b, 10c) of the first mold (10); a first placing process S103 of placing a fiber base material on the molding surface (10a, 10b, 10c) of the first mold (10); a measurement process S104 of measuring a gap formed between the second mold (20) and a second end portion (12) of the first mold (10) in a state in which the fiber base material is in contact with a first end portion (11) of the first mold (10) in a first direction and the second mold (20) is in contact with the fiber base material; an insertion process S105 of inserting, between the second mold (20) and the second end portion (12) of the first mold (10), a spacer (25) with a length in the first direction in accordance with the measured gap; a tightly closing process S107 of sealing the fiber base material in the first mold (10) with a tightly closing member (30) and forming a tightly closed space; and an injection process S108 of injecting a resin material into the tightly closed space.