Continuous Composite Mold Production via Tensioned Curing
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Solution Overview
Problem
Current methods for producing molds for aircraft structural members from composite materials are costly, time-consuming, and require the production of an inverted mold, which can be brittle and prone to cracking, and often result in material wastage and increased processing time.
Innovation Solution
A method involving the continuous passing of prepreg sheets impregnated with thermosetting resin through a hot press and heat curing oven under tension to form a completely-cured two-dimensional mold, followed by laminating and curing joggle portions to create a mold with varying shapes without the need for an inverted mold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an inverted mold is produced from inorganic porous material or epoxy resin, then the mold can be produced without mechanical processing, but the material is brittle and prone to cracking under heat and pressure
Solution Approach 1:
The patent changes the material parameters by using thermosetting resin-impregnated fibrous materials instead of traditional inorganic porous materials or epoxy resin. This material substitution fundamentally alters the mechanical properties, providing both ease of manufacture and high reliability by eliminating brittleness while maintaining moldability.
Solution Approach 2:
The patent employs composite materials consisting of fibrous reinforcement (such as glass fiber or carbon fiber) combined with thermosetting resin. This composite structure provides both the ease of shaping required for manufacturing and the mechanical strength needed to withstand autoclave processing without cracking.
2Ease of manufacture
If a long inverted mold is produced from inorganic porous material, then the mold can be manufactured, but the long brittle material is difficult to handle and may crack
Solution Approach 1:
The patent changes the material parameters by using thermosetting resin-impregnated fibrous materials that can be continuously supplied in long lengths. This material substitution fundamentally alters the mechanical properties, providing both ease of manufacture and high reliability by eliminating brittleness while maintaining moldability.
3Ease of manufacture
If autoclave molding is performed on inorganic porous material, then the mold can be used, but the material strength is reduced and cracks may occur due to thermal stress
Solution Approach 1:
The patent changes the material parameters by using thermosetting resin-impregnated fibrous materials instead of traditional inorganic porous materials or epoxy resin. This material substitution fundamentally alters the mechanical properties, providing both ease of manufacture and high reliability by eliminating brittleness while maintaining moldability.
Solution Approach 2:
The patent employs composite materials consisting of fibrous reinforcement (such as glass fiber or carbon fiber) combined with thermosetting resin. This composite structure provides both the ease of shaping required for manufacturing and the mechanical strength needed to withstand autoclave processing without cracking.
4Reliability
If mechanical processing is performed on metal block to produce mold, then the mold can be produced, but material is largely wasted and processing time is increased
Solution Approach 1:
The patent changes the material parameters by using thermosetting resin-impregnated fibrous materials that can be directly formed into the desired mold shape through autoclave molding. This eliminates the need for extensive mechanical processing of metal blocks, significantly reducing material waste while producing reliable molds.
5Reliability
If metal mold is produced through casting and mechanical processing, then the mold can be produced, but the production cost increases and lead time becomes longer
Solution Approach 1:
The patent changes the material parameters by using thermosetting resin-impregnated fibrous materials that can be directly formed into the desired mold shape through autoclave molding. This eliminates the need for extensive mechanical processing of metal blocks, significantly reducing material waste while producing reliable molds.
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 reduces production costs and time while avoiding material wastage and brittleness issues, enabling the efficient creation of long composite material molds with complex shapes.
Implementation Method 1
a material obtained by overlapping a required number of prepreg sheets in which a composite material such as carbon fiber is impregnated with thermosetting resin to continuously pass through a hot press and a heat curing oven while applying a tension to the material
Implementation Method 2
pass through a hot press and a heat curing oven
Implementation Method 3
applying a tension to the material
Implementation Method 4
laminating a required number of prepreg sheets on a portion of a surface of the completely-cured two-dimensional mold material; and completely curing the mold material where the joggle portion is formed by heating and pressurization
Implementation Method 5
heating and pressurization
Data Source
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AI summary
A method for producing a mold (3) for use in molding a long member according to the present invention includes, as basic means, the steps of: molding a material (2) of a mold having a two-dimensional shape and in a completely-cured state by causing a material obtained by overlapping a required number of prepreg sheets (4) in which a composite material such as carbon fiber is impregnated with thermosetting resin to continuously pass through a hot press and a heat curing oven while applying a tension to the material; forming a joggle portion (2a,2b) partially having a different shape in section by laminating a required number of prepreg sheets (21,22,23,24,25,26) on a portion of a surface of the completely-cured two-dimensional mold material; and completely curing the mold material where the joggle portion is formed by heating and pressurization.