Composite Molding via Dynamic Clamping Pressure Control
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Solution Overview
Problem
The existing composite material molding methods face challenges in shortening molding time while suppressing clamping pressure, leading to larger pressing machines and increased equipment costs due to the risk of mold opening during resin injection, resulting in burrs and defective molding.
Innovation Solution
A composite material molding method and device that utilize a mold with adjustable clamping pressure and suction units to control resin injection pressure, injecting resin with pressure equal to or greater than clamping pressure until a threshold is reached, then suctioning to maintain pressure below clamping pressure, allowing resin injection without additional pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the injection pressure of the resin is increased to shorten the molding time, then the molding time is shortened, but the pressure inside the cavity increases and may exceed the clamping pressure causing the dies to open and creating burrs
Solution Approach 1:
The patent applies dynamics by making the clamping pressure adjustable and variable during the molding process. The clamping pressure is increased during resin injection to prevent mold opening, then reduced after injection to allow mold opening without burrs. This dynamic adjustment resolves the contradiction between short molding time (requiring high injection pressure) and molding quality (requiring mold closure).
Solution Approach 2:
The patent changes the parameter of clamping pressure from a fixed value to a variable parameter that is adjusted according to the process stage. By setting the clamping pressure to a first value during injection and a second value after injection, the system can accommodate both high injection pressure requirements and mold closure requirements, resolving the contradiction between productivity and manufacturing precision.
2Manufacturing precision
If the clamping pressure is increased to prevent mold opening during injection, then the molding quality is improved, but the pressing machine becomes larger and the equipment cost increases
Solution Approach 1:
The patent uses dynamic clamping pressure adjustment to apply high pressure only when necessary (during resin injection) and reduce it when not needed (after injection). This temporal separation of high-pressure requirements allows the use of a smaller pressing machine while maintaining molding quality, resolving the contradiction between manufacturing precision and device complexity.
Solution Approach 2:
The patent implements periodic action by applying high clamping pressure during the injection phase and reducing it during the post-injection phase. This periodic variation in clamping pressure allows the system to achieve high molding quality during the critical injection period while using a smaller, more cost-effective pressing machine overall.
3Productivity
If the resin is injected with high pressure to fill the cavity quickly, then the productivity is improved, but the pressure inside the cavity exceeds the clamping pressure causing the dies to open
Solution Approach 1:
The patent applies dynamics by adjusting the clamping pressure in response to the injection process. The clamping pressure is set to a first value during resin injection to maintain mold closure stability even under high injection pressure, then reduced to a second value after injection. This dynamic adjustment resolves the contradiction between injection speed and mold closure stability.
Solution Approach 2:
The patent implements feedback by monitoring the injection process and adjusting the clamping pressure accordingly. The control unit receives information about the injection status and adjusts the clamping pressure to maintain mold closure stability during high-pressure injection, then reduces pressure after injection completes, resolving the contradiction between productivity and stability.
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 molding time and clamping pressure, enabling miniaturization of the pressing machine and reducing equipment costs while ensuring high-quality composite material production with improved dimensional stability and mechanical properties.
Implementation Method 1
after the pressure inside the cavity has reached the threshold value, the inside of the cavity is suctioned... the resin injection unit injects the resin inside the cavity without exerting the injection pressure on the resin
Data Source
AI summary
A composite material molding method is provided for forming a composite material. The molding includes disposing carbon fiber in a cavity inside an openable and closable mold, injecting resin into the cavity in a state in which a clamping pressure is exerted on the mold and curing the resin. When a threshold value of the pressure inside the cavity is set to a pressure that is lower than the clamping pressure and the resin is injected into the cavity while exerting an injection pressure that is equal to or greater than the clamping pressure on the resin until the pressure inside the cavity reaches the threshold value. Then, after the pressure inside the cavity has reached the threshold value, the inside of the cavity is suctioned.