Thermoplastic Composite Molding for Wrinkle-Free Inner Openings
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Solution Overview
Problem
The existing methods for forming thermoplastic composites with inner openings are prone to wrinkling due to the inward movement of material, which compromises the structural integrity, particularly in applications requiring curvature or bending.
Innovation Solution
A mold system with a third mold part movably arranged around the first mold parts allows the inner parts to move relative to the first mold parts while clamping the outer part, using resilient elements to control the movement and prevent material accumulation, thereby reducing the risk of wrinkling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the thermoplastic composite is formed by moving mold parts to push inner part in a different direction than outer part, then the inner opening can be formed, but material moves inwardly causing accumulation and wrinkling
Solution Approach 1:
Instead of pushing material inwardly to form the inner opening, the invention allows the inner part to move outwardly relative to the first mold part. This reverses the conventional forming direction, preventing material accumulation and wrinkling while still achieving the desired inner opening shape.
Solution Approach 2:
The invention introduces a movable third mold part that can dynamically adjust during the forming process. The third mold part moves outwardly with the inner part, allowing controlled material flow and preventing wrinkling through dynamic adaptation to the forming stage.
2Stability of the object's composition
If a single substantially integral body of thermoplastic material is used to support fibers, then consolidation is achieved, but forming requires heating above melting point which complicates the process
Solution Approach 1:
The consolidation of the thermoplastic composite is performed before the forming operation. By completing the consolidation process first, the material is already in a stable, fiber-supported state, which simplifies the subsequent forming process and reduces the need for complex heating control during forming.
3Manufacturing precision
If the third mold part is movably arranged around the first mold parts, then inner part can move outwardly preventing wrinkling, but the device complexity increases
Solution Approach 1:
The mold is divided into multiple independent parts: first mold parts for engaging the inner part, a second mold part for engaging the outer part, and a third mold part that moves outwardly. This segmentation allows each part to perform its specific function independently, achieving wrinkling prevention through a modular rather than monolithic structure.
4Shape
If material moves inwardly to a region of smaller size, then inner opening is formed, but excess material accumulates causing structural integrity issues
Solution Approach 1:
The invention inverts the material flow direction by allowing the inner part to move outwardly relative to the first mold part during forming. This prevents material accumulation in the inner opening region, maintaining structural integrity while still achieving the desired shape.
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 effectively mitigates wrinkling by allowing material to move outwardly to a larger radius, ensuring a well-defined shape and facilitating cooling, thus enhancing the structural integrity of the formed thermoplastic composite.
Implementation Method 1
the thermoplastic composite to be heated to a temperature above a melting temperature of the thermoplastic material inside the thermoplastic composite allowing the thermoplastic composite to be formed
Implementation Method 2
one or more resilient elements, in each case arranged in between the supporting frame and the third mold part
Data Source
AI summary
A method and mold for forming a thermoplastic composite that has one or more inner openings, and a thermoplastic composite manufactured using such method. Typically, forming of a thermoplastic composite is achieved using a mold comprising a first and second mold part that are moved towards each other for the purpose of forming the thermoplastic composite. The mold further comprises a third mold part that is movably arranged around the one or more first mold parts. Furthermore, an additional step is used of clamping the outer part in between the second and third mold parts during the mutual movement of the first and second mold parts while allowing the one or more inner parts to move relative to the one or more first mold parts thereby increasing the one or more inner openings, respectively.