Composite Molding Recess Positioning Method
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Solution Overview
Problem
The existing composite material molding methods require high work accuracy for positioning and sealing, leading to potential positional deviation and wrinkling of fiber base materials during the integration process, especially when using an outer mold line method.
Innovation Solution
A composite material molding method using a molding tool with an inner mold line, where a recess is formed to accommodate the second fiber base material, and a first fiber-reinforced portion is fixed to cover the recess, allowing for accurate positioning and integration of the second fiber base material without contact issues, using a resin infusion process to prevent wrinkles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the outer mold line method is used with accurate positioning, then the composite material components can be integrally molded, but high work accuracy is required and the sealing process becomes complicated
Solution Approach 1:
The patent inverts the traditional outer mold line approach by using an inner mold line method where the recess is formed inside the molding tool rather than relying on external positioning and sealing. This inversion eliminates the need for complex sealing processes while maintaining positioning accuracy through the recess geometry itself.
Solution Approach 2:
The patent extracts the sealing function from the positioning system by using the recess structure to inherently contain the fiber base material. The recess walls themselves provide the containment function that would otherwise require separate sealing mechanisms in the outer mold line method.
2Manufacturing precision
If the inner mold line method is used with a recess, then positioning accuracy is improved and sealing work is reduced, but the fiber base material may contact the composite material component causing movement or wrinkles
Solution Approach 1:
The patent segments the molding process into distinct steps: first installing the fiber base material in the recess, then adding the laminate. This segmentation allows for controlled interaction between components and prevents unwanted contact that could cause movement or wrinkles.
Solution Approach 2:
The patent performs preliminary action by pre-installing the fiber base material in the recess before adding the laminate. This preliminary positioning ensures the fiber base material is securely held in the correct position before any potential contact with the laminate occurs during the molding process.
3Ease of manufacture
If a release film is used between the molding tool and laminate, then the laminate can be easily removed, but the release film may move or get caught between components
Solution Approach 1:
The patent uses the recess structure as an intermediary mechanism that provides both positioning and containment functions. The recess geometry itself acts as the mediator between the molding tool and the fiber base material, eliminating the need for separate release films that could move or get caught.
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 method effectively prevents positional deviation and wrinkling of the second fiber base material during the molding process, reducing man-hours and improving work accuracy by using a recessed molding tool and resin infusion for integration.
Implementation Method 1
a resin material is injected into the closed space to impregnate a fiber base material forming the skin and the stringer with the resin material
Implementation Method 2
By heating and curing the resin material with which the fiber base material is impregnated, a molded product in which the stringer and the skin are integrated is completed
Data Source
AI summary
A composite material molding method for molding a composite material by integrating a first fiber base material which is formed in a plate shape and a second fiber base material. The method includes installing; in a recess in a first molding surface of a molding tool, the second fiber base material formed in a shape corresponding to the recess; fixing a first fiber-reinforced portion which is a part of a plurality of fiber reinforced sheets included in the first fiber base material to the first molding surface to cover the recess in which the second fiber base material is installed by the installation step; laying up a second fiber-reinforced portion on the first fiber-reinforced portion fixed by the fixing step; and molding the composite material by integrating and curing the first fiber base material and the second fiber base material installed in the recess using a resin material.