Composite Material Molding with Separate Heating and Cooling Dies
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Solution Overview
Problem
Existing composite material processing methods result in uneven temperature distribution in molding dies, leading to uneven solidification of the composite material, which causes insufficient pressurization and contact failures, resulting in voids and deteriorated component quality.
Innovation Solution
A processing apparatus and method using a pair of pallets, a heating die, and a cooling die with a temperature adjustment unit, allowing for controlled heating and cooling of the composite material via separate dies to maintain even temperature distribution and pressure, using a conveyance unit to transfer the material between dies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single set of dies is used for both heating and cooling, then device complexity is reduced, but temperature distribution becomes uneven leading to poor manufacturing precision
Solution Approach 1:
The patent divides the molding system into separate heating die and cooling die components. The heating die includes heating elements while the cooling die includes cooling channels, allowing independent temperature control of each die. This segmentation enables uniform temperature distribution in both heating and cooling phases without requiring a single complex die design.
2Temperature
If cooling passage is arranged in the die, then cooling efficiency is improved, but temperature distribution becomes uneven causing solidification issues
Solution Approach 1:
The patent separates the heating and cooling functions into different dies. The cooling passage is arranged in the cooling die rather than the heating die, allowing optimized cooling channel placement without interfering with heating element arrangement. This enables uniform cooling across the entire composite material surface.
Solution Approach 2:
The patent introduces a release film as an intermediary between the heating die and the composite material during heating, and between the cooling die and composite material during cooling. This release film ensures uniform heat transfer and pressure distribution while preventing direct adhesion, contributing to uniform temperature distribution.
3Productivity
If heating and cooling are performed in the same die, then process time is reduced, but contact failure occurs leading to voids in the composite material
Solution Approach 1:
The patent divides the molding process into distinct heating and cooling phases using separate dies. The heating die is used exclusively for heating and shaping, then replaced by the cooling die for cooling and solidification. This segmentation prevents contact failure and void formation that would occur if the same die attempted both functions.
Solution Approach 2:
The patent performs preliminary heating and shaping in the heating die before transitioning to the cooling die. The composite material is pre-heated and pre-shaped to the desired configuration, then transferred to the cooling die for solidification. This preliminary action ensures proper contact and shape before cooling begins.
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
Improves the quality of molded components by ensuring even temperature distribution and pressure, reducing voids and enhancing the consistency of the molding process.
Implementation Method 1
a heating die configured to press and heat the composite material via the pair of pallets
Implementation Method 2
a cooling die configured to press and cool the composite material via the pair of pallets
Implementation Method 3
a temperature adjustment unit configured to adjust a temperature of the cooling die
Data Source
AI summary
An object of the disclosure is to improve the quality of a molded component after processed. A processing apparatus 10 is the processing apparatus 10 for a composite material 1 in which fibers and a thermoplastic resin are compounded. The processing apparatus 10 includes: a pair of pallets 20 configured to clamp the composite material 1; a heating die 30 configured to press and heat the composite material 1 via the pair of pallets 20; a cooling die 40 configured to press and cool the composite material 1 via the pair of pallets 20; a temperature adjustment unit configured to adjust a temperature of the cooling die 40; and a conveyance device 50 configured to convey the pair of pallets 20 clamping the composite material 1 from the heating die 30 to the cooling die 40.