Thermoplastic Composite Compression Molding Without Fixing Ears
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Solution Overview
Problem
Existing compression molding devices for thermoplastic composite materials result in significant waste due to the need for cutting and removing fixing ears, which complicates the process and increases material loss.
Innovation Solution
A compression molding method using grippers that clamp onto the peripheral edge of the plate and release during molding, eliminating the need for fixing ears and reducing scrap by integrating extensible support arms and actuator means to adapt to different plate profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fixing ears are used to hold the plate during molding, then the plate can be securely positioned, but material waste increases due to cutting and removing the ears
Solution Approach 1:
The invention removes the harmful fixing ears that cause material waste while maintaining plate positioning through alternative means. The gripper system directly holds the plate body without requiring separate fixing ears, extracting the problematic element from the process.
Solution Approach 2:
The plate itself serves as the holding structure through the gripper system that directly grasps the plate body. The plate does not need external fixing ears to be held during molding, as the gripper provides secure positioning through direct contact with the plate's peripheral edge.
2Ease of operation
If fixing ears are cut from the plate, then the plate can be held during molding, but the process complexity increases
Solution Approach 1:
The invention eliminates the fixing ear creation and removal steps from the process. By using a gripper that directly holds the plate body, the complex sequence of cutting ears, positioning them, and later removing them is extracted and replaced with a single direct holding operation.
Solution Approach 2:
The plate is positioned and held by the gripper before molding begins, without requiring preliminary cutting of fixing ears. The gripper system is prepared in advance to directly grasp the plate's peripheral edge, eliminating the need for ear preparation steps.
3Device complexity
If a fixed holding system is used, then the structure is simple, but it cannot adapt to different plate profiles
Solution Approach 1:
The holding system transitions from a fixed rigid structure to a dynamic extensible arm system with grippers that can adapt their position and orientation. The extensible arms can extend and retract, and the grippers can rotate and adjust to match different plate profiles, providing versatility while maintaining structural simplicity.
Solution Approach 2:
The extensible arm with gripper serves multiple functions: it can hold plates of different sizes and profiles, position them accurately, and release them after molding. This universal holding mechanism replaces the need for different fixed structures for different plate types.
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 significantly reduces material waste by eliminating the need for cutting and removing fixing ears, enhancing process efficiency and reducing material loss.
Implementation Method 1
grippers (16), in a releasable manner, on the peripheral edge (18) of the plate (3)
Implementation Method 2
actuator means (33) configured to move the support arms (22) between an extended position and a retracted position
Implementation Method 3
a preheating station (6), in which a pre-consolidated plane plate (3) in composite material with a matrix in thermoplastic resin is subjected to a heating operation so as to obtain the softening thereof
Implementation Method 4
a compression molding operation so as to obtain the desired part or component
Data Source
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AI summary
A compression molding device (1) configured for the production of a part (2, 2', 2", 2''') in composite material starting from a plate (3) in composite with a thermoplastic matrix is described; the device (1) comprises: a fixed support structure (9); an upper half-die (10) provided with a first contoured surface (11) corresponding to the profile of an upper surface (4) of the part (2, 2', 2", 2''') to be made; a lower half-die (12) provided with a second contoured surface (13) corresponding to the profile of a lower surface (5) of the part (2, 2', 2", 2''') to be made; holding means (15) carried by the support structure (9) and configured to hold the plate (3) in a position interposed between the half-dies (10, 12); and moving means for moving at least one of the half-dies (10, 12) from and towards the plate (3); the holding means (15) comprise two or more releasable grippers (16) gripping by friction distinct portions of the peripheral edge (18) of the plate (3) and configured to completely release or allow the complete release of the plate (3) itself when the latter is compressed between the half-dies (10, 12) during molding.