Composite Molding Method for Wrinkle-Free 3D Shapes

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Solution Overview

Problem

Composite materials with fiber sheets laminated over one another tend to generate wrinkles when three-dimensionally bent, limiting design freedom due to the need to minimize wrinkle formation.

Innovation Solution

A molding method that involves shaping the laminate with fiber sheets to create a first inclined surface and a second inclined surface with a smaller angle, using a mold with complementary surfaces to reduce wrinkle formation, allowing for increased design flexibility by adjusting resin content and fiber volume.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If the laminate is three-dimensionally bent into a predetermined shape, then the composite materials can be formed with complex geometries, but wrinkles are generated in the fiber sheets

Engineering Contradiction:

Improvethree-dimensional shapeVSAvoidwrinkle formation

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The molding process is divided into two distinct stages: a shaping process that creates intermediate shapes with reduced curvature, and a final molding process that achieves the target three-dimensional shape. This segmentation allows the fiber laminate to be progressively deformed without excessive wrinkling in either stage.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The shaping process performs preliminary three-dimensional bending to create an intermediate shape that reduces wrinkle formation. This preliminary action prepares the laminate for the final molding stage by pre-positioning the fibers in a configuration that minimizes subsequent deformation issues.

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If the inclination angle of the first inclined surface is increased, then design freedom is improved, but wrinkle formation increases

Engineering Contradiction:

Improvedesign freedomVSAvoidwrinkle formation

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The inclined surface is divided into two zones with different inclination angles: a first inclined surface with a larger angle for design freedom, and a second inclined surface with a smaller angle to reduce wrinkles. This segmentation allows both large design angles and reduced wrinkle formation to coexist.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the composite material structure are assigned different inclination angles based on their functional requirements. The first inclined surface uses a larger angle for aesthetic or structural design freedom, while the second inclined surface uses a smaller angle in wrinkle-prone areas to maintain manufacturing quality.

Inventive Principle:

Principle #3Local quality

3Shape

If the laminate is two-dimensionally bent and then three-dimensionally bent, then complex three-dimensional shapes are achieved, but the process complexity increases

Engineering Contradiction:

Improvethree-dimensional shapeVSAvoidmolding process complexity

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The shaping process and molding process are merged into an integrated manufacturing method where the shaping step creates an intermediate configuration that facilitates the subsequent molding step. This combination allows complex three-dimensional shapes to be achieved through a coordinated two-stage process rather than attempting single-step formation.

Inventive Principle:

Principle #5Merging (Combining)

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 reduces wrinkle formation, enabling larger inclination angles and thicker plate thickness in critical areas, thus enhancing design freedom and reducing strength loss.

Implementation Method 1

impregnating a resin material into the laminate while adjusting an amount of the resin material filled therein

Methodology Applied

Scientific EffectResin infusion:

Implementation Method 2

molding the composite materials that have cured into a shape having a first inclined surface inclined at the first inclination angle

Methodology Applied

Scientific EffectCompression molding: Compression

Implementation Method 3

the composite materials that have cured

Methodology Applied

Scientific EffectCuring: Photopolymerisation

Data Source

PatentUS10688736B2Composite materials molding method, and composite materials

Publication Date: 2020.06.23 MITSUBISHI HEAVY IND LTD

AI summary

A method of molding composite materials including shaping a laminate having fiber sheets laminated over one another, by bending the laminate in an X-direction and a Y-direction, in a three-dimensional orthogonal coordinate system. The method further includes mounting the laminate that has been shaped, onto a mold material deformed in a Z-direction, impregnating a resin material into the laminate while adjusting an amount of the resin material filled in, and molding the composite materials that have cured such that the composite materials are shaped to have a first inclined surface inclined at a first inclination angle with respect to a reference plane in the Z-direction. The mold material has a first inclination molding surface that molds the first inclined surface, and a second inclination molding surface that molds a surface of the composite materials into a second inclined surface having a second inclination angle smaller than the first inclination angle.