Composite Panel Molding With Predefined Contours Without Cutting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional processes for manufacturing composite panels require a cutting step to define the panel's contour, which necessitates additional time and tools, increasing costs and complexity.
Innovation Solution
A process involving the use of dry woven or nonwoven materials with a structuring element to define the panel's contour, followed by resin injection and molding, eliminating the need for post-cutting operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a cutting step is used to define the panel contour, then the panel shape precision is improved, but the manufacturing time and device complexity increase
Solution Approach 1:
The structuring element is placed on the ply before resin injection, pre-defining the contour shape. This preliminary action eliminates the need for subsequent cutting operations, as the contour is already established during the molding process itself.
Solution Approach 2:
The cutting operation is completely removed from the manufacturing process. Instead of manufacturing the panel with excess material and then cutting it to shape, the invention extracts the contour definition step and integrates it into the molding process through the structuring element.
2Manufacturing precision
If a cutting step is used to define the panel contour, then the panel shape precision is improved, but the device complexity and cost increase
Solution Approach 1:
The contour definition function is merged with the molding process. The structuring element serves dual purposes: it defines the contour shape and acts as a mold insert during resin injection, combining what were previously separate operations into one integrated process.
Solution Approach 2:
The structuring element performs multiple functions: it defines the panel contour, serves as a mold insert during resin injection, and eliminates the need for separate cutting tools. This multi-functionality reduces overall device complexity.
3Manufacturing precision
If the ply is folded over the structuring element, then the contour definition is improved, but the manufacturing process complexity increases
Solution Approach 1:
The folding of the ply over the structuring element is performed as a preliminary action before resin injection. This pre-positioning ensures the contour is properly defined early in the process, and the resin then simply needs to flow and cure, simplifying the overall sequence.
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
Simplifies the manufacturing process, reduces time and costs, and enhances mechanical strength while maintaining complex shapes without excess thickness.
Implementation Method 1
injecting a thermoplastic or thermosetting resin into the mould, in particular to impregnate the plies
Implementation Method 2
injecting a thermoplastic or thermosetting resin into the mould
Implementation Method 3
pressing the assembly into the mould to obtain the composite panel
Data Source
AI summary
A process for manufacturing a composite panel includes providing at least one first ply of a woven or nonwoven dry material, the first ply defining a peripheral contour. A structuring element is placed inside the peripheral contour of said first ply, over at least one portion of this peripheral contour. A second ply of a woven or nonwoven dry material is placed so that said second ply covers both the first ply and the structuring element, or at least one portion of the first ply, which includes the peripheral contour, is folded over to cover the structuring element, and a second ply of a woven or nonwoven dry material is placed so that said second ply covers the first ply, but not the structuring element. A thermoplastic or thermosetting resin is injected into mould containing the stack to impregnating the plies. The impregnated piles are pressed into a composite panel.