Composite Hollow Pole Mold Thermoregulation and Resin Injection
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Solution Overview
Problem
Existing methods for manufacturing hollow elongated composite bodies, such as poles, face issues with uneven resin distribution and geometrical inaccuracies due to non-uniform thermal conditions and inadequate support during the molding process, leading to inconsistent mechanical characteristics.
Innovation Solution
An apparatus and process that maintain uniform thermal conditions within the mold using a thermoregulation fluid system and provide precise resin distribution through a fixed injection nozzle, combined with a rotating mold and supporting structure to ensure even fiber impregnation and resin management, allowing for the collection and reuse of surplus resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If resin is introduced by pouring at open ends of rotating mould, then the process is simple, but resin distribution becomes uneven leading to geometrical inaccuracies
Solution Approach 1:
The resin introduction system is segmented into multiple injection nozzles positioned at different locations within the mold, allowing independent control of resin flow to different sections. This enables uniform distribution across the entire mold cavity while maintaining process simplicity through automated multi-point injection.
Solution Approach 2:
A thermoregulation fluid system is introduced as an intermediary between the heating/cooling sources and the mold. This fluid circulates through channels in the mold, precisely controlling thermal conditions during resin injection and curing, thereby ensuring uniform resin distribution and eliminating geometrical inaccuracies.
2Productivity
If mold rotates at high speed for centrifugating resin, then fiber impregnation is enhanced, but thermal uniformity deteriorates
Solution Approach 1:
The mold is pre-heated to uniform temperature before resin injection and centrifugation begins. The thermoregulation system is activated in advance to establish thermal equilibrium, ensuring that high-speed rotation does not create thermal gradients that would affect resin distribution or curing uniformity.
Solution Approach 2:
Temperature sensors are positioned within the mold to provide real-time feedback on thermal conditions during rotation. The thermoregulation fluid flow rate and temperature are dynamically adjusted based on this feedback, maintaining uniform thermal conditions even during high-speed centrifugation that enhances fiber impregnation.
3Reliability
If flange is fixed at lower end of conical mold to prevent resin flow, then resin containment is improved, but apparatus complexity increases
Solution Approach 1:
The permanent flange structure is extracted from the mold design and replaced with a removable containment mechanism. This allows resin flow control without adding permanent structural complexity to the mold, enabling easy mold disassembly and reuse while maintaining reliable resin containment during the forming process.
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 approach results in the production of high-quality, uniformly formed hollow elongated bodies with controlled thickness, minimizing resin waste and ensuring optimal thermal management for consistent mechanical properties.
Implementation Method 1
maintain uniform thermal conditions within the mold using a thermoregulation fluid system
Implementation Method 2
the rotating mould centrifugates at high speed the resin which in turn impregnates the fibre arranged inside the mould
Data Source
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AI summary
An apparatus and a process for manufacturing elongated hollow bodies, such as tapered poles, made of reinforced synthetic resin are described, wherein a rotating mould receives reinforcing fibres and resin; the temperature of the mould is controlled by a thermoregulation fluid suitably directed and, at the end of each manufacturing cycle, part of the synthetic resin suitably treated, is recycled in a new cycle.