Fiber Reinforced Composite Preform Gap Filling
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Solution Overview
Problem
Existing methods for manufacturing fiber-reinforced composite material moldings face issues such as gaps between cut pieces leading to fiber meandering or voids, uneven thickness causing molding defects, and reduced physical properties, which affect the consistency and quality of the final product.
Innovation Solution
A method involving the formation of multiple partial preforms by cutting and preshaping prepreg sheets, followed by integration with a foamable material to fill gaps and ensure even thickness, and subsequent compression-molding to produce a fiber-reinforced composite material molding with excellent physical properties and consistent quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If higher pressure is applied during compression-molding to close gaps between cut pieces, then gap closure is improved, but fiber meandering occurs due to excess prepreg flowing into the gap
Solution Approach 1:
The invention applies preliminary action by pre-forming the cut pieces with overlapping edges before compression-molding. This preliminary overlapping structure ensures that when pressure is applied, the prepreg flows in a controlled manner to fill gaps without causing excessive fiber meandering, as the overlapping design anticipates and compensates for the material flow during molding.
Solution Approach 2:
The invention changes the parameter of pressure application by using controlled compression-molding pressure rather than excessive pressure. This parameter adjustment allows sufficient gap closure while preventing the excess prepreg flow that causes fiber meandering, optimizing the balance between gap closure and fiber alignment.
2Strength
If lower pressure is applied during compression-molding to prevent fiber meandering, then fiber alignment is improved, but voids occur due to insufficient pressure on gaps
Solution Approach 1:
The overlapping structure of cut pieces serves as a preliminary action that facilitates gap closure at lower pressures. The geometric configuration of overlapping edges ensures that gaps are naturally closed during molding without requiring high pressure, thereby preventing void formation while maintaining fiber alignment.
Solution Approach 2:
The invention changes the pressure parameter to a lower, controlled range that is sufficient for gap closure in overlapping structures but low enough to prevent fiber meandering. This parameter optimization resolves the contradiction between gap closure and fiber alignment.
3Ease of manufacture
If cut pieces are designed with overlapping end faces to structure preform, then preform formation is simplified, but thickness becomes uneven causing molding defects
Solution Approach 1:
The invention applies local quality by making the overlap degree variable rather than uniform across all cut pieces. Different regions of the preform have different overlap characteristics, allowing thickness compensation in specific areas. This enables simplified preform formation while achieving more uniform overall thickness by addressing local thickness variations.
Solution Approach 2:
The invention introduces dynamics by making the overlap configuration adaptable rather than fixed. The overlapping design allows for adjustment of overlap degrees to compensate for thickness variations, transforming a static uniform overlap approach into a dynamic compensated approach that maintains both ease of manufacture and thickness uniformity.
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 prevents fiber meandering and voids, maintains consistent thickness, and enhances the physical properties and quality of the molded products by using a foamable material to fill gaps and match the preform thickness with the die clearance during compression-molding.
Implementation Method 1
arranging foamable material between multiple partial preforms when they are combined
Implementation Method 2
compression-molding the preform
Data Source
AI summary
The present invention relates to a method for manufacturing a fiber-reinforced composite material molding, having a step (A) for forming a plurality of partial preforms, each having a partial shape obtained by dividing the three-dimensional shape of a target fiber-reinforced composite material molding, by cutting a prepreg sheet containing reinforcing fibers and a matrix resin composition, and by preshaping the cut prepreg pieces; a step (B) for forming a preform having the three-dimensional shape of the target fiber-reinforced composite material molding by combining and integrating the plurality of partial preforms; and a step (C) for producing a fiber-reinforced composite material molding by compression-molding the preform, wherein the step (B) includes arranging a foamable material between the plurality of partial preforms when they are combined.