Composite Shaping Apparatus Roller Speed Differential
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing composite shaping methods, such as those using vacuum pressure or extruders, face challenges like long shaping times and wrinkle formation during the shaping of prepreg stacks and fillers, particularly for noodle fillers, which require complex and large apparatuses to manage resistance and achieve uniform pressure.
Innovation Solution
A composite shaping apparatus with multiple rollers, where the first and second rollers are rotated by motors, allowing for differences in rotation speed, roller diameter, and presence/absence of rotating power, to uniformly apply pressure and reduce wrinkle formation by optimizing the inclination angles and materials of the rollers for effective shaping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If vacuum pressure is used for shaping prepreg stacks, then the shaping can be performed, but the shaping time becomes very long (several hours to about one day)
Solution Approach 1:
The patent replaces the vacuum pressure system with a mechanical roller pressing system. The rollers directly apply mechanical pressure to the prepreg stack, eliminating the need for vacuum pumps and lengthy vacuum cycles, thereby dramatically reducing shaping time while maintaining effective compression.
Solution Approach 2:
The patent employs hydraulic pressure systems to generate and control the pressing force applied by the rollers. This allows for precise, high-magnitude pressure application that can be quickly adjusted, enabling fast shaping without the time-consuming vacuum process.
2Productivity
If an extruder is used to shape a prepreg stack, then the shaping can be performed, but the resistance is so large that a hefty apparatus is needed
Solution Approach 1:
The patent divides the shaping function into multiple independent rollers that can be individually controlled. Instead of using one large extruder, several smaller rollers work in parallel, each contributing to the overall shaping process. This segmentation reduces the complexity and size requirements of individual components while maintaining effective shaping capability.
Solution Approach 2:
The patent transitions from linear extrusion in one dimension to multi-directional pressing by arranging rollers in different orientations and positions. This dimensional approach distributes the shaping load across multiple contact points, reducing the resistance any single component must overcome and eliminating the need for a single hefty extruder apparatus.
3Manufacturing precision
If three rollers are used to press a bar-shaped material, then the filler can be shaped with sufficiently high quality, but the apparatus becomes more complex
Solution Approach 1:
The patent designs the roller system so that the same three rollers perform multiple functions: they apply pressure, shape the filler, and control material flow. By making the rollers multi-functional, the patent achieves high shaping quality without adding extra complex components, as each roller is optimized to handle various aspects of the shaping process simultaneously.
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 solution significantly reduces wrinkle formation and warpage in shaped fillers, improving their quality by allowing for precise control over pressure distribution and material handling, thus enhancing the efficiency and effectiveness of the shaping process.
Implementation Method 1
The at least one first roller and the at least one second roller are rotated while at least one of rotation speed, roller diameter, or presence/absence of rotating power is made different between the at least one first roller and the at least one second roller
Data Source
AI summary
A composite shaping apparatus includes at least one first roller that loads a prepreg with pressure, at least one second roller that loads the prepreg with pressure, and at least one motor that rotates at least one of the first roller or the second roller. The at least one first roller and the at least one second roller are rotated while at least one of rotation speed, roller diameter, or presence/absence of rotating power is made different between at least one of the first roller and at least one of the second roller.