Composite Material Shaping Device Using Three Rollers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for shaping composite materials like noodle fillers, which fill gaps between laminated prepregs with T- or I-shaped cross sections, are inefficient due to long shaping times, difficulty in achieving satisfactory quality, and the need for complex equipment and processes to change cross-sectional shapes continuously.
Innovation Solution
A composite material shaping device using three rollers with an angle adjusting structure that applies pressure from different directions, allowing continuous angle changes of at least one roller to shape bar-like prepregs efficiently and uniformly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vacuum pressure shaping method is used, then shaping quality is improved, but shaping time becomes excessively long (several hours to one day)
Solution Approach 1:
The patent replaces the vacuum pressure system with a mechanical pressing system using three rollers that apply pressure directly to the prepreg material. This mechanical approach achieves shaping in minutes rather than hours by physically compressing and forming the material through controlled roller pressure, eliminating the need for vacuum chambers and lengthy evacuation processes.
Solution Approach 2:
The shaping process is divided into three independent pressing actions, each applied by a separate roller. This segmentation allows simultaneous multi-directional pressure application to different portions of the material, achieving comprehensive shaping much faster than sequential vacuum processing while maintaining quality through distributed pressure control.
2Productivity
If extrusion molding device is used, then shaping speed is improved, but device scale becomes excessively large due to great shaping resistance
Solution Approach 1:
Instead of applying uniform pressure through a large extrusion system, the patent uses three localized rollers that apply pressure at specific contact points. This localized approach reduces the force required at each point, allowing compact device design while maintaining overall shaping effectiveness through coordinated multi-point pressure application.
Solution Approach 2:
The patent transitions from uniaxial extrusion pressure to multi-directional pressure application using three rollers arranged in space. This three-dimensional pressure distribution reduces resistance by directing force along multiple vectors simultaneously, enabling effective shaping with a compact device rather than requiring large-scale single-direction extrusion equipment.
3Device complexity
If conventional single roller is used, then device simplicity is maintained, but pressure uniformity and shaping quality become insufficient
Solution Approach 1:
The single roller is segmented into three separate rollers, each independently applying pressure to a specific region of the material. This segmentation enables uniform pressure distribution across the entire workpiece by dividing the total pressing load among three contact points, achieving quality that would be impossible with a single roller while keeping the device structure relatively simple and modular.
Solution Approach 2:
The patent merges three pressing actions into a single integrated shaping operation. By coordinating the three rollers to work simultaneously on the same material piece, the system achieves uniform pressure distribution and high shaping quality while maintaining operational simplicity through synchronized multi-point pressing rather than requiring complex multi-stage processing.
4Stability of the object's composition
If rollers with fixed angles are used, then device stability is maintained, but ability to change cross-sectional shape continuously is lost
Solution Approach 1:
The patent introduces dynamic adjustability to the roller system, allowing the angles of the rollers to be changed during operation. This enables continuous variation of the cross-sectional shape of the shaped material by adjusting roller orientations, while the overall device structure remains stable and the adjustment mechanism maintains operational consistency. The system transitions from static fixed-angle rollers to dynamically adjustable rollers.
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 method enables high-quality shaping of composite materials in a shorter time without the need for vacuum pressure or large-scale equipment, allowing for uniform pressure application and improved flatness and uniformity of the shaped product.
Implementation Method 1
three rollers apply pressures on a laminated body of prepregs, laminated in a bar shape, from directions different from each other
Implementation Method 2
the angle adjusting structure continuously changes an angle of a rotating axis of at least one roller out of the three rollers
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
According to one embodiment, a composite material shaping device includes three rollers and an angle adjusting structure. The three rollers apply pressures on a laminated body of prepregs, from different directions. The prepregs are laminated in a bar shape. The angle adjusting structure continuously changes an angle of a rotating axis of at least one roller out of the three rollers. Further, according to one embodiment, a composite material shaping method includes applying pressures on a laminated body of prepregs laminated in a bar shape, from different directions, using three rollers; and producing a shaped laminated body of the prepregs by continuously changing an angle of a rotating axis of at least one roller out of the three rollers.