Composite Substrate Shaping for Fiber-Reinforced Resin Molding
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Solution Overview
Problem
Existing methods for producing molded bodies from fiber-reinforced resin substrates often result in displacement during press-molding, leading to inefficiencies and inaccuracies due to the substrate being displaced from the desired position or shape during deformation into a three-dimensional form.
Innovation Solution
A method involving shaping the composite substrate into a three-dimensional form at a site separate from the press dies, then conveying and placing it on a die surface, where it is pressed and cured, using a multi-directional suction and pressing mechanism to maintain the shape and prevent displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the composite substrate is made to fit the surface of one of the pair of dies before press-molding, then displacement of the composite substrate is prevented, but press-molding by means of a press device cannot be performed, decreasing production efficiency
Solution Approach 1:
The process is divided into two separate locations: a shaping site where the composite substrate is formed into a three-dimensional shape, and a press-molding site where the shaped substrate is placed on the die for curing. This segmentation allows the substrate to be pre-shaped with high positioning accuracy at one location and then transferred to the press-molding equipment at another location, resolving the contradiction between positioning accuracy and production efficiency
Solution Approach 2:
The composite substrate is pre-shaped into its final three-dimensional form before being transferred to the press-molding die. This preliminary shaping action ensures that the substrate maintains its desired shape and position throughout the transfer process, eliminating the need to make it fit the die surface at the press-molding location while still achieving high positioning accuracy
2Productivity
If the flat composite substrate is placed directly in the opened pair of dies for press-molding, then production efficiency is maintained, but the composite substrate is likely to be displaced from the die during deformation into three-dimensional shape
Solution Approach 1:
The composite substrate is pre-shaped into its final three-dimensional form at a location separate from the press-molding die before being transferred. This preliminary shaping ensures that the substrate already has the correct shape and dimensional accuracy before press-molding, preventing displacement during the deformation process while maintaining production efficiency through continuous operation
3Productivity
If the composite substrate is shaped into three-dimensional shape at a site different from where the pair of dies is located, then production efficiency is improved, but the three-dimensional shape may not be maintained during conveyance
Solution Approach 1:
A suction mechanism is used to hold the composite substrate during conveyance from the shaping site to the press-molding location. The suction force counteracts gravity and prevents the substrate from deforming or losing its three-dimensional shape during transfer, enabling efficient separation of shaping and press-molding operations while maintaining shape stability
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 effectively suppresses substrate displacement during molding, allowing for accurate and efficient production of multiple molded bodies by ensuring the substrate maintains its shape and adheres uniformly to the die surface, thereby enhancing production efficiency.
Implementation Method 1
pressing the composite substrate placed on the one of the pair of dies with the other of the pair of dies while heated, thereby curing the thermosetting resin and thus forming the molded body
Data Source
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AI summary
Provided is a method for producing a molded body (M) that is capable of effectively and accurately producing a molded body from a composite substrate (F) made of a fiber-reinforced resin containing a thermosetting resin and reinforcing fibers. The method includes shaping the composite substrate (F) with the a thermosetting resin in an uncured state into a three-dimensional shape at a site different from where a molding unit is located; conveying the composite substrate (F) to the molding unit so as to maintain the three-dimensional shape thereof; then, placing the conveyed composite substrate (F) on a molding surface (41a) of a lower die (41) formed to suit the three-dimensional shape, so as to maintain the three-dimensional shape thereof; and pressing the composite substrate (F) placed on the lower die (41) with an upper die (42) while heated, thereby curing the thermosetting resin and forming the molded body (M).