Compression Moulding Blank with Flow Guide Recesses
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Solution Overview
Problem
Current methods for producing three-dimensional mouldings from two-dimensional blanks are inefficient, particularly when creating sharp projections like ribs and stiffeners, as they require additional manufacturing steps, result in scrap material, and can lead to surface imperfections.
Innovation Solution
A process involving a stack of quasi-isotropic chopped moulding compounds with a fibrous reinforcement and liquid or particulate epoxy resin, where parts of the uppermost or lowermost blank are removed to create a recess, guiding the moulding compound to flow into the compression mould and form three-dimensional structures, ensuring continuous surface finish and improved production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If additional strips or pieces of moulding compound are provided in the location of protrusions such as ribs, then three-dimensional structures like ribs and stiffeners can be formed, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The invention creates recesses in the blank before moulding, which serve as guides for the moulding compound flow. This preliminary action eliminates the need for additional strips or pieces during the moulding process, thereby simplifying the manufacturing process while still enabling three-dimensional structures like ribs and stiffeners to be formed
2Shape
If additional strips or pieces of moulding compound are provided in the location of protrusions, then three-dimensional structures can be formed, but scrap material is produced
Solution Approach 1:
The invention extracts or removes material to create recesses in the blank at locations where protrusions are to be formed. This extraction approach allows the moulding compound to flow into these recesses and form three-dimensional structures directly, eliminating the need for additional material that would otherwise become scrap
3Shape
If additional strips or pieces of moulding compound are provided in the location of protrusions, then three-dimensional structures can be formed, but surface imperfections occur on the protrusion surface
Solution Approach 1:
By creating recesses in the blank before moulding, the invention establishes predetermined flow paths for the moulding compound. This preliminary action ensures that the compound flows smoothly into the recesses and forms continuous, imperfection-free surfaces on the protrusions, eliminating surface defects that would otherwise occur
4Ease of manufacture
If conventional compression moulding is used on two-dimensional blanks, then simple planar mouldings can be produced, but sharp projections and vertical ribs cannot be successfully formed
Solution Approach 1:
The invention introduces recesses locally at specific locations in the blank where three-dimensional structures are required. This local modification maintains the simplicity of the overall compression moulding process while enabling the formation of sharp projections and vertical ribs at the recess locations
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 process simplifies the production of three-dimensional mouldings with improved surface finish and enables the creation of complex shapes like ribs and stiffeners, reducing manufacturing time and scrap while maintaining the strength and integrity of the components.
Implementation Method 1
the moulding compound flows into the removed area in the uppermost or lowermost layer and the sections of the mould defining the three dimensional structure
Implementation Method 2
they are heated and compressed so that the resin flows to enclose the fibrous reinforcement and the resin is also cured
Implementation Method 3
compressed so that the resin flows to enclose the fibrous reinforcement
Data Source
Figure 1~2
Figure 3~4
AI summary
This invention relates to a moulding compound blank, a method for compression moulding the same and the resulting product. The blank comprisies a moulding compound comprising a fibrous reinforcement material and a resin material wherein the moulding compound comprises a flow guide (6, 7, 8) located at the surface of the blank for directing flow of the moulding compound within the cavity of the compression mould during compression moulding.