Cutting Core Heating for Fiber Reinforced Resin Gate Removal
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Solution Overview
Problem
Current methods for manufacturing high-pressure tanks, such as those used in fuel cell vehicles, face issues with foreign matter contamination and increased costs due to post-processing techniques like laser or water jet cutting, which can affect the tank's strength and performance.
Innovation Solution
A method and device for manufacturing fiber reinforced resin molded articles that utilize a mold with a cutting core heated to a higher temperature than the mold to cut the resin within a predetermined viscosity range, allowing for stable curing and elimination of foreign matter, while also incorporating an aftercure step to enhance the tank's strength and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If post-processing by laser or water jet is used to cut the gate, then the gate can be removed, but foreign matter may enter the high-pressure tank leading to deterioration of strength
Solution Approach 1:
The gate cutting operation is performed preliminarily within the mold before demolding, rather than as a post-processing step. The cutting core is positioned to cut the gate during the molding cycle, preventing foreign matter contamination that would occur with subsequent laser or water jet cutting after the tank is removed from the mold.
2Ease of manufacture
If post-processing by laser or water jet is used to cut the gate, then the gate can be removed, but capital investment and time are required resulting in increase in costs
Solution Approach 1:
The gate cutting function is merged with the molding operation by integrating a cutting core into the mold structure. This eliminates the need for separate post-processing equipment such as laser cutters or water jet machines, thereby reducing capital investment and simplifying the manufacturing system.
3Ease of manufacture
If post-processing by laser or water jet is used to cut the gate, then the gate can be removed, but variation in processing time leads to variation in cured state
Solution Approach 1:
The gate cutting is performed preliminarily during the molding cycle at a controlled timing when resin viscosity is within a predetermined range. This ensures consistent cutting conditions and uniform cured state across all production cycles, eliminating the variability introduced by post-processing operations performed at different times after molding.
4Ease of manufacture
If the cutting core is heated to higher temperature than the mold, then the resin can be cut effectively, but energy consumption increases
Solution Approach 1:
Only the cutting core, not the entire mold, is heated to higher temperature. This localized heating approach provides sufficient thermal energy for effective resin cutting at the gate location while minimizing overall energy consumption compared to heating the whole mold system.
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 increases the strength and quality of the high-pressure tank by preventing foreign matter contamination and reducing production costs, while ensuring consistent curing conditions and excellent cutting surfaces.
Implementation Method 1
heating the cutting core to a higher temperature than the mold
Implementation Method 2
a viscosity of a portion of the resin in the runner in a position of the cutting core is within a predetermined range
Data Source
AI summary
Provided is a method for manufacturing a fiber reinforced resin molded article capable of effectively increasing the strength of a fiber reinforced resin molded article, such as a high-pressure tank, and such a manufacturing device thereof. With use of a cutting core that is heated to a higher temperature than a mold, the curing of a portion of resin (thermosetting resin) to be cut in a runner is facilitated, and the portion of the resin to be cut in the runner is cut by the cutting core. The heating temperature of the cutting core is higher than the temperature of the mold and lower than the heating temperature in an aftercure step performed after removing the high-pressure tank from the mold.