Deformable Granular Core for Uniform Resin Impregnation in FRP Molding
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Solution Overview
Problem
Existing methods for manufacturing fiber-reinforced plastics (FRP) with closed cross-sections face challenges in achieving high precision and uniform resin content, particularly with complex shapes, leading to regions un-impregnated with resin and safety concerns due to high-pressure fluid or gas leakage, which can cause damage and injuries.
Innovation Solution
A method involving a core with a flowable granular material in a flexible bag, where the core is deformed to increase internal pressure, allowing slippage between particles and improving fluidity and pressure transmission, enabling uniform resin impregnation and reducing the risk of leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a core with rigid structure is used to maintain predetermined shape during resin injection, then the core maintains its shape, but resin cannot be uniformly impregnated and regions remain un-impregnated
Solution Approach 1:
The core is designed with deformable characteristics that allow it to change shape dynamically during the resin injection process. The core can be deformed by a pressing means to increase internal pressure, enabling the resin to be uniformly impregnated throughout the fabric while maintaining the ability to return to or settle into the predetermined shape after injection.
Solution Approach 2:
The internal pressure of the core is changed as a controllable parameter during the resin injection process. By deforming the core with a pressing means, the internal pressure is increased to facilitate uniform resin impregnation. This parameter change allows the system to transition between different states (deformed/high-pressure and recovered/normal-pressure) to achieve both uniform impregnation and shape maintenance.
2Manufacturing precision
If high pressure is applied during resin injection to ensure complete impregnation, then resin spreads over the entire preform, but fluid or gas leakage occurs causing damage and injuries
Solution Approach 1:
The deformable core acts as an intermediary pressure control mechanism between the resin injection system and the mold cavity. By controlling the core's internal pressure through deformation, the system can maintain high pressure during injection for complete impregnation while preventing uncontrolled pressure spikes that would cause fluid leakage and damage.
Solution Approach 2:
The core's deformable nature provides inherent feedback on pressure conditions. When the core is deformed to increase internal pressure for impregnation, the system can monitor and adjust the deformation程度 to prevent excessive pressure buildup that would cause leakage. This feedback mechanism allows safe high-pressure operation.
3Shape
If particles are used to form the core structure, then the core can be formed into desired shapes, but the particles cannot flow freely causing uneven pressure distribution
Solution Approach 1:
The core is designed to be dynamically deformable, allowing the particle structure to reconfigure and flow freely when pressure is applied. The particles can move and redistribute themselves as the core deforms under pressing, ensuring uniform pressure distribution throughout the core structure while maintaining the ability to form desired shapes.
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 ensures high-dimensional precision and uniform resin distribution in FRP products, minimizing defects and safety hazards by controlling internal pressure and preventing resin unevenness and leakage.
Implementation Method 1
allowing slippage between particles and improving fluidity and pressure transmission
Implementation Method 2
increasing the internal pressure inside the core
Implementation Method 3
accommodating a flowable granular material comprising a large number of particles in a flexible bag to form a core
Implementation Method 4
injecting a resin into the molding die in which the fabric and core have been placed, and then performing curing
Data Source
AI summary
The present invention relates to a method for molding fiber-reinforced plastic that is characterized: in comprising a process (1) for accommodating flowable grains comprising multiple particles in a flexible bag to form a core, a process (2) for interposing the core between fabric configured from fibers and placing the fabric and core inside a molding die, and a process (3) for injecting a resin into the molding die into which the fabric and core have been placed and curing; and in that, when performing the curing in process (3), a portion of one of the outer surfaces of the core is pressed and deformed by a pressing means to increase the internal pressure inside the core. The present invention provides a method for manufacturing fiber-reinforced plastics of excellent external appearance in which there are no defects such as wrinkles in the outer surface during forming using a core.