Disposable Mold Core for Fiber-Reinforced Components
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Solution Overview
Problem
The high cost of manufacturing mold cores and components using existing rinsable mold cores for fiber-reinforced components is a significant economic disadvantage.
Innovation Solution
A disposable mold core composed of a hard binder shell and a binder-free granulate core, where the granulate is free-flowing or loose, allowing easy removal after component production, and a rapid prototyping process can be used to produce the core, with a thin shell and optional separating layer to prevent matrix diffusion and facilitate solvent-based binder removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a traditional rinsable mold core is used, then the component can be produced, but the manufacturing cost is very high
Solution Approach 1:
The patent applies the disposable principle by creating a mold core that is intentionally designed to be inexpensive and single-use. The mold core consists of a hard shell with a binder-free inner core that can be easily removed after use, eliminating the need for expensive, reusable mold cores. This directly reduces manufacturing costs while maintaining production feasibility through the simplified disposable design.
Solution Approach 2:
The patent segments the mold core into two distinct parts: a hard shell that remains with the component and a binder-free inner core that can be easily removed. This segmentation allows the expensive shell to be reused or disposed of independently from the easily removable inner core, significantly reducing the overall manufacturing cost of the mold core system.
2Stability of the object's composition
If the granulate is compressed to prevent deformation, then the mold core stability improves, but the granulate sticks together and becomes difficult to remove
Solution Approach 1:
The patent applies local quality by creating different properties in different regions of the mold core. The shell region has binder and granulate compressed together to provide structural stability and prevent deformation during component production. The inner core region has no binder and loose granulate that maintains stability through granulate grain contact while remaining easily removable after use. This spatial differentiation of material properties resolves the contradiction between stability and removability.
3Strength
If the shell is made thicker to provide stability, then the mold core strength improves, but the amount of granulate that must be removed increases
Solution Approach 1:
The patent applies local quality by concentrating the binder and granulate compression only in the shell region where structural strength is needed, while leaving the inner core with no binder and loose granulate. This localized approach provides sufficient mold core strength through the shell while minimizing the quantity of granulate that must be removed, as only the shell granulate needs to be separated from the component.
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 reduces manufacturing costs by simplifying the removal of the mold core from the component and maintaining stability during production, while also enabling the production of complex components like undercuts and hollow structures without deformation.
Implementation Method 1
the granulate can therefore absorb pressure forces in the interior of the core, which occur for example when the reinforcement fibers are placed on the mold core with the matrix or when the component is being produced. This prevents a deformation of the mold core
Implementation Method 2
the binder can be dissolved with a solvent, so that it can be rinsed off after the fiber-reinforced component has been produced
Data Source
AI summary
A disposable mold core for producing a fiber-reinforced component includes a support core having a granulate and a binder. The support core has a hard shell formed of the binder and the granulate, and an inner core which is binder-free and formed of the granulate. A related method of producing a fiber-reinforced component is disclosed.