Fiber Composite Component Injection Molding Process
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Solution Overview
Problem
Current methods for producing fiber composite components for motor vehicles are complex and inefficient, particularly in forming connections that can withstand high loads and maintain structural integrity, often requiring internal pressure or form-fitting connections that are not permanently stable.
Innovation Solution
A method involving embedding fibers in a thermoplastic material, forming cavities and free spaces before injecting additional thermoplastic material or a monomer, which polymerizes to create a strong and quick connection, allowing for the integration of reinforcement elements and a visually appealing surface, with the entire process completing within approximately 2.5 minutes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If connection elements are molded onto the tube bend in an injection molding tool with high pressure, then the connection between molded material and pipe bend is formed, but the pipe bend must be loaded with internal pressure or filled with sand or fluid or wooden cores to prevent crushing, which is complex
Solution Approach 1:
The invention applies a preliminary protective layer to the pipe bend before injection molding, preventing the need for internal pressure loading or filling with sand/fluid/wooden cores during the molding process. This preliminary protection eliminates complex preparatory steps while enabling strong connections between the molded material and pipe bend.
Solution Approach 2:
The invention introduces a protective layer as an intermediary between the pipe bend and the injection molding process. This intermediary layer protects the pipe bend from high molding pressures without requiring complex internal support structures, simplifying the overall process while maintaining connection strength.
2Ease of operation
If a form-fitting connection is used between molded material and pipe bend, then non-rotatable connection is achieved, but the connection may be loosened in the event of changing loads and cannot permanently withstand loads in other directions
Solution Approach 1:
The invention creates a composite connection structure where molded material with integrated connection elements forms a permanent bond with the pipe bend. This composite approach eliminates the loosening issue of form-fitting connections by creating a unified structural connection that can permanently withstand loads in multiple directions.
3Productivity
If the fiber composite component is produced quickly with a cycle time of approx. 2.5 minutes, then productivity is improved, but the component must withstand higher loads and allow connection of fibers and thermoplastic material with additional thermoplastic material
Solution Approach 1:
The invention optimizes processing parameters including temperature, pressure, and cycle time to achieve rapid production (approx. 2.5 minutes) while maintaining high load-bearing capacity. By carefully controlling these parameters, the process produces strong connections between fibers and thermoplastic material without sacrificing productivity.
Solution Approach 2:
The invention implements a continuous injection molding process that maintains constant pressure and temperature throughout the molding cycle, ensuring strong fiber-thermoplastic connections are formed continuously without interruption. This continuous action enables both rapid production and high structural integrity.
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 method enables the rapid and efficient production of fiber composite components that can withstand higher loads, integrate reinforcement elements, and offer a visually appealing design, while minimizing water absorption and material reuse potential, significantly reducing production costs.
Implementation Method 1
the flowable or free-flowing heated thermoplastic material or the monomer partially, preferably largely, but not completely penetrated into cavities and/or spaces between the fibers
Implementation Method 2
an additional thermoplastic material or a monomer, which becomes an additional thermoplastic material through polymerisation
Implementation Method 3
the injection mold, for example heated, is then closed and connected to the injected additional thermoplastic in an injection process
Data Source
AI summary
A composite component is obtained by embedding fibers in thermoplastic resin, injecting additional thermoplastic polymer or additional monomer to composite component and heating fiber-composite component to form hollow and/or free spaces which are filled from closed mold with additional thermoplastic polymer. An independent claim is included for manufacture of composite component.