Fiber-Reinforced Resin Corner Portions Wrinkle Elimination
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Solution Overview
Problem
Fiber-reinforced resin molded articles with differently directed corner portions often develop wrinkles during press molding, leading to reduced strength and increased manufacturing costs due to the need for a cutting step to prevent folded portions.
Innovation Solution
Incorporating thick-walled sections laminated at sites with wrinkles, formed through injection molding, to cover and reinforce corner portions, thereby eliminating wrinkles and enhancing strength without additional cutting steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a cutting step is performed to prevent folded portions during press molding, then the strength and basis weight uniformity are improved, but labor and manufacturing cost increase
Solution Approach 1:
The invention performs preliminary action by forming recesses at corner portions before press molding. These recesses are pre-prepared to receive and accommodate folded portions that will inevitably occur during molding, eliminating the need for post-processing cutting steps while maintaining strength and basis weight uniformity
2Shape
If pressing pressure is applied to folded portions during press molding, then the molded article takes shape, but basis weight becomes non-uniform and strength decreases
Solution Approach 1:
The invention applies local quality by creating recesses with different depths at different locations, specifically at corner portions where folded portions occur. This localized structural modification allows the pressed portions to be accommodated without compromising overall strength, while maintaining uniform basis weight distribution across the molded article
3Productivity
If wrinkles are formed at corner portions during press molding, then the molding process is simple, but the strength and accuracy of the molded article deteriorate
Solution Approach 1:
The invention converts the harmful effect of wrinkles and folded portions into a beneficial outcome by designing recesses that intentionally accommodate these pressed portions. What would normally be defects are transformed into expected features that do not compromise strength or precision, allowing simple molding processes to produce high-quality articles
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 allows for high-accuracy molding with designed pressing pressure, reduces labor, and enhances the strength of fiber-reinforced resin molded articles by covering potential wrinkle sites, while integrating thick-walled sections into the manufacturing process.
Implementation Method 1
an injection molding machine to inject a molten resin into the cavity, thereby laminating thick-walled sections at sites where the wrinkles, which have entered into the cavity, are formed
Implementation Method 2
a press molding die to fold the sheet-shaped base material by pressing, thereby molding differently directed corner portions constituted by plate sections joined in three or more mutually different directions
Data Source
AI summary
A fiber-reinforced resin molded article is molded into a three-dimensional shape on the basis of a sheet-shaped base material containing a fiber-reinforced resin. The fiber-reinforced resin molded article includes three-way directed corner portions constituted by plate sections joined in three mutually different directions. The fiber-reinforced resin molded article includes wrinkles that protrude from the differently directed corner portions by folding the sheet base material, and thick-walled sections which are laminated at sites where at least the wrinkles are formed.