Fiber-Reinforced Resin Deep-Drawn Die with Recessed Portion
Solution Overview
Problem
In the press forming process of fiber-reinforced resin materials, the fiber layers often rupture near bent portions, leading to resin loss and a deteriorated appearance, which compromises the strength and design quality of the resultant composite material.
Innovation Solution
A die apparatus with a gradually changing portion-forming region is used to increase resin flow resistance and promote fiber impregnation, preventing rupture and resin loss, while maintaining design flexibility and allowing for the formation of deep-drawn shapes with improved surface appearance and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the clearance between dies is made smaller than the total thickness of starting materials to enable deep-drawn shaping, then the deep-drawn shape can be formed, but the second convex portion penetrates through the outermost resin layer causing fiber exposure and deteriorated appearance
Solution Approach 1:
The patent applies preliminary action by pre-forming a recessed portion in the die surface before the main forming process. This recessed portion is created in advance to accommodate the resin layer thickness variation, preventing the convex portion from penetrating through the resin layer during deep-drawn shaping, thereby maintaining surface appearance quality while achieving the desired deep-drawn shape.
Solution Approach 2:
The patent applies local quality by creating a recessed portion at specific locations on the die surface where the resin layer thickness varies. This localized modification allows the die to accommodate thickness variations in specific areas without affecting the overall forming process, preventing fiber exposure and deteriorated appearance in critical surface areas while maintaining the deep-drawn shape elsewhere.
2Shape
If the second convex portion is brought into contact with the resin layer first during die closing, then deep-drawn shaping can be achieved, but the convex portion penetrates through the resin layer causing fiber layer exposure
Solution Approach 1:
The patent applies preliminary action by pre-forming a recessed portion in the die surface before the main forming process. This recessed portion is created in advance to accommodate the resin layer thickness variation, preventing the convex portion from penetrating through the resin layer during deep-drawn shaping, thereby maintaining surface appearance quality while achieving the desired deep-drawn shape.
Solution Approach 2:
The patent applies local quality by creating a recessed portion at specific locations on the die surface where the resin layer thickness varies. This localized modification allows the die to accommodate thickness variations in specific areas without affecting the overall forming process, preventing fiber exposure and deteriorated appearance in critical surface areas while maintaining the deep-drawn shape elsewhere.
3Productivity
If a stack of fiber layers and thin thermoplastic resin layers is press-formed directly without prepreg preparation, then production time is reduced and efficiency is improved, but fiber layers rupture in the vicinity of bent portions due to insufficient resin impregnation
Solution Approach 1:
The patent applies parameter changes by modifying the die surface geometry to include recessed portions that accommodate resin layer thickness variations. This parameter modification allows the resin to be properly contained and impregnated during direct press-forming of stacked fiber and resin layers, preventing fiber rupture in bent portions while maintaining the production efficiency benefits of the direct stacking method.
Solution Approach 2:
The patent applies the intermediary principle by using the recessed portion in the die surface as a mediator between the convex portion and the resin layer. This recessed portion acts as an intermediate space that prevents direct penetration of the convex portion through the resin layer, allowing proper resin impregnation and fiber reinforcement while maintaining the desired deep-drawn shape.
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
The solution effectively prevents fiber rupture and resin loss, resulting in a formed article with enhanced strength and appearance, maintaining design flexibility and allowing for the creation of complex shapes with improved rigidity and aesthetic quality.
Implementation Method 1
When the second shaping die 78 is brought into contact with the resin Re, the contact portion of the resin Re starts to be melted.
Implementation Method 2
The first shaping die 74 and the second shaping die 78 are heated to a temperature equal to or higher than the melting point of the resin Re before the closing process.
Data Source
AI summary
A formed article of a fiber-reinforced resin material is provided. The fiber-reinforced resin material is obtained by impregnating a plurality of stacked fiber layers with a resin. The formed article contains a first portion and a second portion formed to have a deep-drawn shape with respect to the first portion. The second portion contains a gradually changing portion with its thickness gradually changing, and the thickness of the gradually changing portion decreases with distance from the first portion.