Fiber Reinforced Resin Molded Article Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High-pressure tanks for fuel cell vehicles face issues with oxidation and degradation of the liner at high temperatures during the resin transfer molding process, leading to low-quality and low-performance products due to deformation and difficulty in resin impregnation.
Innovation Solution
A method and device for manufacturing fiber reinforced resin molded articles that involves forming a preform with a fiber layer on a hollow liner, applying internal pressure with inert gas, vacuum degassing, and filling the mold with inert gas before pouring high-temperature resin to prevent oxidation and degradation, using a mold with a gap structure to ensure effective impregnation and curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high-temperature resin is injected into the mold to impregnate the fiber layer, then resin impregnation is achieved, but the liner undergoes oxidation and degradation
Solution Approach 1:
The patent applies inert gas (such as nitrogen or carbon dioxide) to displace oxygen within the mold cavity before and during resin injection. This creates an inert atmosphere that prevents oxidation of the liner while allowing high-temperature resin to be injected for effective impregnation of the fiber layer.
Solution Approach 2:
The patent performs vacuum degassing to remove air and moisture from the mold cavity before resin injection. This preliminary action ensures that the mold is ready for resin impregnation while minimizing the risk of oxidation by removing oxygen-containing gases in advance.
2Manufacturing precision
If vacuum degassing is performed to remove air from the mold, then resin impregnation is improved, but the process time is extended
Solution Approach 1:
The patent performs vacuum degassing as a preliminary step before resin injection to remove air and moisture from the mold cavity. This ensures proper resin impregnation while the vacuum state is maintained briefly to minimize total process time.
Solution Approach 2:
The patent maintains vacuum state continuously during the resin injection process rather than creating and breaking vacuum multiple times. This continuous vacuum maintenance ensures consistent resin impregnation quality while avoiding repeated vacuum cycles that would extend total process time.
3Object-affected harmful factors
If inert gas is filled into the mold to prevent oxidation, then liner protection is achieved, but the mold complexity increases
Solution Approach 1:
The patent introduces inert gas (nitrogen or carbon dioxide) into the mold cavity through simple gas supply ports and control valves, creating a protective atmosphere without requiring complex mold structures. The inert gas displaces oxygen naturally through pressure differential during resin injection.
Solution Approach 2:
The patent uses inert gas as an intermediary substance between the external environment and the liner. This intermediary displaces oxygen and prevents oxidation without requiring direct contact between protective measures and the liner, simplifying the overall system design.
4Manufacturing precision
If internal pressure is applied to the preform to improve resin impregnation, then resin distribution is improved, but the risk of liner deformation increases
Solution Approach 1:
The patent applies internal pressure using inert gas to stabilize the liner shape while preventing oxidation. The inert gas pressure counteracts external pressure variations and prevents liner deformation during resin injection, while the same inert atmosphere protects the liner from oxidation.
Solution Approach 2:
The patent applies inert gas pressure to the preform before resin injection to cushion and stabilize the liner shape. This beforehand cushioning prevents liner deformation during subsequent resin injection by maintaining internal pressure balance.
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 prevents oxidation and degradation of the liner, maintaining high-quality and high-performance fiber reinforced resin molded articles by controlling the internal pressure and inert gas filling, resulting in improved productivity and reduced costs.
Implementation Method 1
a vacuum degassing mechanism configured to vacuum degas the mold
Implementation Method 2
a step of filling inert gas into the mold
Implementation Method 3
a step of placing the preform in a mold while applying internal pressure to the preform
Implementation Method 4
a step of pouring resin into the mold to impregnate the fiber layer with the resin
Data Source
AI summary
Provided is a method for manufacturing a fiber reinforced resin molded article capable of preventing oxidation and degradation of a liner making up a preform at a high temperature, and such a manufacturing device thereof. Prior to pouring resin into a mold, the method fills inert gas (nitrogen gas, for example) into the mold. After filling inert gas (nitrogen gas, for example) into the mold, the method closes an upper mold (second mold) placed with a gap (second gap) with a preform (i.e., brings it closer to the preform).