Fiber Reinforced Resin Molded Article with Integrated Insert
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Solution Overview
Problem
The existing methods for manufacturing fiber reinforced resin molded articles require secondary processing steps and increased costs due to the need for injection molding to achieve functional components, which complicates the manufacturing process and reduces efficiency.
Innovation Solution
A method involving a fiber reinforced resin molded article with a functional site made from a resin layer that does not contain reinforcing fibers, where an insert member is integrated within the fiber reinforced resin layer, allowing for simultaneous press molding and elimination of secondary processes, enhancing support strength and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If secondary processing such as resin molding is performed to create functional components, then the functionality of the molded article is improved, but the manufacturing process becomes more complex and costs increase
Solution Approach 1:
The patent combines the functional component molding and insert member integration into a single press molding process. The functional site is formed by stacking a resin sheet (without fibers) at the required location, and the insert member is embedded in this resin sheet during the same molding operation, eliminating the need for separate secondary processing steps.
Solution Approach 2:
The patent segments the resin material into two types: fiber-reinforced resin for structural components and non-fiber resin for functional sites. This allows different regions of the molded article to have different properties (strength vs. functionality) while being manufactured in a single process.
2Adaptability or versatility
If an injection molding apparatus is used to create functional components, then the functionality is improved, but costs increase
Solution Approach 1:
The press molding die is designed to perform multiple functions simultaneously: molding the fiber-reinforced resin structure, forming the functional site with non-fiber resin, and embedding the insert member. This multi-functional approach eliminates the need for separate injection molding equipment and processes.
3Adaptability or versatility
If the number of processing steps is increased to obtain the final product shape, then the functionality is improved, but efficiency decreases
Solution Approach 1:
The resin sheet for the functional site and the insert member are prepared and positioned in advance during the stacking process. The functional site is pre-formed with the required thickness and geometry before the final molding, so that no additional processing steps are needed afterward.
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 simplifies the manufacturing process, reduces costs, and enhances the support strength of insert members by integrating them within the fiber reinforced resin layer, eliminating the need for secondary processing steps and allowing for efficient production of fiber reinforced resin molded articles with improved functionality.
Implementation Method 1
the resin of the resin layer for molding surrounds the insert member while conforming to the insert member at the time that the functional site is molded, and undergoes hardening or solidification in this state
Implementation Method 2
a fiber reinforced resin layer (52) made up from a fiber reinforced resin in which reinforcing fibers (56) are impregnated with a resin
Data Source
AI summary
A fiber reinforced resin molded article includes a fiber reinforced resin layer, and a functional site made up from a resin layer for molding that does not contain reinforcing fibers. An insert member is retained in an integrated manner in the functional site.