Filler Orientation Analysis in Resin Moldings Using X-Ray CT Spectra
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for analyzing the orientation state of fillers in resin molded products, such as fibrous fillers, are time-consuming and lack accuracy due to issues with binarization processes, threshold setting, and image processing, making it difficult to predict mechanical strength accurately.
Innovation Solution
An analysis method using X-ray CT to acquire slice images, perform Fourier transform on selected slice images to obtain power spectrum images, and analyze the orientation state based on a two-dimensional tensor, eliminating the need for binarization and threshold setting, thereby enhancing accuracy and reducing processing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If binarization process and threshold setting are used to analyze filler orientation from X-ray CT images, then the orientation angle and degree of orientation can be obtained, but the processing time becomes excessive and the results vary depending on the method used
Solution Approach 1:
The invention extracts only the essential information needed for orientation analysis by directly calculating the orientation angle and degree of orientation from the gray-level pixel values in the X-ray CT image, eliminating the need for time-consuming binarization and threshold setting processes. This extraction approach obtains the necessary orientation data without requiring intermediate image processing steps.
Solution Approach 2:
The invention changes the parameter representation by using the gray-level values directly as the basis for orientation calculation rather than converting to binary values. By computing the orientation based on the continuous gray-level distribution and its spatial derivatives, the method achieves both accuracy and efficiency without the time loss associated with binarization.
2Measurement precision
If physical cross-sectioning and SEM imaging are used to analyze filler orientation, then orientation data can be obtained without X-ray CT, but sample preparation time becomes excessive and cutting direction definition widens reducing resolution
Solution Approach 1:
The invention uses X-ray CT to create a virtual three-dimensional copy of the internal structure of the resin molded product, eliminating the need for physical cross-sectioning and SEM imaging. This virtual copying approach allows orientation analysis to be performed on the digital model without time-consuming sample preparation, cutting, and mounting operations.
Solution Approach 2:
The invention replaces the mechanical sample preparation process (cutting, mounting, and SEM imaging) with a non-contact X-ray CT scanning process. By substituting the mechanical system with a radiation-based imaging system, the method eliminates the time loss and resolution degradation associated with physical sectioning while maintaining measurement accuracy.
3Productivity
If conventional numerical analysis methods are used to predict mechanical strength, then design period can be shortened, but the accuracy of prediction is insufficient when filler orientation is not properly considered
Solution Approach 1:
The invention provides accurate feedback on filler orientation state (orientation angle and degree of orientation) that can be directly input to numerical analysis models. By obtaining precise orientation data through the improved image processing method, the numerical analysis can accurately predict mechanical strength, thereby maintaining design efficiency while improving prediction accuracy.
Solution Approach 2:
The invention performs preliminary analysis of the filler orientation state before conducting mechanical strength prediction through numerical analysis. By pre-calculating the orientation parameters from X-ray CT images using the efficient method, the subsequent strength prediction can proceed with accurate input data, ensuring both speed and accuracy in the overall design process.
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
Enables rapid and precise analysis of filler orientation in resin molded products, allowing for accurate prediction of mechanical properties without the need for time-consuming image processing steps.
Implementation Method 1
a slice image acquisition step of acquiring a slice image in a predetermined direction regarding at least a part of a resin molded product
Implementation Method 2
an attempt to substitute a mechanical strength test or the like of a variety of resin products with a numerical analysis method
Implementation Method 3
performing Fourier transform on the selected slice images, thereby acquiring a power spectrum image
Data Source
AI summary
A method for analyzing an orientation state of a filler in a resin molded product, the method having a slice image acquisition step of acquiring a slice image in a predetermined direction regarding at least a part of a resin molded product obtained by molding a resin composition containing a filler in a predetermined proportion, a power spectrum image acquisition step of selecting, from the slice image, one or more slice images and performing Fourier transform on the selected slice images, thereby acquiring a power spectrum image, and an orientation state analysis step of analyzing and digitalizing an orientation state of the filler in each power spectrum image based on the power spectrum image.