Floating Mold Insert for Composite Rib-and-Sheet Alignment
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Solution Overview
Problem
Existing methods for manufacturing composite rib-and-sheet parts face challenges in maintaining desired fiber alignment during the molding process, leading to disruptions in the preform stack when the male mold is inserted, which affects the structural integrity and material properties of the final part.
Innovation Solution
A floating-mold insert is used to stabilize and align the preform layup or preform charge within the mold cavity, preventing disruption during mold closure and ensuring consistent fiber alignment, which is then molded with the sheet in a co-molding process to enhance the part's strength and stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the male mold is inserted into the cavity to close the mold for compression molding, then the molding process can be completed, but the preform stack is disrupted and fiber alignment is compromised
Solution Approach 1:
The mold is divided into three main segments: the stationary cavity-defining member, the movable male mold, and the floating mold insert. This segmentation allows the floating insert to remain in place during mold closure while the male mold moves independently, preventing disruption to the preform stack and maintaining fiber alignment during the molding process
Solution Approach 2:
The floating mold insert acts as an intermediary element between the stationary cavity and the movable male mold. It provides a stable platform that supports the preform stack during mold closure, mediating the interaction between the moving and stationary components to prevent fiber misalignment while still allowing the molding process to complete
2Ease of manufacture
If traditional bonding methods are used to attach ribs to sheets, then manufacturing is simpler, but the part has lower strength and stiffness
Solution Approach 1:
The rib and sheet components are merged into a single integrated structure through co-molding. The floating mold insert enables the rib preforms to be molded directly onto the sheet in one continuous process, eliminating the need for separate bonding operations while creating a structurally integrated part with superior strength and stiffness
3Ease of manufacture
If chopped fibers are used to create ribs and sheets, then material processing is easier, but the part has lower strength and stiffness
Solution Approach 1:
The fiber form parameter is changed from chopped/random to continuous/unidirectionally aligned. The floating mold insert facilitates this parameter change by providing a stable platform that maintains fiber orientation during molding, enabling the use of high-performance continuous fibers without compromising the molding process
Data Source
AI summary
Some embodiments of a compression mold for forming a rib-and-sheet part includes a mold cavity and a mold insert. A sheet is placed in the mold cavity, and the mold insert is placed on the sheet. A preform assemblage is placed in a gap that is formed between the mold insert and the wall of the mold cavity. A mold core is biased above the preform assemblage, prior to molding operations, via a compression spring.