Composite Molded Article Using Foamed Resin Core
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Solution Overview
Problem
Composite material molded articles with unwoven fabric core layers exhibit significant deformation under pressing forces and increased mass due to the crushing of the fabric and the need for increased matrix resin impregnation.
Innovation Solution
Incorporating an intermediate layer formed from a composite of unwoven fabric and foamed resin, or foamed resin reinforced with unwoven fabric, which reduces deformation and matrix resin usage, thereby minimizing mass increase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If unwoven fabric is used in the core layer to reduce mass, then the mass of the product is reduced, but the amount of deformation under pressing force increases significantly
Solution Approach 1:
The patent applies composite materials by combining unwoven fabric with foamed resin to create a composite molded body for the intermediate layer. This composite structure maintains the mass reduction benefit of unwoven fabric while the foamed resin provides structural support that significantly reduces deformation under pressing forces, thereby resolving the contradiction between mass reduction and deformation control.
2Manufacturing precision
If matrix resin is increased to impregnate all unwoven fabric and reduce deformation, then the amount of deformation is reduced, but the mass of the product increases
Solution Approach 1:
The patent utilizes porous foamed resin as the matrix material in the intermediate layer. The foamed resin's cellular structure provides sufficient mechanical support and deformation resistance while occupying less volume and mass compared to solid matrix resin. This allows the unwoven fabric to be partially impregnated rather than fully saturated, thereby reducing deformation without causing mass increase.
3Shape
If unwoven fabric in the core layer is crushed to conform to surface deformation, then the surface finish is improved, but the amount of deformation increases and structural integrity is compromised
Solution Approach 1:
The composite molded body of unwoven fabric and foamed resin in the intermediate layer provides enhanced structural integrity compared to unwoven fabric alone. The foamed resin acts as a binding matrix that holds the fabric structure together, preventing excessive crushing and deformation while still allowing controlled conforming to surface geometry, thus maintaining both surface finish and structural integrity.
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 reduces deformation under pressing forces and suppresses mass increase by utilizing foamed resin as a matrix with multiple cells, enhancing the structural integrity and reducing resin content in the intermediate layer.
Implementation Method 1
the composite molded body constituting the intermediate layer includes the foamed resin as a matrix, which includes multiple cells therein
Data Source
AI summary
A method of producing a composite material molded article includes enclosing a core fiber base material formed from unwoven fabric in a molding tool with the core fiber base material placed between a first reinforcing fiber base material and a second reinforcing fiber base material, injecting matrix resin into the first and second reinforcing fiber base materials in the molding tool, and injecting foamable resin into the core fiber base material in the molding tool.