Foldable Composite Forming Frame for Complex Mold Conformity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing fiber-reinforced polymer matrix composites face inefficiencies in forming parts with complex geometries, particularly in thermoforming processes, leading to suboptimal production outcomes.
Innovation Solution
A composite part production system utilizing a male and female mold setup with a foldable frame and electromagnets to facilitate precise shaping of composite plates under temperature and pressure, allowing for efficient formation of parts with complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional fixed frame is used for transporting composite plates, then the plate can be transported to the mold, but the plate cannot effectively overlap with the mold surface to take its shape, resulting in poor forming quality for complex geometries
Solution Approach 1:
The frame is designed with movable elements that can rotate about pins, transforming it from a static structure to a dynamic one. This allows the frame to adapt its configuration to match complex mold geometries, enabling the composite plate to conform properly to the mold surface and achieve high forming quality.
Solution Approach 2:
The frame is divided into multiple segments or elements connected by pins, allowing independent movement of each segment. This segmentation enables the frame to flex and adapt to complex geometries while maintaining the ability to transport the composite plate effectively.
2Manufacturing precision
If the frame is folded to allow complete overlap with the mold, then the plate can take the shape effectively, but the transport and positioning becomes more complex
Solution Approach 1:
Electromagnets are used to replace manual mechanical operations for gripping and positioning the frame. The electromagnets can be controlled to automatically grip the frame during transport and release it during folding, simplifying the operation while enabling complex frame movements.
Solution Approach 2:
The frame elements are designed to fold automatically under their own weight or controlled forces after being positioned by the electromagnets. This self-folding capability reduces the need for complex external mechanisms while achieving complete overlap with the mold surface.
3Adaptability or versatility
If electromagnets are used to grip the frame elements, then the grip becomes adjustable and controllable, but the device complexity increases
Solution Approach 1:
The electromagnet system serves multiple functions: gripping the frame elements during transport, releasing them for folding, and providing controllable force adjustment. This multi-functionality justifies the added complexity by eliminating the need for separate mechanical gripping mechanisms.
Solution Approach 2:
The electromagnets allow dynamic adjustment of grip force through electrical parameter control. This enables precise control over when and how strongly the frame elements are held, providing adaptability for different operational phases (transport vs. folding) without mechanical complexity.
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 the production of high-quality, geometrically complex composite parts with improved efficiency and precision, overcoming the limitations of conventional thermoforming processes.
Implementation Method 1
a plurality of electromagnets located on the arm and/or frame and allowing the grip between the arm and/or the frame to be made in an adjustable manner
Implementation Method 2
allows the composite plate to be formed under temperature and pressure when the second mold matches with the first mold
Implementation Method 3
the magnetic force on the second electromagnet releases the second element when the arm is brought on the first mold and/or the second mold such that the second element is moved into the second position by rotating relative to the first element with the effect of gravity
Data Source
AI summary
A composite part production system is disclosed which includes a body. A first mold is located on the body. A second mold is located on the body in a form-fitting manner with the first mold and allows a composite plate to be formed by overlapping on the first mold under temperature and pressure. A frame is located on the body and allows the composite plate to be transported to the first mold and/or the second mold by holding the composite plate.