Hollow FRP Handle Manufacturing via Flexible Core Extraction
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Solution Overview
Problem
Traditional methods for manufacturing fibre reinforced plastic (FRP) handles require a core for shaping, making them heavier and difficult to process, especially for complex 3D shapes, and are limited by the availability of braided fibres in standard diameters and weights, restricting the variety of shapes and weights of the final product.
Innovation Solution
A process using a flexible core that can be removed after manufacturing, allowing for the use of commonly available glass fabrics and enabling the production of hollow, lightweight FRP handles in various diameters and configurations, including complex 3D shapes, by wrapping glass fibres around the core and curing them in a mould, which eliminates the need for braided fibres and allows for greater design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a core is used for shaping FRP handles, then the handle shape can be maintained during processing, but the handle becomes heavier and more difficult to process
Solution Approach 1:
The patent removes the core from the final product structure. A hollow FRP handle is formed without requiring a permanent core, extracting the core-related weight and processing difficulties while maintaining shape during manufacturing through the molding process itself
Solution Approach 2:
The patent uses a flexible mold or form that can be removed after curing, allowing the FRP to take shape during processing without a rigid core. The flexible shell approach enables shape maintenance during processing while allowing easy removal afterward, eliminating the weight penalty of permanent cores
2Ease of manufacture
If braided fibres are used for hollow sections, then hollow FRP handles can be produced, but the product is limited to standard diameters and weights
Solution Approach 1:
The patent changes the parameters of the fiber reinforcement approach by using continuous or chopped glass fibers with resin instead of pre-braided fibers. This allows continuous variation of diameter, wall thickness, and weight parameters, enabling custom configurations rather than being constrained to standard sizes
Solution Approach 2:
The patent employs composite materials consisting of glass fibers (continuous or chopped) combined with resin matrices. This composite approach provides flexibility in designing hollow structures with varying diameters, wall thicknesses, and weights, overcoming the limitations of pre-braided fiber constraints
3Shape
If solid retained cores are used for complex 3D shapes, then the handle geometry can be achieved, but extra manufacturing operations and costs are required
Solution Approach 1:
The patent incorporates the shaping function directly into the molding process itself. The FRP material is formed into the final complex 3D shape during the curing process in the mold, eliminating the need for separate core manufacturing and assembly operations that would be required for solid retained cores
Solution Approach 2:
The patent extracts the core from the process entirely by using hollow molding techniques. Complex 3D shapes are achieved through the mold cavity design and FRP laying patterns rather than through physical cores, eliminating the need for core manufacturing, fitting, and retention operations
Data Source
AI summary
A method of producing, for example, handles for using in rolling stock or other transport situations, employs a flexible core mould that is coated with an impregnated glass fiber. The coated core mould is placed into a tool for curing, whereupon the rubber core is pulled out of the center of the resulting handle member after curing. The method helps create 3D shapes of any form and cross section in a cost effective manner and using a standardized methodology and process. Further, the method enables creation of a hollow and lightweight part. The method allows use of standard glass fiber instead of more specialized braided fiber of the prior art.