HP-RTM Composite Structure Axial Spacing for Resin Distribution
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Solution Overview
Problem
Existing HP-RTM technology for manufacturing motor vehicle bodywork and chassis composite structures using thermosetting resin faces challenges in achieving uniform resin distribution and sufficient stiffness and strength due to resin sliding issues within the mold, resulting in incomplete coverage and inadequate structural integrity.
Innovation Solution
The solution involves wrapping prefabricated resin foam structural elements with reinforcing fibers, such as carbon fibers, and arranging them in a mold with axial spacing to facilitate even resin injection and distribution, forming transversal joints that enhance structural reinforcement and resin cohesion between elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high pressure resin injection is used to achieve complete mold filling, then resin distribution improves, but resin sliding among structural elements increases causing incomplete coverage
Solution Approach 1:
The patent applies preliminary action by pre-arranging the structural elements and reinforcing fibers in the mold cavity before resin injection. This pre-positioning ensures that when high pressure resin is injected, the elements are already in optimal positions to receive and retain the resin, preventing sliding and ensuring complete coverage. The structural elements are carefully positioned to create proper spacing and orientation before the resin injection process begins.
2Device complexity
If structural elements are placed close together to achieve geometric shape, then manufacturing complexity reduces, but resin flow and distribution worsen
Solution Approach 1:
The patent applies segmentation by dividing the structural elements into discrete, separately positionable units with specific spacing between them. Instead of using a continuous or densely packed arrangement, the structural elements are segmented and positioned at predetermined intervals. This segmentation allows resin to flow freely between elements while maintaining the overall geometric shape, resolving the contradiction between arrangement simplicity and resin distribution quality.
Solution Approach 2:
The patent applies local quality by creating different spacing configurations in different regions of the mold cavity. Certain areas have structural elements positioned closer together while other areas have greater spacing, depending on the local geometric requirements and resin flow patterns. This localized adjustment of spacing optimizes both the overall arrangement complexity and local resin distribution, allowing each region to have the appropriate density for its specific function.
3Strength
If reinforcing fibers are added to increase structural strength, then stiffness improves, but resin sliding resistance increases causing incomplete filling
Solution Approach 1:
The patent applies composite materials by combining structural elements, reinforcing fibers, and thermosetting resin into an integrated composite structure. The reinforcing fibers are embedded within the resin matrix and positioned around the structural elements, creating a multi-material composite system. This composite approach allows the structure to achieve high stiffness and strength while the resin properly distributes throughout the mold cavity, as the composite configuration is designed to facilitate resin impregnation during the HP-RTM 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
This approach ensures excellent resin distribution and increased structural rigidity and resistance by forming a self-supporting composite structure with improved resin flow and connectivity between structural elements, resulting in a more robust and stiff composite structure suitable for motor vehicle bodywork.
Implementation Method 1
injection of a thermosetting resin into a mold... employing working pressures ranging for example from 30 to 150 bars, preferably more than 50 bars, so as to achieve an excellent resin distribution within the geometric shape of the structure
Implementation Method 2
The injection into the mold of a thermosetting resin, e.g. an epoxy resin, determines the connection of the various structural elements to each other and to the reinforcing fibers, thus creating the composite structure
Data Source
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AI summary
The present invention concerns a self-supporting composite structure with reinforcing fibers for motor vehicle parts, obtained by means of a molding technology called HP-RTM (High Pressure Resin Transfer Molding), comprising prefabricated resin foam structural elements (2, 3, 4, ... 11) mutually aligned according to the geometric shape of the composite structure, characterized in that said prefabricated resin foam structural elements (2, 3, 4, ... 11) are longitudinally spaced from one another through a predetermined section (17), said section (17) being occupied by corresponding transversal joints (22) formed as a result of the resin setting.