Laminate Forming on Curved Molds Using a Holding Jig
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Solution Overview
Problem
Existing methods for forming laminates of sheet-shaped materials with reinforcing fibers struggle to maintain the shape of the laminate along the forming die, particularly in concave or convex portions, leading to deformation and misalignment.
Innovation Solution
A forming method and device that includes a fixation step, forming step, and installation step using a forming jig and holding jig to ensure the laminate is pressed and fixed along the surface shape of the forming die, with the holding jig maintaining the laminate's position during the forming process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a bladder is used to press the laminate against the forming die and then withdrawn, then the forming process can be completed, but the laminate may separate from the forming surface and deform into a shape different from the die surface
Solution Approach 1:
The holding jig is installed on the curved portion of the forming die before the laminate is fully formed, in advance of potential deformation. This preliminary positioning ensures that when the forming jig is withdrawn, the holding jig is already in place to maintain the laminate's adherence to the forming surface, preventing separation and deformation.
Solution Approach 2:
The holding jig acts as an intermediary element between the forming die and the laminate. It provides continuous support and maintains the laminate's position on the curved portion of the forming die, especially in concave areas where direct contact with the forming jig may be insufficient. This intermediary holding mechanism prevents the laminate from separating from the forming surface.
2Productivity
If a bladder is used to press the plate-shaped material against the forming tool, then forming can be achieved, but it is difficult to make the bladder fit in with concave portions and appropriately press the material
Solution Approach 1:
The forming system is segmented into multiple functional components: the forming jig for initial pressing, the holding jig for maintaining position in concave areas, and the installation mechanism for positioning the holding jig. This segmentation allows each component to specialize in specific tasks, with the holding jig specifically addressing the challenge of maintaining material adhesion in concave portions that the forming jig cannot adequately serve.
Solution Approach 2:
The solution introduces a temporal dimension to the forming process by implementing a two-stage approach: first the forming jig presses the material, then the holding jig is installed to maintain position. This dimensional change from a single simultaneous action to a sequential two-stage process enables precise control over material formation in difficult-to-reach concave areas.
3Device complexity
If the forming jig presses the laminate against the forming die without additional holding, then the process is simple, but the laminate cannot be reliably maintained along the surface shape of the forming die
Solution Approach 1:
The holding jig serves as an intermediary device that bridges the gap between the forming jig's pressing action and the laminate's need for continuous positional maintenance. While the forming jig applies pressure, the holding jig is installed to provide ongoing support, particularly in curved and concave areas, ensuring the laminate remains reliably adhered to the forming die surface throughout the process.
Solution Approach 2:
The holding jig is installed in advance on the curved portion of the forming die while the forming process is ongoing. This preliminary installation ensures that when the forming jig completes its pressing action and is withdrawn, the holding jig is already positioned to prevent any potential separation or deformation of the laminate from the forming surface.
Data Source
AI summary
A method for forming a laminate by stacking sheet materials containing reinforcing fibers includes a fixation step wherein a first region of the laminate in the length direction is fixed to a forming mold having a curved part which comprises at least either a convex shape or a concave shape in a predetermined direction; forming steps wherein the laminate is formed along the surface shape of the forming mold by pressing a second region of the laminate in the length direction, the first region of said laminate having been fixed in the fixation step, against the forming mold by means of a forming jig; and an installation step wherein a holding jig, which holds a state where the laminate is pressed against the curved part, is installed onto the curved part, while maintaining the state where the laminate is pressed against the forming mold by means of the forming jig.