Magnetic Layer Prepreg Positioning Thermoforming

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Solution Overview

Problem

Existing methods for producing three-dimensional motor vehicle components using prepregs face challenges in accurately supporting and positioning semi-products during thermoforming, as conventional needles can cause defects and require additional space, while floating suspension systems fail to precisely position the components.

Innovation Solution

Incorporating a magnetic material layer between prepreg layers, which can be attracted by a magnet to securely support and position the semi-products during thermoforming, enhancing mechanical strength and adhesion, and potentially reducing weight and production costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a needle is used to support and position the semi-product during thermoforming, then the semi-product can be retained in position, but the needle may leave holes or cones in the final product and requires additional control space

Engineering Contradiction:

Improvepositioning accuracyVSAvoiddefects in final product

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the mechanical needle support system with a magnetic field-based positioning system. Magnets are embedded in the die to attract and hold the magnetic material layer, eliminating physical contact that causes holes or cones while maintaining precise positioning throughout the thermoforming process

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If a needle is used to support the semi-product, then positioning is possible, but additional space for needle control means is required

Engineering Contradiction:

Improvepositioning accuracyVSAvoidapparatus space requirement

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The magnetic positioning system eliminates the need for mechanical needle control mechanisms, reducing apparatus complexity and space requirements while maintaining precise positioning through embedded magnets in the die

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The magnetic material layer itself provides the positioning function through magnetic attraction to the die, eliminating the need for separate support structures or control mechanisms

Inventive Principle:

Principle #25Self-service

3Strength

If the semi-product is heated until the prepreg resin matrix softens, then adhesion is improved, but the semi-product becomes tougher to handle and position

Engineering Contradiction:

Improveadhesion strengthVSAvoidhandling difficulty

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The magnetic material layer acts as an intermediary between the heated semi-product and the die, providing magnetic attraction that maintains positioning control even when the resin matrix softens and becomes tacky, making the hot semi-product easier to handle

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

Magnetic forces replace mechanical holding forces, enabling positioning of the softened semi-product without direct mechanical contact that would be difficult to maintain at elevated temperatures

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Device complexity

If a floating suspension system is used to support the semi-product, then the apparatus is simpler, but the semi-product cannot be precisely positioned in the die

Engineering Contradiction:

Improveapparatus simplicityVSAvoidpositioning accuracy

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The magnetic material layer serves as an intermediary that enables precise positioning through magnetic attraction to embedded die magnets, achieving positioning accuracy comparable to mechanical systems while maintaining apparatus simplicity

Inventive Principle:

Principle #24Intermediary (Mediator)

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 magnetic material layer ensures precise positioning and support of prepreg semi-products during thermoforming, improving the accuracy and mechanical strength of the final overmolded parts, while reducing defects and production costs.

Implementation Method 1

a magnetic material layer is laid between the first prepreg layer and the second prepreg layer

Methodology Applied

Scientific EffectMagnetic attraction: Magnetism

Data Source

PatentEP3072684B1Semi-finished product manufactured from prepreg, three-dimensional preformed body and overmoulded part

Publication Date: 2020.08.12 COMPAGNIE PLASTIC OMNIUM SA

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AI summary

The present invention provides a semi-product made of a prepreg, a three-dimensional preform and an overmolded part. More particularly, the present invention provides a semi-product made of a prepreg, including at least a first prepreg layer and a second prepreg layer, characterized in that a magnetic material layer is laid between the first prepreg layer and the second prepreg layer. Since the magnetic material layer is added between the prepreg layers, the produced semi-product, when being made into a three-dimensional preform and further into an overmolded part, can be well supported and positioned due to attraction to the magnetic material layer by the magnet on the die, and therefore be precisely shaped.