Mold Design for Prepreg Lamination with Variable Arc Radius
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Solution Overview
Problem
In prepreg lamination, molds with bent parts cause direction deviations during tape compression, leading to gaps or overlaps between tapes, which reduce the strength and uniformity of the molded article, necessitating increased repetition of the compression process.
Innovation Solution
A mold design with a first surface having a flat shape, a second surface at a predetermined angle, and a third surface with an arc cross-section, featuring protruding or recessed bent parts that reduce direction deviation by gradually changing the arc diameter along the length direction, allowing for more precise tape alignment and compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a mold with bent parts is used to form composite materials with changed plate thickness or stepped parts, then the shape requirement is satisfied, but direction deviation occurs during tape compression causing gaps or overlaps between tapes
Solution Approach 1:
The mold surface is designed with different local characteristics: the third surface has a varying arc diameter along the length direction to control tape direction locally, while the first and second surfaces maintain flat geometry for precise tape alignment. This local differentiation allows the mold to accommodate shape changes without causing directional deviation in tape compression.
Solution Approach 2:
The mold is designed in advance with a specific arc diameter variation pattern on the third surface, so that when tapes are compressed, the direction deviation is prevented before it can cause gaps or overlaps. This preliminary geometric configuration ensures proper tape alignment automatically during the compression process.
2Manufacturing precision
If the width of the tape is narrowed or the number of tapes is reduced to reduce gaps or overlaps, then tape direction deviation is reduced, but the width and number of tapes that can be compressed at the same time are reduced, increasing lamination time
Solution Approach 1:
The mold's third surface features a locally optimized arc diameter that varies along the length direction, creating specific local compression characteristics that prevent tape direction deviation. This allows standard-width tapes to be compressed without gaps or overlaps, maintaining high lamination productivity while ensuring manufacturing precision.
3Device complexity
If the arc diameter of the third surface is kept constant, then the mold structure is simple, but tape direction deviation increases causing gaps or overlaps between tapes
Solution Approach 1:
The arc diameter parameter of the third surface is changed along the length direction, transitioning from a constant value to a variable value. This parameter variation optimizes the compression characteristics to prevent tape direction deviation while maintaining a relatively simple mold structure without requiring complex additional components.
Data Source
AI summary
This mold for prepreg lamination includes a first surface only having a surface flat along one direction; second surfaces having a surface flat along the one direction and disposed at a predetermined angle with respect to the first surface; and a third surface with a cross-sectional shape, which is a surface yielded from a cut in an orthogonal direction to the one direction, that is an arc, and with one end side connected to the first surface and the other end side connected to the second surface. First bend sections having a protruding shape are formed on the second surface and the third surface and serve as boundaries, and one of the surfaces is slanted relative to the other surfaces. On the third surface, the diameter of the arc on the other surface becomes gradually smaller as further away from the first bend section along the one direction.