Molding Fiber Reinforced Composite Thick Features
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Solution Overview
Problem
Current methods struggle to form thick portions like bosses or ribs with fine and complicated shapes using fiber reinforced composite materials containing continuous fibers, as they tend to break under concentrated stress due to inferior mechanical characteristics compared to materials with discontinuous fibers.
Innovation Solution
A molding method and apparatus that uses a thermoplastic matrix resin and continuous fibers, where the mold cavity forming surfaces are heated and pressed to create a recessed portion for forming thick features, allowing the matrix resin to flow and reinforce fibers to integrate seamlessly, enhancing moldability and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If continuous fibers are used as reinforced fibers in fiber reinforced composite materials, then mechanical characteristics and strength are improved, but moldability and ability to form complicated shapes deteriorate
Solution Approach 1:
The patent changes the physical state of the matrix resin from solid to liquid by heating it above its melting point, enabling continuous fiber reinforced composite material to flow and fill complicated mold cavities. This parameter change (temperature) allows the material to transition from a rigid state that maintains strength to a fluid state that enables complex shaping.
Solution Approach 2:
The patent utilizes the phase transition of the thermoplastic matrix resin between solid and liquid states. By heating the material above the melting point of the matrix resin, it transitions to a liquid state allowing flow and molding. Upon cooling, it transitions back to solid state, maintaining the mechanical strength provided by continuous fibers while achieving complicated shapes.
2Ease of manufacture
If discontinuous fibers are used as reinforced fibers, then moldability and passage through material improves, but mechanical characteristics and strength deteriorate
Solution Approach 1:
The patent employs parameter change by heating the thermoplastic matrix resin above its melting point, transforming the material into a flowable liquid state. This enables discontinuous fiber reinforced composite material to be molded into complicated shapes while maintaining adequate mechanical properties through proper fiber orientation and distribution in the liquid state.
3Ease of manufacture
If fiber reinforced composite material is heated and pressed to form thick portions with fine and complicated shapes, then moldability improves, but fiber breakage under stress increases
Solution Approach 1:
The patent utilizes phase transition of the thermoplastic matrix resin to solve the contradiction. By heating above the melting point, the material becomes liquid and highly moldable, allowing formation of thick portions with fine and complicated shapes without fiber breakage. The continuous fibers remain intact in the liquid state and are properly distributed. Upon cooling and solidification, the fibers maintain their strength and the formed shape is preserved, achieving both moldability and reliability.
Solution Approach 2:
The patent changes the temperature parameter to above the melting point of the matrix resin, transforming the material properties from rigid to fluid. This parameter change allows the fiber reinforced composite material to be molded into complex thick portions without fiber breakage, as the liquid state accommodates fiber movement and distribution. After molding and cooling, the material returns to solid state with restored mechanical strength and fiber integrity.
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
Enables the integral formation of fine and complicated shapes like bosses or ribs with continuous fibers, improving mechanical characteristics and reducing the likelihood of breakage under stress, while maintaining high moldability.
Implementation Method 1
one of the cavity forming surface of the first mold and the cavity forming surface of the second mold with a recessed portion for molding a thick portion such as a boss or a rib is brought into contact with the fiber reinforced composite material, and the cavity forming surface including the recessed portion is set at a higher temperature than the other cavity forming surface not including the recessed portion
Implementation Method 2
a pressing step of pressing the fiber reinforced composite material in the closed first mold and second mold so as to pass the fiber reinforced composite material in the cavity of the molds and the recessed portion
Implementation Method 3
a cooling step of cooling the fiber reinforced composite material by cooling the cavity forming surface of the first mold and the cavity forming surface of the second mold
Data Source
AI summary
According to a molding method for a fiber reinforced composite material, a cavity forming surface 13 of a second mold 12 with a recessed portion 14 for molding a thick portion is brought into contact with a fiber reinforced composite material 15. The fiber reinforced composite material 15 is heated in a state in which the temperature of the cavity forming surface 13 is higher than that of a cavity forming surface 11 of a first mold 10. After that, the first mold 10 and the second mold 12 are closed with a pressure to the fiber reinforced composite material 15 so as to pass the fiber reinforced composite material 15 into the recessed portion 14. This can integrally mold the thick portion with the main body of a molded component.