Movable Core Mold for Uniform Resin Impregnation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge in manufacturing high-pressure tanks for fuel cell vehicles lies in uniformly impregnating the fiber layer with resin, particularly at the resin flow end portion, where resin infiltration is difficult to detect and ensure, leading to potential quality issues and performance degradation.
Innovation Solution
A method and device utilizing a movable core with a pressure sensor in the mold to detect resin pressure and determine complete impregnation, allowing for controlled resin flow and improved infiltration at the resin flow end portion, ensuring uniform resin distribution and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If resin is poured into the mold to impregnate the fiber layer, then the fiber layer is impregnated with resin, but resin hardly enters the fiber layer at the resin flow end portion located away from the gate
Solution Approach 1:
A movable core is introduced as an intermediary element at the resin flow end portion. This movable core actively facilitates resin infiltration by being movable relative to the preform, allowing it to adjust position and promote resin entry into the difficult-to-reach fiber layer regions at the flow end, thereby resolving the incomplete impregnation issue without compromising overall impregnation uniformity
Solution Approach 2:
The core is designed to be movable rather than fixed, allowing dynamic adjustment of its position relative to the preform during the resin impregnation process. This mobility enables the core to adapt to resin flow patterns and maintain optimal contact with the fiber layer at the resin flow end portion, ensuring complete and uniform resin infiltration throughout the preform
2Measurement precision
If a pressure sensor is installed in the movable core to detect resin pressure, then resin impregnation state can be detected, but the device complexity increases
Solution Approach 1:
The movable core serves multiple functions: it acts as a structural element to facilitate resin flow, a positioning element relative to the preform, and now also as a carrier for the pressure sensor. By integrating the sensing function into the existing movable core structure, the system achieves precise resin impregnation detection without proportionally increasing overall device complexity
Solution Approach 2:
The movable core, which already requires mobility to perform its resin flow facilitation function, is made to also serve the detection function by housing the pressure sensor. This self-service approach allows the core to simultaneously perform mechanical and sensing functions, reducing the need for separate dedicated sensing components and minimizing additional complexity
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 enables non-destructive detection of resin impregnation, improves resin infiltration at challenging areas, and enhances the quality and performance of high-pressure tanks by ensuring complete and uniform resin impregnation.
Implementation Method 1
the movable core having a pressure sensor for detecting a pressure of resin flowing in the mold
Data Source
AI summary
Provided is a method for manufacturing a fiber reinforced resin molded article capable of detecting a resin impregnation state in a fiber layer of a preform at a position corresponding to a resin flow end portion and uniformly impregnating the fiber layer of the preform with resin, and such a manufacturing device thereof. For example, when a relation between a resin pouring time and a pressure of resin detected by a pressure sensor satisfies a predetermined condition or when the pressure of resin detected by the pressure sensor is higher than or equal to a predetermined value, it is determined that the resin flow end portion of the preform is completely impregnated with resin.