Fiber-Reinforced Plastic Profile Moulding with Strap-Like Areas
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Solution Overview
Problem
Existing methods for producing moulded plastic parts with fibre reinforcement struggle to create complex shapes efficiently, precisely, and cost-effectively, often resulting in fibre buckling or bulging during deformation.
Innovation Solution
Incorporating strap-like areas made of a harder, second plastic component that forms an interlaminar bond with the plastic matrix at high temperatures, preventing fibre displacement and using organic sheet profiles with aligned fibres to maintain mechanical efficiency and prevent buckling, while allowing for internal mould pressure and optional integration of elastic metal straps for additional functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If braided structures are used for fibre reinforcement, then the profile can be easily manufactured, but the fibres buckle and bulge during deformation, reducing manufacturing precision
Solution Approach 1:
The patent combines organic sheet profiles with thermoplastic matrix material to create a composite structure. The organic sheet contains axially aligned fibres (0° to 90° orientations) that provide reinforcement while the thermoplastic matrix binds them together, preventing buckling during deformation and enabling precise shaping without braided structures
Solution Approach 2:
The patent changes the physical state of the thermoplastic matrix by heating it above its melting point during forming, allowing the profile to be deformed while the organic sheet maintains fibre alignment. After cooling, the matrix solidifies and locks the fibres in their stretched position, preventing lateral displacement
2Reliability
If pre-pressure is applied before mould closure to build up pressure, then the deformation process is improved, but the device complexity increases
Solution Approach 1:
The patent applies pre-pressure to the interior of the profile before complete mould closure occurs. This preliminary action builds up pressure gradually, ensuring proper deformation and fibre alignment without requiring complex pressure control systems during the final closing stage
3Manufacturing precision
If internal pressure is applied during deformation, then the shaping precision is improved, but the risk of fibre displacement increases
Solution Approach 1:
The thermoplastic matrix acts as a binding medium that holds the organic sheet fibres in place during deformation. When internal pressure is applied, the matrix softens and allows shaping while simultaneously constraining the fibres, preventing lateral displacement and buckling even under pressure
Solution Approach 2:
By controlling the temperature of the thermoplastic matrix above its melting point during deformation, the patent creates a state where the matrix is soft enough to allow precise shaping under internal pressure but still maintains sufficient viscosity to prevent fibre displacement. After cooling, the matrix solidifies and permanently locks the fibre positions
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 method enables the production of complex moulded parts with high mechanical efficiency and low weight, preserving fibre properties and allowing for internal mould pressure, while also providing additional functionalities like conductivity and strain sensing.
Implementation Method 1
the plastic profile being heated and deformed by means of an outer or inner mould, respectively
Implementation Method 2
the glass transition point thereof is just exceeded when the deformation temperature of the plastic matrix is reached
Implementation Method 3
the interior of the plastic profile is acted upon with a pressure of 50 to 500 mbar during the deformation process
Data Source
AI summary
In a method for the production of a molded part based on a plastic profile reinforced by incorporated fibers, with the plastic profile being heated and deformed by means of an outer or inner mold, respectively, the plastic profile is provided, preferably in the longitudinal direction, with strap-like areas which are relatively harder and less flexible at the deformation temperature of the plastic matrix than the plastic matrix itself, thus counteracting a lateral, wave-like displacement of the fibers.