Prepreg Manufacturing Device Dual Mold Resin Impregnation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional prepreg manufacturing methods face challenges in achieving uniform resin impregnation and result in vertical impregnation ratio deviations, which degrade the physical properties of continuous fiber reinforced composite materials.
Innovation Solution
A prepreg manufacturing device with dual resin inflow parts in the upper and lower molds, featuring expanded cross-section outlets and temperature control, ensures uniform resin distribution and reduced impregnation ratio deviations by branching the resin supply line from an extruder and adjusting temperatures across divided sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional tube type upper portion is used in the impregnation mold, then the resin can be introduced and discharged, but the resin cannot be impregnated uniformly due to flow type characteristics causing large discharge amount at the front end and decreased discharge amount at the end portion
Solution Approach 1:
The upper portion is divided into multiple discharge ports (first discharge port at the front end, second discharge port at the end portion, and third discharge port in the middle) instead of using a single tube type structure. This segmentation allows independent control of resin discharge at different locations, enabling uniform impregnation throughout the prepreg while simplifying the discharge control mechanism at each port
Solution Approach 2:
Different discharge ports are positioned at specific locations (front end, middle, end portion) with different cross-sectional areas to provide locally optimized resin discharge characteristics. The first discharge port has a larger cross-sectional area to handle the higher resin flow tendency at the front end, while the second discharge port has a smaller area to ensure adequate resin supply at the end portion, achieving uniform impregnation through localized adaptation
2Manufacturing precision
If most resin is discharged through the upper mold, then the impregnation process can be completed, but a deviation occurs in the impregnation ratio of the resin due to vertical position difference in the prepreg
Solution Approach 1:
The resin discharge system is segmented into two independent pathways: an upper mold with discharge ports for the upper surface of the prepreg, and a lower mold with discharge ports for the lower surface. This dual-path segmentation ensures that resin is discharged from both sides simultaneously, eliminating vertical position differences in impregnation ratio and achieving uniform impregnation throughout the thickness of the prepreg
Solution Approach 2:
The resin discharge is extended from a single-dimensional (upper mold only) approach to a two-dimensional approach by adding the lower mold with discharge ports. This allows resin to be discharged from both the upper and lower surfaces of the prepreg simultaneously, creating a more uniform impregnation distribution through the vertical dimension and eliminating the impregnation ratio deviation caused by vertical position differences
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 solution enables uniform resin impregnation, reduces vertical impregnation ratio deviations, and enhances the physical properties of continuous fiber reinforced composite materials by improving the quality of upper and lower surfaces.
Implementation Method 1
a tube type upper portion 30 is formed inside an upper mold 10 and a resin R is introduced into one side of the tube type upper portion 30. The introduced resin R flows toward the blocked other side of the tube type upper portion 30 and is discharged downwards
Implementation Method 2
a first temperature control section which controls a temperature of the resin in a front end section of the upper mold; and a second temperature control section which controls a temperature of the resin in an end portion section of the upper mold
Data Source
AI summary
Disclosed are a prepreg manufacturing device and a prepreg manufacturing method using the same. A prepreg manufacturing device according to an embodiment of the present invention comprises: a first resin inflow part which is formed inside an upper mold, receives a resin supplied from an extruder, and discharges the resin to a reinforced fiber flowing to a lower part in the upper mold; and a second resin inflow part which is formed inside a lower mold, receives the resin supplied from the extruder, and discharges the resin to the reinforced fiber flowing to an upper part of the lower mold.