Deformable Prepress Moulded Body for Uniform Fiber Preform Compression
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Solution Overview
Problem
Existing pre-pressing devices for fiber-containing materials suffer from insufficient deformation, leading to varying wall thicknesses and moisture content in preforms, which results in sticking, tearing, and damage during subsequent hot-pressing processes, along with increased cycle times and tool temperatures.
Innovation Solution
A molded body for pre-pressing tools with an integral support structure made of deformable material, featuring a shell and connecting strands that counteract deformation, ensuring uniform pressure and moisture content across the preform surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If elastic molded parts are used for pre-compression, then the preforms can be compressed, but the deformation is insufficient and varies depending on the geometry of the preforms, resulting in non-uniform wall thicknesses and moisture contents
Solution Approach 1:
The molded body is segmented into a shell and an integrally formed support structure. The support structure consists of multiple struts that are distributed throughout the molded body, allowing independent control of deformation in different regions. This segmentation enables uniform pressure distribution across preforms of varying geometries without requiring complex external support structures.
Solution Approach 2:
The support structure is integrally formed with the shell, merging two previously separate components (support structure and molded body) into a single unit. This integration simplifies the device by eliminating the need for separate support structures while maintaining the ability to provide uniform deformation across the preform surface.
2Stability of the object's composition
If support structures are added to prevent collapsing of elastic molded parts, then structural stability is improved, but the elastic material cannot be adequately inflated, preventing uniform pressure application
Solution Approach 1:
The support structure consists of strategically positioned struts that provide localized reinforcement only where needed to prevent collapsing. The struts are distributed throughout the molded body at positions that correspond to areas requiring structural support, allowing the remaining areas to deform uniformly under pressure. This local quality approach maintains structural stability while preserving uniform pressure distribution capabilities.
3Reliability
If areas of varying moisture content are present in preforms, then the preforms are susceptible to damage in subsequent hot-pressing processes, but improving moisture uniformity requires more complex pre-pressing mechanisms
Solution Approach 1:
The molded body is designed to be dynamically deformable, allowing it to adapt its shape and pressure distribution to match the specific geometry of each preform. The elastic material can inflate and deform uniformly across the entire preform surface, ensuring consistent moisture removal regardless of preform shape. This dynamic adaptability achieves reliable moisture uniformity without requiring complex adjustable mechanisms.
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 integral support structure allows for uniform compression and moisture content in preforms, reducing damage and cycle times while maintaining tool integrity and reducing maintenance costs.
Implementation Method 1
the molded body consists of a deformable material and has a shell which essentially reflects the geometry of a preform to be pressed
Implementation Method 2
the molded body has at least one support structure made of deformable material which is integrally formed with the shell
Implementation Method 3
connecting strands that counteract deformation, ensuring uniform pressure and moisture content across the preform surface
Implementation Method 4
The pressure and heat cause residual moisture to be removed, reducing the moisture content of the preforms from approximately 60% by weight before hot pressing to, for example, 5-10% by weight afterward. The steam generated during hot pressing is extracted through openings in the cavities and channels in the hot pressing tool.
Data Source
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AI summary
A molded body for a pre-compression tool for pressing three-dimensional preforms made of a fiber-containing material and a pre-compression station with a pre-compression tool with at least one molded body are described, wherein the molded body consists of a deformable material and has a shell which essentially reflects the geometry of a preform to be pressed, wherein the molded body has at least one support structure made of deformable material which is integrally formed with the shell.