Press-molding Material with Self-laminatable Regions
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Solution Overview
Problem
Existing methods for press-molding fiber-reinforced thermoplastic composite materials often result in shaped products with wrinkles, reduced strength due to weld lines, and low productivity, especially when using thermoplastic resin matrices.
Innovation Solution
A press-molding material with discontinuous reinforcing fibers of 3 mm to 100 mm length, a thermoplastic resin matrix, and specific structural features such as a reference plane, standable planes, and self-laminatable regions, which allows for self-lamination during molding to prevent wrinkles and enhance strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If incisions are made in the molding material to prevent wrinkles during press-molding, then appearance quality is improved, but resin aggregation and welding occur at cut portions causing strength decrease
Solution Approach 1:
The patent applies preliminary action by pre-forming convex portions and concave portions with specific dimensional relationships in the molding material before press-molding. The convex portion has a height H1 and the corresponding concave portion has a depth H2 where H1 > H2, creating predetermined deformation zones that guide material flow during molding to prevent wrinkles without requiring incisions that would compromise strength.
Solution Approach 2:
The patent changes geometric parameters by defining specific height relationships between convex portions (height H1) and concave portions (depth H2), where H1 > H2. This parameter change creates a controlled deformation mechanism that prevents surface defects while maintaining structural integrity, avoiding the need for strength-compromising incisions.
2Manufacturing precision
If stepwise press-molding of partially separated pieces is performed to avoid wrinkles, then appearance quality is improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent merges multiple molding operations into a single-step press-molding process by incorporating predetermined convex and concave portions that self-regulate material flow. This combines the functions of multiple separated molding steps into one operation, achieving wrinkle-free surfaces without the complexity of stepwise processing or multiple mold operations.
Solution Approach 2:
The patent applies self-service by designing the molding material with built-in convex portions and concave portions that automatically control material deformation and flow during press-molding. The predetermined geometric features guide the material to deform in a controlled manner without requiring external intervention or complex multi-step processes, achieving wrinkle prevention through self-regulating material behavior.
3Productivity
If thermoplastic resin is used as matrix for press-molding, then productivity and recyclability are improved, but wrinkle generation and appearance defects occur more frequently
Solution Approach 1:
The patent applies preliminary action by pre-forming convex portions and concave portions in the thermoplastic resin molding material before press-molding. This predetermined geometric structure guides material flow during the rapid thermoplastic molding process, preventing wrinkle generation while maintaining the high productivity and recyclability benefits of thermoplastic resins.
Solution Approach 2:
The patent changes geometric parameters by defining specific height relationships (H1 > H2) between convex portions and concave portions, which controls material deformation behavior during fast thermoplastic press-molding. This parameter control prevents surface defects while maintaining the speed and efficiency advantages of thermoplastic processing.
Data Source
AI summary
A press-molding material includes discontinuous reinforcing fibers having an average fiber length of 3 mm to 100 mm, and a thermoplastic resin as a matrix. The press-molding material has a certain reference plane; at least one standable plane; and at least one self-laminatable region. A portion of the standable plane is included in the self-laminatable region.