Resin Case With Stepped Fiber Sheet And Rib Reinforcement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Molded products with complex shapes and multiple projections and recesses made from thermoplastic resin with continuous fibers often suffer from fiber cutting or wrinkling, leading to reduced strength when divided and bonded, particularly in the peripheral walls.
Innovation Solution
A resin case design incorporating a continuous fiber sheet with a stepped portion and a resin member featuring rib portions that are bonded to the stepped portion and extend orthogonally, enhancing both compression and tensile strength by distributing stress laterally and improving structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If continuous fiber sheet is subjected to press-working for complex shapes with projections and recesses, then the molded product can achieve complex geometry, but the continuous fibers may be cut or wrinkled leading to reduced strength
Solution Approach 1:
The molded product is divided into multiple sections along the peripheral wall, with each section containing continuous fibers intact. This segmentation prevents fiber cutting while achieving complex geometry through multiple bonded sections.
Solution Approach 2:
The invention introduces a stepped portion that creates a dimensional transition zone between the bottom surface and peripheral wall. This stepped structure allows the continuous fiber sheet to bend without cutting or wrinkling, maintaining strength while achieving complex 3D geometry.
2Ease of manufacture
If the molded product is divided and bonded to avoid fiber cutting, then complex shapes can be manufactured, but the strength of the molded product is lowered
Solution Approach 1:
The invention uses a composite structure combining continuous fiber sheet with a resin member containing rib portions. The rib portions bond to the stepped portion, creating a strong composite joint that maintains high strength while enabling divided manufacturing for complex shapes.
3Strength
If rib portions are added to improve compression strength, then structural rigidity increases, but device complexity increases
Solution Approach 1:
The rib portions are integrated directly into the resin member that bonds to the continuous fiber sheet. This merging of functions allows the resin member to simultaneously serve as a bonding agent and a structural reinforcement element, improving compression strength without proportionally increasing complexity.
Data Source
AI summary
Strength of a resin case is improved. A continuous fiber sheet includes a bottom surface portion which forms a bottom surface of the resin case, an erected wall portion which is erected from the bottom surface portion and forms a peripheral wall of the resin case, and a stepped portion in which the continuous fiber sheet connecting the bottom surface portion and the erected wall portion to each other is bent like steps along the peripheral wall. A resin member includes a rib portion which is bonded to the stepped portion and extends from the stepped portion toward an outer edge of the resin case.