Resin Composite Plate Thickness Control via Segmented Sheet Stacking
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Solution Overview
Problem
The existing manufacturing methods for resin composite plates face challenges in reducing the number of fiber-reinforced thermoplastic resin sheets to be stacked while maintaining the ability to finely adjust the thickness, leading to increased manufacturing costs and potential strength issues due to directional dependency.
Innovation Solution
A method involving the stacking and heating under pressure of fiber-reinforced thermoplastic resin sheets with varying thickness and fiber volume fractions, along with curved or polygonal joint surfaces, to reduce the number of sheets and processes, allowing for precise thickness adjustment and improved strength distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the unit thickness of carbon fiber composite resin materials is reduced to finely adjust the thickness of the resin sheet, then the desired thickness can be obtained, but the manufacturing cost rises because the number of pieces to be stacked increases
Solution Approach 1:
The resin sheet group is divided into multiple resin sheets with different thicknesses rather than using many thin sheets of uniform thickness. This segmentation by thickness allows achieving precise overall thickness control while using fewer total sheets, thereby reducing manufacturing cost.
Solution Approach 2:
Different regions of the resin sheet group have different sheet thicknesses tailored to local requirements. By assigning specific thicknesses to specific sheets based on their position or function in the stack, the overall thickness precision is improved without unnecessarily increasing the total number of sheets.
2Ease of manufacture
If the unit thickness of carbon fiber composite resin materials is thickened to decrease the number of pieces to be used, then the manufacturing cost decreases, but it becomes impossible to finely adjust the thickness of the resin sheet
Solution Approach 1:
Instead of using a small number of uniformly thick sheets, the resin sheet group is segmented into multiple sheets with varying thicknesses. This allows using fewer sheets overall while maintaining the ability to precisely adjust the total thickness through strategic selection of individual sheet thicknesses.
Solution Approach 2:
The thickness parameter of individual resin sheets is varied within the sheet group rather than maintaining a uniform thickness. By changing the thickness parameter across different sheets, both cost reduction (fewer sheets) and precision control (fine thickness adjustment) are achieved simultaneously.
3Ease of manufacture
If fiber-reinforced thermoplastic resin sheets with fibers arranged in one direction are stacked, then the manufacturing process is simple, but the resin composite plate has directional dependency in strength
Solution Approach 1:
The resin sheets are arranged in an asymmetric configuration where sheets with the same fiber direction are positioned at different locations within the sheet group. This asymmetric arrangement optimizes strength distribution while maintaining manufacturing simplicity, as it doesn't require complex alternating patterns but rather strategic placement of identical sheets.
4Manufacturing precision
If a large number of fiber-reinforced thermoplastic resin sheets are stacked to achieve desired thickness, then the thickness can be adjusted, but the number of stacking processes increases leading to increased manufacturing cost
Solution Approach 1:
The resin sheet group is segmented into sheets of different thicknesses, allowing the desired total thickness to be achieved with fewer sheets. This reduces the number of stacking processes required while maintaining precise thickness control.
Solution Approach 2:
The thickness parameter of individual sheets is optimized to reduce the total number of sheets needed. By selecting appropriate thickness values for each sheet in the group, the desired precision is achieved with minimal stacking operations.
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
This approach decreases manufacturing costs by reducing the number of sheets required and enhances the strength of the resin composite plate by eliminating directional dependency and preventing breakage at joint surfaces, while allowing for precise thickness control.
Implementation Method 1
manufacturing a resin composite plate by heating under pressure a resin sheet group having a plurality of fiber-reinforced thermoplastic resin sheets stacked together, and thereby integrating the resin sheet group into one resin composite plate
Data Source
AI summary
In a manufacturing method of a resin composite plate for manufacturing a resin composite plate by heating under pressure a resin sheet group having a plurality of fiber-reinforced thermoplastic resin sheets stacked together, and thereby integrating the resin sheet group into one resin composite plate, the fiber-reinforced thermoplastic resin sheets each containing fibers arranged in one direction, the resin composite plate having a desired thickness is manufactured by stacking the plurality of fiber-reinforced thermoplastic resin sheets having different thickness.