Resin Rotator Molding via Slurry Diffusion and Cleaning
Solution Overview
Problem
Existing methods for manufacturing resin rotators face challenges with slurry viscosity and fiber length, leading to fluctuations in short fiber and powdery resin distribution, potential die damage, and material entanglement, which disrupt continuous production.
Innovation Solution
A method involving the preparation of a slurry with short fibers and powdery resin in a dispersion medium, pouring into a cylindrical die with a slurry diffusion member, cleaning the diffusion portion to prevent entanglement, and compressing the aggregate under controlled conditions to form a molding material, allowing for continuous production without die damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the viscosity of the slurry is high or the length of the short fibers is long, then the slurry can maintain fiber structure, but the slurry remains on the slurry diffusion portion causing fiber aggregation fluctuation and potential die damage
Solution Approach 1:
The slurry diffusion portion is cleaned with water before slurry pouring to remove any residual fibers or contaminants. This preliminary cleaning action prevents fiber aggregation and ensures consistent slurry flow, resolving the contradiction between maintaining fiber structure and achieving uniform fiber distribution.
Solution Approach 2:
The invention changes the physical state of the slurry diffusion portion by controlling its temperature and surface properties. By maintaining the slurry diffusion portion at a temperature that prevents premature fiber aggregation and ensuring proper surface wetting, the system allows high viscosity slurry with long fibers to flow smoothly without remaining on the diffusion portion.
2Stability of the object's composition
If the slurry is poured onto the slurry diffusion portion, then the slurry can be distributed evenly, but the short fibers and powdery resin may remain on the diffusion portion causing material entanglement
Solution Approach 1:
The invention extracts the harmful residual materials (short fibers and powdery resin) from the slurry diffusion portion by cleaning it with water before each pouring cycle. This removal action prevents material entanglement while preserving the beneficial even distribution of slurry during the pouring process.
Solution Approach 2:
The cleaning step is performed as a preliminary action before slurry pouring. By removing residual fibers and resin beforehand, the system ensures that subsequent slurry pours distribute evenly without causing material entanglement on the diffusion portion.
3Quantity of substance
If the short fibers remain on the slurry diffusion portion, then the fiber aggregate may form, but the amount of short fibers per product fluctuates and die damage may occur
Solution Approach 1:
The invention implements a feedback mechanism where the system monitors and responds to fiber accumulation on the slurry diffusion portion by automatically cleaning it. This feedback loop ensures consistent short fiber amounts in each product by removing excess fibers that would otherwise cause aggregation fluctuations and potential die damage.
4Device complexity
If the slurry diffusion portion is not cleaned, then the production process is simpler, but the die may be damaged and continuous production is interrupted
Solution Approach 1:
The slurry diffusion portion is designed to be self-cleaning through the water pouring mechanism. The system uses the production process itself (pouring water) to clean the diffusion portion, eliminating the need for separate complex cleaning equipment while ensuring die durability and continuous production.
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 method ensures consistent short fiber and powdery resin distribution, prevents die damage, and enables continuous production by effectively managing slurry viscosity and fiber length, resulting in uniform resin rotators with enhanced durability.
Implementation Method 1
a slurry diffusion member (7) is disposed at the center of the cylindrical die (3) to extend in the upward direction, and includes a slurry diffusion portion (71) shaped such that the area of a transverse section taken along a direction orthogonal to the upward direction becomes smaller as the slurry diffusion portion (71) extends in the upward direction
Implementation Method 2
a dispersion medium or water is poured onto the slurry diffusion member (7) to cause the short fibers and the powdery resin adhering to and remaining on the slurry diffusion member (7) to fall down
Data Source
AI summary
Provided herein is a molding material that attains little fluctuation in amount of short fibers and powdery resin among individual products and that allows continuous production without damaging a die. In the step of pouring, slurry is poured onto a slurry diffusion member 7 from above the slurry diffusion member 7. The slurry diffusion member 7 extends in an upward direction, and is shaped such that the area of a transverse section taken along a direction orthogonal to the upward direction becomes smaller as the slurry diffusion member 7 extends in the upward direction. In the step of cleaning, a dispersion medium that is the same as the dispersion medium used in the step of pouring or water is poured onto the slurry diffusion member 7 from above the slurry diffusion member 7 to cause the short fibers and the powdery resin adhering to a slurry diffusion portion 71 of the slurry diffusion member 7 to fall down. After that, the dispersion medium is discharged from a cylindrical die 3 to accumulate the short fibers and the powdery resin in the cylindrical die 3 to obtain an aggregate 38 of the short fibers and the powdery resin. Then, the aggregate 38 is compressed.