Rotary Mould Stack Molding for Composite Uniformity

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Solution Overview

Problem

Conventional hand lay-up methods for composite material manufacturing are inefficient, leading to high processing times, low productivity, and uneven fiber impregnation, resulting in non-uniform thickness and strength issues in composite articles, with the added health risk of volatile substance exposure.

Innovation Solution

A high-speed stack molding apparatus utilizing a rotary-type mould with a movable driving frame, articulated robot arm, and pressure rollers to uniformly impregnate and stack fiber-reinforced resin on a multi-mould's circumferential surface, ensuring consistent thickness and strength, while minimizing exposure to hazardous fumes through integrated air purification.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If hand lay-up method is used to stack fiber on mould surface, then operator can manually place fiber, but processing time is excessive and productivity is low

Engineering Contradiction:

Improvemanual fiber placementVSAvoidproduction speed

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The patent replaces the manual mechanical hand lay-up method with an automated robotic system. A robot arm equipped with a stacking head automatically places fiber-reinforced resin on the rotary mould, eliminating manual labor and dramatically increasing production speed while maintaining operational capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a rotary-type mould that rotates during the fiber stacking process. This dynamic element allows continuous fiber placement on multiple hull profiles simultaneously, transforming the static manual process into a dynamic automated system that enhances productivity.

Inventive Principle:

Principle #15Dynamics

2Quantity of substance

If manual stacking and air drying is used, then one hull or few hulls can be manufactured, but mass production is impossible due to time required for stacking and drying

Engineering Contradiction:

Improvenumber of hulls producedVSAvoidstacking and drying time

Core Design Contradiction:

Quantity of substanceVSLoss of time

Solution Approach 1:

The rotary mould is divided into multiple segments, each representing a different hull profile. This segmentation allows the system to manufacture multiple different hull types simultaneously on a single rotating mould, enabling mass production of varied composite articles without sequential processing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The rotary mould enables continuous fiber placement operation. As the mould rotates, the robotic stacking head continuously deposits fiber-reinforced resin without interruption, eliminating the batch processing delays inherent in manual methods and enabling sustained high-speed production.

Inventive Principle:

Principle #20Continuity of useful action

3Ease of manufacture

If fiber is impregnated with resin using roller and brush, then fiber can be dried in air, but volatile substances are released into atmosphere causing health hazards

Engineering Contradiction:

Improveresin impregnation processVSAvoidvolatile substance exposure

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent replaces air drying with vacuum drying. By creating a vacuum environment, the system eliminates atmospheric oxygen that would otherwise allow volatile substance release. The vacuum atmosphere safely contains and removes volatile compounds during the drying process, protecting operator health while maintaining manufacturing ease.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

4Adaptability or versatility

If fiber is stacked manually on mould surface, then fiber can be placed in various fabric forms, but layer thickness is non-uniform and hull surface is not evenly formed

Engineering Contradiction:

Improvefabric form flexibilityVSAvoidlayer thickness uniformity

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent replaces manual fiber placement with an automated robotic stacking system. The robot-controlled stacking head precisely deposits fiber-reinforced resin with consistent positioning and pressure, ensuring uniform layer thickness across the entire hull surface while maintaining the ability to handle various fabric forms through programmable operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS9539768B2High-speed stack molding apparatus utilizing rotary-type mould

Publication Date: 2017.01.10 RES INST OF MEDIUM & SMALL SHIPBUILDING

AI summary

A high-speed stack molding device utilizing a rotary multi-mould, including a base having a moving rail formed on an upper surface thereof; a mould-rotating unit disposed on the base and supporting both ends of a multi-mould to selectively rotate the multi-mould; a movable driving frame including vertical frames extending upward from slide-coupling parts, which are moved forward and rearward along the moving rail and an upper frame connecting upper end portions of the vertical frames to cover an upper portion of the multi-mould; a fiber-reinforced resin supplying unit connected to the movable driving frame and supplying a fiber discharged from a supplying roller to the upper frame through pressure rollers; and a stacking head provided at an end portion of an articulated robot arm connected operably to the upper frame for pressurizing and stacking the fiber-reinforced resin.