Rotating Mold Thermoregulation for Composite Pole Manufacturing
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Solution Overview
Problem
Existing methods for manufacturing hollow elongated composite bodies, such as poles, face issues with uneven resin distribution and mechanical inaccuracies due to non-uniform thermal conditions and inadequate support during the molding process, leading to geometrical inaccuracies and waste of synthetic resin.
Innovation Solution
An apparatus with a thermally controlled, rotating mold featuring a frusto-conical shape, an injection nozzle for precise resin distribution, and a temperature regulation system using thermoregulation fluid distributors to maintain uniform thermal conditions and support the mold, ensuring consistent resin impregnation and reduced waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the mold is rotated at high speed to centrifuge the resin, then the resin is distributed inside the mold, but the resin distribution becomes uneven leading to geometrical inaccuracies
Solution Approach 1:
The patent applies parameter changes by controlling the rotation speed of the mold to vary centrifugal force during different stages of resin injection. The rotation speed is adjusted to optimize both resin distribution and geometrical accuracy, resolving the contradiction between manufacturing speed and precision.
Solution Approach 2:
The patent implements dynamic control of the mold rotation speed during the resin injection process. The rotation speed is not constant but is dynamically adjusted based on the injection stage, allowing the system to adapt between high-speed centrifuging and precision control phases.
2Stability of the object's composition
If the mold is rotated to impregnate fibres with resin, then the composite structure is formed, but thermal conditions become non-uniform affecting quality
Solution Approach 1:
The patent introduces a thermal intermediary system consisting of heating/cooling devices that act as mediators between the mold and the composite material. These devices maintain uniform thermal conditions during rotation, ensuring consistent resin impregnation and composite formation without thermal gradients.
Solution Approach 2:
The patent applies parameter changes by actively controlling temperature parameters during the molding process. Heating and cooling devices adjust thermal conditions to maintain uniformity despite the dynamic rotation and resin injection, resolving the contradiction between structure formation and thermal uniformity.
3Manufacturing precision
If a dispensing head is used to distribute resin, then resin distribution is improved, but the apparatus complexity increases
Solution Approach 1:
The patent applies universality by designing the mold to serve multiple functions: it acts as both the forming cavity and the dispensing mechanism through controlled rotation. The rotation system serves dual purposes of both mixing/impregnating and distributing resin uniformly, eliminating the need for separate complex dispensing heads.
Solution Approach 2:
The patent implements self-service by enabling the mold itself to perform the resin distribution function through its rotation. The centrifugal force generated by rotation automatically distributes the resin without requiring external dispensing equipment, simplifying the overall apparatus while maintaining distribution precision.
4Reliability
If the mold is supported during rotation, then stable operation is achieved, but the support system becomes complex
Solution Approach 1:
The patent applies merging by integrating the support function directly into the rotation mechanism. The bearings and support structures are combined with the drive system, creating a unified rotating assembly that provides both stable support and rotational motion without requiring separate complex support systems.
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
The solution achieves high-quality, uniformly formed hollow elongated bodies with controlled thickness by maintaining uniform thermal conditions and optimizing resin distribution, reducing waste and ensuring reliable mechanical properties.
Implementation Method 1
a plurality of thermoregulation fluid distributors (33) spaced along said longitudinal development and configured for directing said fluid towards a predetermined number of portions of an external lateral surface of the mold itself
Implementation Method 2
the rotating mold centrifugates at high speed the resin which in turn impregnates the fibre arranged inside the mould
Implementation Method 3
the liquid resin is absorbed by the supporting layers made of reinforcing fibre
Data Source
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AI summary
An apparatus and a process for manufacturing elongated hollow bodies, such as tapered poles, made of reinforced synthetic resin are described, wherein a rotating mould receives reinforcing fibres and resin; the temperature of the mould is controlled by a thermoregulation fluid suitably directed and, at the end of each manufacturing cycle, part of the synthetic resin suitably treated, is recycled in a new cycle.