Resin Transfer Molding Mold with Moving Core for Preform Deformation Control
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Solution Overview
Problem
The existing resin transfer molding (RTM) method for manufacturing high-pressure tanks concentrates pressure at the resin inlet, leading to deformation of the preform and uneven resin impregnation, particularly in tanks with thick carbon fiber layers, resulting in poor quality and performance.
Innovation Solution
A method and device that utilize a mold with a moving core and pressure sensors to create gaps that distribute resin pressure evenly, allowing for controlled filling and uniform impregnation by adjusting the position of the core and molds to match resin pressure across the tank, preventing deformation and ensuring thorough resin penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If resin is injected at high pressure to impregnate the fiber layer, then resin impregnation is improved, but pressure concentrates at the resin inlet causing preform deformation
Solution Approach 1:
The mold is divided into a fixed mold and a moving mold, allowing independent control of resin injection and mold closing actions. This segmentation enables resin to be injected first while the moving mold remains separated, then the moving mold closes to apply uniform compression, preventing pressure concentration at the resin inlet during impregnation.
Solution Approach 2:
Resin is injected into the mold cavity before the moving mold closes. This preliminary action allows the fiber layer to become saturated with resin under low pressure while the moving mold is still separated, avoiding the preform deformation that would occur if high pressure were applied simultaneously with mold closing.
Solution Approach 3:
The moving mold is designed to transition from a separated state during resin injection to a closed state during compression. This dynamic adjustment allows the system to adapt pressure conditions: low pressure during resin injection for uniform impregnation, then high pressure during closing for complete saturation without deforming the preform.
2Manufacturing precision
If resin is injected at high pressure to ensure complete impregnation of thick fiber layers, then impregnation completeness is improved, but pressure difference between resin inlet and flow end increases
Solution Approach 1:
The injection and compression processes are segmented into distinct phases. Resin is first injected while the moving mold remains separated, allowing pressure to distribute more evenly. Then the moving mold closes to apply uniform compression force, ensuring complete impregnation of thick fiber layers while maintaining controlled pressure distribution throughout the preform.
Solution Approach 2:
The system dynamically transitions from an open mold state during resin injection to a closed mold state during compression. This dynamic change allows the pressure application method to adapt: initial injection at moderate pressure followed by uniform compression, thereby achieving complete impregnation while minimizing excessive pressure differences between the resin inlet and flow end.
3Quantity of substance
If the mold is tightly closed during resin injection, then resin containment is improved, but preform deformation occurs due to pressure concentration
Solution Approach 1:
The mold closing action is segmented from the resin injection process. The moving mold remains separated during resin injection, allowing resin to be contained within the defined cavity space without applying compressive force to the preform. After injection is complete, the moving mold then closes to apply uniform compression, ensuring resin containment without causing deformation.
Solution Approach 2:
Resin injection is performed as a preliminary action before the moving mold closes. This sequence allows the resin to be contained within the mold cavity boundaries established by the fixed mold and the positioned moving mold, without the additional constraint of tight closing that would cause pressure concentration and preform deformation.
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 prevents pressure concentration at the resin inlet, achieves uniform resin impregnation across thick carbon fiber layers, improving tank quality and performance by distributing pressure evenly and optimizing resin flow behavior.
Implementation Method 1
pouring the resin from a resin inlet toward the second gap in the mold
Implementation Method 2
impregnate the fiber layer of the preform with resin
Data Source
AI summary
Provided is a method for manufacturing a fiber reinforced resin molded article capable of distributing the pressure without concentration on the vicinity of the resin inlet and so preventing the deformation of a preform, and such a manufacturing device thereof. The method lowers a lower core as a moving core in a lower mold (first mold) (away from a preform) to let resin flow toward the lower mold (first mold). This distributes the pressure concentrated in the vicinity of the resin inlet and prevents deformation of the preform.