RTM Mold Resin Flow Detection and Interruption Control
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Solution Overview
Problem
Existing resin transfer molding (RTM) processes lack the ability to easily detect when the mold cavity is completely filled and to prevent resin from escaping, leading to inefficiencies and potential damage due to excessive pressure.
Innovation Solution
An apparatus with a measuring unit to detect resin flow at the mold outlet, coupled with a resin flow closing unit that closes when resin is detected, ensuring the resin flow is interrupted and excess resin can be reused, and pressure sensors to manage pressure within the mold cavity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If resin is continuously injected into the mold cavity without detection, then the mold cavity can be completely filled, but excess resin escapes causing waste and potential damage
Solution Approach 1:
The patent implements a feedback control system where a measuring unit continuously monitors the resin outlet for escaping resin and provides signals to a control unit, which then actuates a resin flow closing unit to interrupt flow. This closed-loop feedback mechanism prevents resin waste by stopping injection exactly when the mold cavity is filled, eliminating the need for continuous monitoring and manual intervention.
Solution Approach 2:
The patent replaces manual monitoring and mechanical control of resin injection with an automated sensing and control system. The measuring unit detects resin flow conditions and the control unit automatically actuates the closing unit, substituting human operation with an automated electromechanical system that provides precise control and eliminates resin waste.
2Productivity
If resin injection continues after mold cavity is filled, then injection rate can be maintained, but excessive pressure damages the mold and reduces component quality
Solution Approach 1:
The measuring unit continuously monitors the resin outlet for signs of overfilling and provides real-time feedback to the control unit. When resin escape is detected, the control unit immediately actuates the resin flow closing unit to interrupt injection, preventing excessive pressure buildup that would damage the mold and compromise component quality, while allowing high injection rates during the filling phase.
Solution Approach 2:
The system takes preliminary anti-action by detecting resin escape at the outlet before excessive pressure can build up in the mold cavity. The measuring unit and control unit work proactively to interrupt resin flow at the first sign of overfilling, preventing the harmful effect of excessive pressure before it occurs, rather than reacting after damage has already been done.
3Reliability
If no detection system is used, then the apparatus complexity is low, but resin escape cannot be detected and prevented
Solution Approach 1:
The patent introduces a feedback-based detection and control system consisting of a measuring unit, control unit, and resin flow closing unit. The measuring unit monitors resin flow conditions at the outlet, the control unit processes the signals, and the closing unit executes flow interruption when needed. This feedback mechanism significantly improves reliability of resin flow control while adding only the necessary minimum complexity to achieve automated detection and prevention.
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 apparatus allows for reliable detection of mold cavity filling and prevents resin escape, reducing strain on the mold and enabling resin reuse, while managing pressure to maintain component quality.
Implementation Method 1
a measuring unit which detects the escaping resin flow is situated at or downstream from the mold outlet
Implementation Method 2
a resin flow closing unit which is closable and from which injection resin may escape after the mold has been filled
Implementation Method 3
pressure sensors to manage pressure within the mold cavity
Data Source
AI summary
Apparatus for resin transfer molding (RTM) and an RTM process for producing integral components. The apparatus has a closable mold (W) with a mold cavity (F), and an injection unit (10) coupled to the mold such that a resin is introducible into the mold; the mold has at least one resin outlet (3) connected to the mold cavity through which resin escapes after the mold is filled; a measuring unit situated at or downstream from the outlet detects escaping resin flow is and is coupled to a resin flow closing unit (5) such that the unit closes the outlet when escaping resin is detected. In the process a control system (11) transmits a signal for closing the resin flow closing unit to the closing unit when resin flow is detected such that the resin flow closing unit is closed and the flow of resin escaping the mold is interrupted.