Thermoplastic Seat Structure In Situ Reactive Injection Molding
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Solution Overview
Problem
Current methods for producing thermoplastic, fiber-reinforced seat structures, such as GMT and D-LFT, face challenges in achieving lightweight, mechanically stable components with high production costs and complex processing steps, while reactive injection molding lacks reinforcing character.
Innovation Solution
The TR-RIM method involves in situ injection molding, where a pre-molded part is injection-molded and then filled with reactive components mixed in a chamber before injection, forming a cohesive bond with fiber layers, allowing for low viscosity impregnation and crystallization within the mold, eliminating the need for prefabricated organosheets and subsequent trimming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If GMT or D-LFT methods are used to produce thermoplastic fiber-reinforced seat structures, then mechanical stability and structural strength are improved, but production costs increase and processing complexity increases
Solution Approach 1:
The patent combines the pre-molded part production and fiber layer impregnation processes into a single integrated injection molding operation. The reactive components are injected directly onto the pre-molded part within the same mold, eliminating the need for separate GMT stacking and heating steps, thereby reducing processing complexity while maintaining mechanical stability
Solution Approach 2:
The pre-molded part is produced first with predetermined geometric features (protruding regions angled inward) that serve as built-in sealing structures. This preliminary action eliminates the need for additional sealing steps during subsequent fiber layer bonding, simplifying the overall processing while ensuring mechanical integrity
2Productivity
If reactive components are injected immediately after pre-molding, then production time is reduced and productivity is improved, but the reactive matrix may react too quickly causing viscosity increase and incomplete fiber impregnation
Solution Approach 1:
The patent changes the physical parameters of the reactive matrix by adjusting temperature and pressure conditions during injection. The mold is heated to maintain the reactive matrix in a low-viscosity state during injection, allowing complete fiber impregnation even though the reaction has started. This parameter control enables both rapid production and high impregnation quality
Solution Approach 2:
The patent employs dynamic control of the injection process, adjusting injection pressure and rate based on the real-time reaction progress of the reactive matrix. The injection parameters are dynamically adapted to maintain optimal flow characteristics throughout the impregnation process, ensuring complete fiber saturation while minimizing total cycle time
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 results in significantly lighter, mechanically stable seat structures with reduced production costs and plant size, enabling efficient, automated manufacturing of thermoplastic continuous fiber-reinforced components, achieving weight savings of at least 30% compared to steel structures.
Implementation Method 1
In a reaction which starts when these components are mixed, the reinforcing layer becomes cohesively bonded to the pre-molded part to form a component. The reaction of the components begins when they are mixed in a mixing chamber immediately prior to the injection thereof into the system
Implementation Method 2
only after the fiber layers have been fully impregnated does the reaction progress to such an extent that the viscosity of the reactive matrix rises and/or crystallization takes place
Data Source
AI summary
A seat structure (1) and a method for the production thereof (1) are provided. A preliminary injected molded article (6) is injected-molded into an injection mold and is subsequently provided with fiber layers in the same injection mold, the layers are filled, at the end, with reactive components. The reactive components are mixed in a mixing chamber directly before injection into the injection mold to form a reactive matrix. The injection takes place prior the reaction of the reactive matrix.