Segmented Molding Core for Low-Force Extraction of Hollow Composite Profiles
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Solution Overview
Problem
Existing methods for molding hollow composite profiles on composite parts face challenges with core extraction due to high friction forces, especially in elongated and curved structures, leading to difficulties in demolding and potential mechanical stresses, and existing core materials lack both rigidity and ease of extraction.
Innovation Solution
A core design comprising a stack of translationally movable and flexible slices, connected by an extraction member, allowing the slices to flex and separate for easy extraction while maintaining rigidity during molding, featuring a molding and extraction configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid core is used to maintain structural integrity during molding, then the core can withstand pressure during draping, but the core cannot be easily extracted from the stiffener due to high friction forces
Solution Approach 1:
The core is divided into multiple rigid segments or blocks along its length. These segments can move relative to each other in the longitudinal direction, allowing the core to be extracted from the stiffener by separating the segments, thereby reducing friction resistance during extraction while maintaining rigidity during molding.
Solution Approach 2:
The core transitions from a static rigid structure to a dynamic structure where segments can move relative to each other. During molding, the segments are positioned to provide rigidity; during extraction, the segments can slide or separate to reduce friction and facilitate removal.
2Ease of operation
If a flexible core is used to enable easy extraction, then the core can be removed from the stiffener, but the core lacks sufficient rigidity to withstand pressure during draping
Solution Approach 1:
The core is segmented into multiple rigid blocks that can move relative to each other. This segmentation allows the core to exhibit flexible behavior during extraction (segments separate) while maintaining rigid behavior during molding (segments remain positioned to provide structural support).
Solution Approach 2:
The core's effective rigidity parameter changes based on the operational phase. During molding, the segments are positioned to maximize rigidity; during extraction, the segments can move to reduce friction, effectively changing the core's mechanical properties to suit each phase.
3Stability of the object's composition
If the core is made as a single continuous piece, then the core maintains structural integrity, but the extraction requires excessive mechanical effort due to large friction surface
Solution Approach 1:
The core is divided into multiple segments that can move relative to each other. This segmentation reduces the total friction surface area in contact with the stiffener during extraction, as only the end segments need to be pulled out at any given time, significantly reducing the extraction force required.
Solution Approach 2:
The core segments are extracted sequentially from the stiffener rather than all at once. This progressive extraction reduces the mechanical effort required at any moment, as the friction force is distributed across multiple smaller extraction steps rather than one large force application.
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
Enables the production of large, curved composite structures with efficient core extraction, reducing mechanical effort and preventing mechanical stresses, while maintaining structural integrity and reusability of the core.
Implementation Method 1
slices being further configured to flex each around a transverse axis substantially orthogonal to said longitudinal direction
Data Source
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AI summary
The invention relates to a molding core (110) comprising a plurality of slices (111) aligned along a longitudinal direction (X) of extension of the core and an extraction member mechanically connecting the slices together so that said slices are movable in translation along the longitudinal direction and can be brought closer to and moved away from each other, said slices being further configured to flex each around a transverse axis (Y) substantially orthogonal to said longitudinal direction, the core being configured to adopt: - a so-called molding configuration, in which the slices are brought closer to each other, so as to form together a compact core and - a so-called extraction configuration, in which said slices are successively mechanically stressed by the extraction member,so that the slices successively bend substantially around the transverse axis and are successively moved away from each other.,