Segmented Tool for Fiber-Reinforced Plastic Ring Parts
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Solution Overview
Problem
Current methods for manufacturing fiber-reinforced plastic parts, particularly those with complex geometries like ring-like shapes, face challenges in maintaining constant temperature and pressure, leading to issues such as layer slippage, uneven material distribution, and difficulty in producing parts with superior mechanical properties and specific shapes.
Innovation Solution
A method involving a first and second tool with segments that move to compress the material, allowing for homogeneous pressure application and forming of parts with predefined shapes, including ring-like structures, by adjusting the travel distance and pressure distribution to ensure consistent processing conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If thermoplastic prepregs are heated and compressed in a moving manner through a slot between fixed tool pieces, then the profile can be shaped, but the layers may slip or bend or displace compromising the final product
Solution Approach 1:
The tool is divided into multiple segments that can move independently. The first tool has at least one set comprising at least one segment, and the second tool has at least one first and one second set of at least one segment each. This segmentation allows controlled movement and pressure application without causing layer displacement.
Solution Approach 2:
The patent employs dynamic tool segments that move during the compression process. The segments are moved such that continually during moving, a momentary travel distance for the second set exceeds a momentary travel distance for the first set. This dynamic movement enables precise control over pressure application and material flow.
2Shape
If thermoplastic prepregs are treated while moving through a slot, then shaping is achieved, but it is difficult to keep temperatures and pressures approximately constant
Solution Approach 1:
The divided tool structure with multiple segments allows different regions to be controlled independently for temperature and pressure. Each segment can be heated or pressed according to specific process requirements, maintaining constant parameters throughout the process.
Solution Approach 2:
The patent ensures continuous and controlled action during the forming process. The segments move in a coordinated manner, with the second set traveling farther than the first set, maintaining continuous pressure and temperature control throughout the material processing.
3Stability of the object's composition
If fixed tool pieces are used for compression, then structural stability is maintained, but parts of certain shapes such as ring-like parts cannot be manufactured
Solution Approach 1:
The tool is segmented into multiple movable parts rather than being a fixed structure. The first and second sets of segments can move relative to each other, enabling the formation of complex shapes including ring-like parts while maintaining structural stability during compression.
Solution Approach 2:
The patent transforms the fixed tool structure into a dynamic system where segments move during the process. This dynamic capability allows the tool to adapt to different part geometries, including ring-like structures, while maintaining compression stability.
4Strength
If unidirectional endless fibers are wound to achieve fiber orientation, then fiber alignment is improved, but implementation in industrial field becomes difficult for complex part geometries
Solution Approach 1:
The segmented tool structure allows for complex fiber orientation patterns to be achieved through mechanical guidance during compression. Different segments can guide fibers in different directions, enabling complex part geometries with optimized fiber reinforcement without difficult manual winding operations.
Solution Approach 2:
The patent changes the processing approach from pre-winding fibers to in-situ fiber orientation during compression. By controlling the movement and positioning of tool segments, fiber orientation is achieved as a result of the compression process parameters rather than pre-processing, simplifying industrial manufacturing.
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 enables the production of parts with improved mechanical properties, such as high stiffness and strength, while allowing for the creation of complex shapes like ring-like structures with reduced structural impairments and enhanced process repeatability.
Implementation Method 1
compressing between at least said first and second tools at least a portion of said material by applying pressure to at least one of said first and second tools
Implementation Method 2
The so-obtained preform can be put into a mold, and then, a resin can be transferred through the preform under vacuum and/or with a transfer pressure, and finally, the resin can be crosslinked at a suitable temperature
Data Source
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AI summary
The method for manufacturing parts comprises the steps of a) providing material (3); b) providing a first tool comprising at least one set comprising at least one segment (1); c) providing a second tool comprising at least one first and at least one second set of at least one segment (2a;2b) each, said segments (2a;2b), when arranged next to each other in a predefined way, referred to as closed position, form a second-tool surface describing the shape of a portion of a surface of said part to be manufactured; d) moving the at least one segments (2a) of said first set of said second tool into said closed position; e) moving the at least one segments (2b) of said second set of said second tool towards and into said closed position; f) compressing between at least said first and second tools at least a portion of said material (3), in particular at least substantially all of said material (3), by applying pressure to at least one of said first and second tools. Therein, said segments (2a; 2b) of said second tool are moved such that continually during moving of the at least one segments (2b) of said second set of said second tool towards said closed position, a momentary travel distance up to said closed position for the at least one segments (2b) of said second set of said second tool exceeds a momentary travel distance up to said closed position for the at least one segments (2a) of said first set of said second tool. This allows to produce parts of fiber- reinforced plastics, in particular ring-like shaped parts, such as wheels and rims.