Fibre-Reinforced Preform with Serrated Edge for Gas Escape
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Solution Overview
Problem
Compression moulding often results in irregularities and faults at the edges of mouldings due to trapped gases, especially when producing complex-shaped fibre reinforced thermosetting resin mouldings, leading to reduced performance.
Innovation Solution
A moulding system with a recess at the edge of the mould cavity and a preform with channels or corrugations at its edges to allow gas escape during moulding, ensuring uniformity and maintaining fibre alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If compression moulding is used to produce fibre reinforced thermosetting resin mouldings, then the desired physical properties can be achieved, but entrapped gas causes irregularities and faults at the edges of the moulding
Solution Approach 1:
The preform edge is segmented into multiple layers with different configurations. The first preform layer has a first edge configuration while the second preform layer has a second edge configuration, creating distinct zones for different functions. This segmentation allows the resin to flow through specific pathways while maintaining structural integrity elsewhere.
Solution Approach 2:
The first preform layer acts as an intermediary element between the mould cavity and the second preform layer. It provides a controlled interface for resin flow and gas escape, mediating the interaction between the moulding pressure and the preform structure to prevent gas entrapment.
2Manufacturing precision
If pressure is applied to force material to extremities of the mould, then complete filling is achieved, but gas cannot escape and becomes intermingled with edges of the moulding material
Solution Approach 1:
The preform is pre-shaped with specific edge configurations before moulding. The first preform layer is positioned to create initial resin flow pathways, and the second preform layer is configured to maintain fibre alignment. This preliminary structuring ensures that when pressure is applied, resin flows through predetermined routes and gas can escape along these paths.
Solution Approach 2:
Different regions of the preform are given different local qualities. The first preform layer has a configuration optimized for resin flow and gas escape, while the second preform layer has a configuration optimized for fibre alignment and structural support. Each layer performs its specific function locally without interfering with the other.
3Adaptability or versatility
If fibre reinforced thermosetting resins are moulded as stacks of layers, then complex shaped mouldings can be produced, but gas entrapment becomes more severe
Solution Approach 1:
The stack of layers is segmented into functional groups. Preform layers are alternating with reinforcement layers, creating a laminated structure where each layer type performs its specific function. This segmentation allows gas to escape through the preform layers while the reinforcement layers maintain the complex shape structure.
Solution Approach 2:
The preform layers act as intermediary elements between the reinforcement layers in the stack. They provide continuous pathways for resin flow and gas escape throughout the multi-layer structure, mediating the pressure distribution and ensuring complete filling without gas entrapment in complex geometries.
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 solution effectively removes entrapped gases, enhancing the uniformity and mechanical properties of mouldings, particularly in complex shapes, by allowing gas escape and maintaining fibre alignment, thus improving the structural integrity and performance of fibre-reinforced composite materials.
Implementation Method 1
the preform having corrugated edges... to permit flow of gas into the recess formed by the corrugation and the cavity during moulding
Implementation Method 2
bring the elements of the mould together to exert pressure on the moulding material and to force the material to the extremities of the mould
Implementation Method 3
a preform comprising a curable thermosetting resin... the mould is capable of being heated so that it can cure a thermosetting material
Data Source
Figure 1~2
Figure 3
AI summary
This invention relates to a mould for moulding materials, the mould comprising at least two corresponding mould elements moveable relative to one another towards and away from each other, the towards movement exerting pressure on a moulding material positioned within a cavity formed with the mould wherein upon the mould elements being in contact the mould cavity comprises a recess, the recess being located beyond the edge of the moulding to allow escape of gas during moulding.