Thermoplastic Composite Annular Structures With Staggered Strip Joints
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Solution Overview
Problem
The high cost and labor-intensive processes of forming composite structures, such as bicycle wheel rims, limit their widespread adoption, while existing injection molding methods result in weak structures and the inability to form complex shapes.
Innovation Solution
A method involving a mandrel and clamping system to form annular composite structures using fiber-reinforced thermoplastic material, where strips are bent and fused under heat and pressure to create strong, complex shapes like bicycle wheel rims.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple sheets of composite material are layered in a mold and set using two-part epoxy, then the structure achieves high strength and complex shapes, but the process becomes time-consuming and labor-intensive
Solution Approach 1:
The patent changes the material parameter from thermoset (epoxy) to thermoplastic, which allows the material to be reheated and reformed multiple times without degradation. This enables faster cycling times and reduces the need for complex multi-step curing processes, directly addressing the time-consuming nature of traditional composite forming while maintaining structural strength through the inherent properties of thermoplastic materials
Solution Approach 2:
The patent replaces the chemical curing mechanism of thermoset materials with a thermal processing mechanism of thermoplastic materials. Instead of relying on chemical reactions to set the structure, the process uses heating to soften and shape the material, followed by cooling to solidify. This substitution eliminates the need for two-part epoxy systems and significantly reduces forming time and labor requirements
2Productivity
If injection molding is used to form structures quickly and cheaply, then production cost and time are reduced, but the resulting structures are weak and cannot form complex three-dimensional shapes
Solution Approach 1:
The patent employs composite materials consisting of thermoplastic polymer matrices reinforced with fibers or particle fillers. This composite approach combines the ease of thermoplastic processing with the strength benefits of reinforcement materials, enabling the formation of complex three-dimensional shapes through techniques like rotational molding while achieving both high productivity and structural integrity
Solution Approach 2:
The patent utilizes the dynamic properties of thermoplastic materials, which transition from solid to semi-molten state upon heating, allowing complex shapes to be formed during the softened phase and then locked in place upon cooling. This dynamic behavior enables the production of intricate three-dimensional geometries that are impossible to achieve with traditional injection molding, while maintaining rapid production cycles
3Strength
If thermoset materials are used in composite structures, then the materials provide good structural properties, but they are relatively brittle and difficult to recycle
Solution Approach 1:
The patent changes the material class from thermoset to thermoplastic, which fundamentally alters the recyclability parameter. Thermoplastic materials can be melted and reformed multiple times without chemical degradation, enabling recycling processes that are impossible with thermoset materials. This parameter change maintains structural properties through proper material selection and reinforcement while making the materials significantly more recyclable and environmentally sustainable
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 method enables the rapid and cost-effective production of high-strength, complex annular composite structures, overcoming the limitations of traditional methods by reducing labor and material costs.
Implementation Method 1
The preheating assembly can include, for example, infrared heaters positioned on opposite sides of the strip of material
Implementation Method 2
the mandrel is turned, bending a portion of the strip about the mandrel. The portion of the strip that has been bent about the mandrel can also be placed under pressure, for example by a shoe or rollers
Implementation Method 3
a final step of heating and applying pressure can be performed to fuse the strips, or portions of a single strip, to one another
Implementation Method 4
a final step of heating and applying pressure can be performed to fuse the strips, or portions of a single strip, to one another
Data Source
Figure 1~2
Figure 3~4B
Figure 5A~5C
AI summary
Annular structures (104) formed using composite materials and systems and methods for forming annular structures using composite materials are provided. The composite materials can include fiber reinforced thermoplastic materials. The annular structures include a number of component parts. Each component part can be in the form of a strip of fiber reinforced thermoplastic material (504) that extends around all or a portion of a circumference of the structure. The ends (508) of the component parts can be staggered, so that they a placed at different locations about the circumference of the structure. Methods for forming annular composite structures include wrapping one or more strips of fiber reinforced thermoplastic material having one or more layers about a mandrel, and fusing the strips to form an integral annular structure.