Thermoplastic Composite Blank Manufacturing via Extrusion
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Solution Overview
Problem
The existing method of manufacturing fiber reinforced thermoplastic components using sheet stock is limited by excessive scrap material production and restricted shape possibilities, as it relies on heating and forming sheet stock in an oven, which does not allow for complex features or efficient use of recycled materials.
Innovation Solution
A method involving heating a pre-formed blank of fiber reinforced thermoplastic material in an oven, where a second extruded fiber reinforced thermoplastic material is combined with the blank to form a composite, allowing for more complex features and reduced waste by using recycled materials, with the extrudate being formed into various shapes or pre-forms within the oven.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If sheet stock is heated and formed in an oven, then the manufacturing process is simple, but excessive scrap material is produced and complex shapes cannot be manufactured
Solution Approach 1:
The manufacturing process is divided into separate stages: a forming station where the blank is formed into shape, and a heating station where the formed blank is heated. This segmentation allows the blank to be formed efficiently and then heated without requiring the entire process to occur in a single oven, reducing material waste while maintaining process simplicity.
Solution Approach 2:
The blank is formed into the desired shape at the forming station before being transferred to the heating station. This preliminary forming action allows complex shapes to be created without requiring the heating oven to be designed for complex geometry, thereby reducing scrap material while enabling shape complexity.
2Ease of manufacture
If sheet stock is heated and formed in an oven, then the process is straightforward, but complex features cannot be manufactured
Solution Approach 1:
The process is segmented into a forming station that handles shape creation and a heating station that handles thermal processing. This separation allows the forming station to accommodate complex geometries without the constraints of oven design, thereby enabling complex feature manufacturing while keeping the overall process straightforward.
Solution Approach 2:
Complex shapes and features are formed at the forming station before the blank is transferred to the heating station. This preliminary forming action enables the manufacture of complex features without requiring the heating process to be complicated, maintaining process straightforwardness while achieving shape versatility.
3Reliability
If virgin material is used for manufacturing, then the material quality is consistent, but waste is generated and recycled materials cannot be utilized
Solution Approach 1:
The system is designed to accept both virgin material and recycled material as input to the forming station. Recycled material can be formed into blanks and then heated, allowing waste reduction while maintaining the ability to use consistent virgin material when needed. This dual-input capability reduces material waste without compromising quality consistency.
Solution Approach 2:
The heating station can process different material types (virgin or recycled) by adjusting heating parameters. This parameter flexibility allows the system to maintain material quality consistency regardless of whether virgin or recycled material is used, thereby reducing waste while preserving reliability.
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 reduces waste by utilizing recycled materials and enables the creation of more complex features in the final workpiece, optimizing material use and maintaining heat for improved formation in the final shaping station.
Implementation Method 1
heating a pre-formed blank of a first fiber reinforced thermoplastic material in an oven
Implementation Method 2
the sheet is heated to nearly the melting point of the thermoplastic
Implementation Method 3
A second fiber reinforced thermoplastic material is heated in an extruder
Implementation Method 4
The second fiber reinforced thermoplastic material is extruded from the extruder to form an extrudate
Data Source
AI summary
A method of manufacturing a workpiece includes heating a pre-formed blank of a first fiber reinforced thermoplastic material in an oven. A second fiber reinforced thermoplastic material is heated in an extruder. The second fiber reinforced thermoplastic material is extruded from the extruder, within the oven, to form an extrudate. The extrudate is positioned on the pre-formed blank of the first fiber reinforced thermoplastic material, within the oven, to form a composite blank. The extrudate may be formed into a shape before being positioned onto the pre-formed blank, after being positioned onto the pre-formed blank. The composite blank may then be transferred to a final shaping station.