Thermoplastic Resin Fiber Reinforcement Process
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Solution Overview
Problem
Conventional methods for producing fiber-reinforced components, such as those used in automobile and electrical equipment components, involve multiple steps and poor energy efficiency, limiting the productivity benefits of combining press molding and injection molding techniques.
Innovation Solution
A production method that involves forming a melt of thermoplastic resin in a lower die, placing a mat-shaped reinforcing fiber material on it, impregnating, and solidifying, followed by injection molding to create a main body part and additional features, allowing for high fiber content and length in the final product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a press molding method is used to produce fiber-reinforced components with long fiber length and high fiber content, then the strength and isotropic properties are improved, but the productivity and energy efficiency deteriorate due to multiple steps and complex processes
Solution Approach 1:
The patent combines press molding and injection molding into a single integrated process. The press molding step forms the main body part with long fiber reinforcement, while the injection molding step adds additional parts in the same cycle. This merging eliminates the need for separate production steps and post-assembly operations, thereby improving productivity while maintaining the strength benefits of press molding.
Solution Approach 2:
The press molding step performs preliminary action by forming the main body part with long fiber reinforcement and high strength properties before the injection molding step adds additional features. This preliminary formation of the core structure allows the subsequent injection molding to focus only on adding supplementary parts, reducing overall process time and improving productivity.
2Length of moving object
If multiple production steps are used to combine press molding and injection molding, then the fiber length and content are improved, but the energy consumption and process complexity increase
Solution Approach 1:
The patent merges press molding and injection molding into a single integrated process that operates in one continuous cycle. The press molding step and injection molding step are performed sequentially within the same equipment setup without removing the workpiece, eliminating the need for separate heating, pressing, and molding cycles. This reduces cumulative energy consumption while achieving both long fiber length and high fiber content.
3Ease of manufacture
If conventional separate production methods are used for main body part and additional parts, then the manufacturing simplicity is maintained, but the fiber content and length in the final component are reduced
Solution Approach 1:
The patent combines the production of main body part and additional parts into a single integrated molding process. The press molding step forms the main body part with high fiber content, and the injection molding step adds additional parts with fiber reinforcement in the same cycle. This merging ensures that both parts achieve high fiber content and long fiber length without requiring separate production processes.
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 efficiently produces fiber-reinforced components with long average fiber length and high fiber content, enhancing productivity and physical properties while minimizing energy consumption and step complexity.
Implementation Method 1
the mat-shaped material impregnated with the thermoplastic resin is cooled and solidified, whereby a main body part obtained from a fiber-reinforced resin is molded
Implementation Method 2
an upper die for pressing is closed on the lower die and is pressed, and an impregnation treatment is performed
Data Source
Figure 1(a)~3(b)
AI summary
This production method for fiber reinforcing members has: a step (1) in which a molten body of thermoplastic resin is formed in a lower mold, a mat-shaped material formed from a reinforcing fiber (B) is placed upon the molten body, an upper mold for pressurizing is closed on the lower mold, pressure is applied thereto and impregnation processing performed, then the resin-impregnated mat-shaped material is cooled and solidified, and a main body section formed from the fiber-reinforcing resin is formed; and a step (2) in which the upper mold for pressurizing is opened, an upper mold for injection molding is closed on the lower mold and an injection molding mold is formed, injection molding is then performed and an additional part is formed, and a fiber reinforcing member having the additional part combined with the main body section is molded.