Thermoplastic Fork Stiffness via Fluid Injection Molding
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Solution Overview
Problem
Existing methods for manufacturing two-wheel fork components from thermosetting plastics are costly and non-recyclable, and thermoplastic materials lack the necessary stability and stiffness for safety-critical applications.
Innovation Solution
A method using plastic injection molding and fluid injection processes to produce a thermoplastic fork with a cavity, where a fluid displaces the plastic core to create a tubular geometry with enhanced stiffness and reduced cooling time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermosetting plastics are used to manufacture fork components, then the required stability and stiffness are achieved, but the manufacturing costs are high and the materials cannot be recycled
Solution Approach 1:
The patent changes the material parameter from thermosetting plastic to thermoplastic, which fundamentally alters the material's recyclability and cost characteristics while maintaining structural performance through optimized geometry and reinforcement
Solution Approach 2:
The patent creates a composite structure by combining thermoplastic material with glass fiber and/or carbon fiber reinforcements, achieving the stiffness and strength previously only attainable with thermosetting plastics while maintaining the recyclability and cost advantages of thermoplastics
2Ease of manufacture
If pure thermoplastic material is used for the fork, then manufacturing costs are reduced and recyclability is improved, but the torsional and bending stiffness are insufficient for safety requirements
Solution Approach 1:
The patent applies composite materials by embedding glass fiber and/or carbon fiber within the thermoplastic matrix, creating a reinforced composite structure that achieves the required torsional and bending stiffness while maintaining the cost and recyclability benefits of thermoplastic materials
Solution Approach 2:
The patent applies local quality by strategically placing fiber reinforcements in specific regions of the fork where strength and stiffness are most critical, such as the tube walls and connection areas, rather than uniformly throughout the entire component
3Strength
If a solid thermoplastic fork is manufactured, then the required strength is achieved, but the manufacturing time is increased due to longer cooling periods
Solution Approach 1:
The patent segments the fork structure by creating a hollow interior with cavities instead of a solid cross-section, which reduces the volume of material that requires cooling while maintaining structural strength through the reinforced tube walls
Solution Approach 2:
The patent transitions from a solid three-dimensional structure to a hollow tubular structure, utilizing the dimensional change to reduce material volume and cooling requirements while maintaining strength through optimized wall thickness and fiber reinforcement
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 method significantly reduces manufacturing costs and time, enhances the stiffness and safety of the fork, and allows for easy recycling of thermoplastic materials.
Implementation Method 1
cooling the injection molded component
Implementation Method 2
injecting at least one fluid into the closed injection molding tool in order to displace the plastic core out of the interior of the fork
Data Source
AI summary
The invention relates to a method for producing a fork which has at least one cavity in the interior and which is made of a thermoplastic for a two-wheeled vehicle by means of a plastic injection molding process and a fluid injection process, having the following steps: closing a configured injection molding tool; injecting a plasticized plastic melt into the closed injection molding tool; injecting at least one fluid into the closed injection molding tool in order to displace the plastic core out of the interior of the fork or in order to fill at least one molding cavity which is introduced into the injection molding tool; cooling the injection molded component; and opening the injection molding tool and removing the fork.