Thermoplastic Injection Molded Element With Integral Positioning System
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Solution Overview
Problem
Current manufacturing methods for structural elements, especially in aircraft/aerospace, face challenges in achieving consistent high strength-to-weight ratios due to inconsistent fiber distribution in fiber-reinforced resin molding, leading to weak spots and increased costs, which are not compatible with low-cost, high-volume manufacturing methodologies.
Innovation Solution
The development of a thermoplastic injection molded element with an integral thermoplastic positioning system (ITPS) that positions reinforcing fibers within a thermoplastic material, providing structural support and consistent fiber distribution, allowing for the use of injection molding to form the element with a composite-ITPS assembly and encapsulating thermoplastic, all made from the same thermoplastic material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fiber reinforced resin molding is used to form structural elements, then high strength-to-weight ratio is achieved, but inconsistent fiber distribution occurs leading to weak spots and reduced manufacturing reliability
Solution Approach 1:
The structural element is divided into discrete fiber bundles that are individually positioned and then joined together. This segmentation allows each fiber bundle to be independently placed in the correct location, ensuring consistent fiber distribution and eliminating the random fiber placement problems of traditional resin molding while maintaining high strength-to-weight ratio.
Solution Approach 2:
Fiber bundles are pre-positioned in their final locations within the mold cavity before resin injection. This preliminary positioning action ensures that fibers are correctly oriented and distributed before the molding process begins, eliminating the inconsistent fiber distribution and weak spots that occur with traditional methods.
2Ease of manufacture
If traditional fiber reinforced resin molding is used, then structural elements can be formed, but knit or meld lines occur at apertures causing significant strength reduction
Solution Approach 1:
Fiber bundles are pre-positioned around aperture locations before resin injection, ensuring continuous fiber reinforcement through the aperture area. This preliminary positioning prevents the formation of knit or meld lines by maintaining proper fiber orientation and distribution even in complex geometric areas, thereby preserving strength at critical aperture locations.
3Strength
If metal elements are used for structural support, then high strength-to-weight ratio is achieved, but extensive machining is required increasing cost and manufacturing time
Solution Approach 1:
The manufacturing process transitions from metal machining to thermoplastic molding by changing the material parameter. This allows structural elements to be formed through injection molding rather than extensive machining, dramatically increasing production speed and reducing costs while maintaining high strength-to-weight ratio through optimized fiber reinforcement.
Solution Approach 2:
The invention uses composite materials (thermoplastic matrix with reinforcing fibers) instead of metal alloys. This composite approach enables high strength-to-weight ratio comparable to metals while allowing for efficient injection molding manufacturing, eliminating the need for time-consuming machining operations and enabling high-volume production.
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 enables the production of elements with consistent structural support, reduced anomalies, and lower production costs, making it compatible with low-cost, high-volume manufacturing while maintaining high strength-to-weight ratios.
Implementation Method 1
injection molding an integral thermoplastic positioning system ('ITPS') onto the composite to form a composite-ITPS assembly; and injection molding an encapsulating thermoplastic onto the composite-ITPS assembly
Data Source
AI summary
Disclosed embodiments may relate generally to manufactured elements having composite reinforcement, and more specifically to elements comprising a composite precisely positioned within the element for support. Embodiments of such elements typically may be formed using injection molding. Embodiments may further comprise an integral thermoplastic positioning system for positioning the composite, and encapsulating thermoplastic forming the exterior geometry of the element.