Three-Roller Composite Shaping for Noodle Fillers
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Solution Overview
Problem
Conventional methods for shaping composite materials like glass fiber reinforced plastics and carbon fiber reinforced plastics, particularly for forming bar-shaped fillers such as noodle fillers, face challenges including long shaping times, the need for complex molds, and difficulties in achieving satisfactory quality, especially with vacuum pressure and extrusion molding techniques.
Innovation Solution
A composite material shaping device utilizing three rollers that apply pressure from different angles to shape laminated prepregs, allowing for uniform compression and forming of noodle fillers with a cross-sectional shape surrounded by symmetrical arcs and a straight line, which can be achieved with a simpler setup compared to traditional methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vacuum pressure shaping method is used, then shaping quality is improved, but shaping period becomes long (several hours to one day)
Solution Approach 1:
The shaping process is segmented into multiple stages using different roller configurations. The first shaping stage uses a simple roller to reduce overall dimensions, and the second shaping stage uses a specialized roller to form the precise final shape, eliminating the need for long vacuum shaping periods
Solution Approach 2:
The first shaping roller performs preliminary shaping to reduce the laminated body dimensions before the second shaping roller creates the final precise shape. This preliminary action reduces the work required in subsequent shaping stages, significantly shortening total shaping time
2Manufacturing precision
If extrusion molding device is used, then shaping capability is improved, but device scale becomes large due to great shaping resistance
Solution Approach 1:
The shaping process is divided into two stages with different rollers. The first roller performs rough shaping to reduce dimensions, and the second roller performs precise shaping. This segmentation reduces the shaping resistance at each stage, eliminating the need for large-scale extrusion molding devices
Solution Approach 2:
The invention replaces the complex extrusion molding mechanical system with a simpler roller-based pressing system. The rollers apply controlled pressure to shape the laminated body through friction and compression, substituting the need for large-scale extrusion equipment
3Productivity
If rollers are used for shaping, then shaping resistance is reduced, but shaping quality becomes insufficient
Solution Approach 1:
The shaping function is segmented between two different rollers. The first shaping roller reduces overall dimensions with lower resistance requirements, while the second shaping roller with a specially designed surface creates the precise final shape, combining the advantages of both approaches
Solution Approach 2:
The second shaping roller has a locally optimized surface that corresponds to the target shape, allowing precise shaping only where needed. This local quality approach ensures high shaping quality without requiring the entire system to overcome high shaping resistance
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 high-quality shaping of prepregs in a shorter time without the need for vacuum pressure or large-scale devices, providing uniform compression and improved material handling, thus enhancing the shaping process efficiency and quality.
Implementation Method 1
three rollers that apply pressures on a laminated body of prepregs, from different angles
Implementation Method 2
allowing for uniform compression and forming of noodle fillers
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
According to one embodiment, a composite material shaping device includes three rollers that apply pressures on a laminated body of prepregs, from different angles. The prepregs are laminated in a bar shape. Further, according to one embodiment, a composite material shaping method includes applying pressures on a laminated body of prepregs, from different angles, using three rollers. The prepregs are laminated in a bar shape.