Fiber-Reinforced Truck Beam Web Structure for Mold Flow Control
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Solution Overview
Problem
Fiber-reinforced plastic materials are difficult to process into structural components like beams due to issues such as short fill and warpage, resulting in high scrap rates and inefficiencies in manufacturing.
Innovation Solution
A structural part for trucks featuring a beam with a I-shaped cross-section, where the web thickness varies, including a larger second portion between two thinner portions, acting as a flow leader for molten material during molding, and a mold design with draft angles for easy opening, allowing for improved injection and reduced viscosity-related issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If fiber-reinforced plastic materials are used to manufacture beam-shaped structural components, then the weight of the vehicle is decreased, but the manufacturing process becomes difficult due to short fill and warpage issues
Solution Approach 1:
The web thickness is varied locally along its length, with a first portion having a first thickness, a second portion having a second thickness greater than the first, and a third portion having a third thickness greater than the second. This local variation in thickness creates flow leaders that guide molten material through difficult-to-fill regions, resolving the short fill issue while maintaining the weight benefits of fiber-reinforced plastic
Solution Approach 2:
The invention changes the geometric parameter of web thickness along its length to optimize both manufacturability and structural performance. By increasing thickness at specific locations (creating the enlarged second portion), the design facilitates molten material flow and reduces warpage, enabling successful manufacturing of fiber-reinforced plastic beams
2Weight of moving object
If fiber-reinforced plastic materials are used for structural beams, then weight is reduced, but the scrap rate increases due to processing difficulties
Solution Approach 1:
The variable web thickness design with an enlarged second portion acts as a flow leader that guides molten material through the mold cavity, ensuring complete filling and reducing defects. This eliminates the short fill and warpage issues that previously caused high scrap rates, making fiber-reinforced plastic beams manufacturable with acceptable yield
Solution Approach 2:
The enlarged second portion is designed in advance to anticipate and prevent filling problems before they occur during injection. By pre-positioning the flow leader geometry, the design ensures smooth material flow and complete mold filling, preventing short fills and reducing scrap
3Ease of manufacture
If the web thickness is increased to improve material flow, then manufacturing becomes easier, but the structural properties may be compromised
Solution Approach 1:
The web thickness is optimized locally rather than uniformly increased. The enlarged second portion provides enhanced material flow and structural reinforcement where needed, while the first and third portions maintain thinner dimensions to preserve overall structural efficiency and prevent excessive weight gain
Solution Approach 2:
Instead of uniformly increasing web thickness throughout, the invention varies thickness along the longitudinal dimension of the web. This dimensional variation creates flow leaders that improve manufacturing while maintaining structural integrity through strategic thickening only where required for both flow and strength
Data Source
AI summary
A structural part for a truck, comprising a beam made of fiber-reinforced plastic, the beam having a I-shaped cross-section, the beam comprising a web extending from a first flange to a second flange, in which a cross-section of the web comprises a first portion with a first thickness; a second portion with a second thickness, the second thickness being larger than the first thickness; and a third portion with a third thickness, the third thickness being smaller than the second thickness, in which the second portion is located between the first portion and the third portion.