Variable Cross-Section Filler for Composite Beam Wedge Gaps
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Solution Overview
Problem
Existing methods for producing beam members with reinforcing fiber base materials face inefficiencies in creating shaped fillers for wedge gaps, particularly when the cross-sectional surface shape changes continuously along the longitudinal direction, leading to strength reduction and delamination issues due to the need for multiple dies and complex processes.
Innovation Solution
A process and apparatus that uses a filler member with reinforcing fibers configured as a flat sheet or strand, combined with an adhesive resin, to form a shaped filler that can be continuously produced and adapted to varying wedge gaps, allowing for efficient filling and integration with the beam member, using a preshaping mold to adjust the filler's shape and density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a shaped filler with constant cross-sectional surface area is used, then the production process is simplified, but gaps remain in some places or fiber density becomes excessive leading to strength reduction and delamination
Solution Approach 1:
The patent applies the dynamics principle by making the cross-sectional surface area of the shaped filler variable along its longitudinal direction. The filler is designed with a cross-sectional surface area that changes continuously or in stages to match the varying wedge gap dimensions, transforming a static constant-area design into a dynamic adaptive design that maintains optimal fiber density and gap filling precision throughout the entire filler length
Solution Approach 2:
The patent applies local quality by creating different cross-sectional surface areas at different positions along the filler's longitudinal direction. Each section of the filler has a locally optimized cross-sectional area that corresponds to the local wedge gap dimensions, ensuring appropriate fiber density and gap filling precision at each specific location rather than using a uniform design throughout
2Manufacturing precision
If multiple dies are used to produce shaped fillers for varying wedge gaps, then manufacturing precision is improved, but device complexity and production time increase
Solution Approach 1:
The patent applies universality by designing a single die that can produce shaped fillers with variable cross-sectional surface areas. This single multi-functional die replaces the need for multiple specialized dies, each designed for a specific gap size. The die is configured to create fillers whose cross-sectional area varies along the longitudinal direction, allowing one die to perform what previously required multiple dies, thereby reducing device complexity while maintaining manufacturing precision
3Productivity
If a shaped filler with constant cross-sectional surface area is used, then production efficiency is maintained, but strength and structural integrity are reduced due to gaps and delamination
Solution Approach 1:
The patent applies dynamics by transitioning from a static constant cross-sectional area design to a dynamic variable cross-sectional area design. The filler's cross-sectional surface area changes along its longitudinal direction to match the varying wedge gap dimensions, ensuring complete gap filling without voids or excessive fiber density. This dynamic adaptation maintains production efficiency while significantly improving junction strength and preventing delamination by achieving optimal fiber distribution throughout the filler structure
Data Source
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AI summary
The present invention is to produce a shaped filler to be filled in a gap continuously and efficiently in producing the beam member made of the reinforcing fiber base material, even in the case where a cross-sectional surface of the gap having a wedge shape formed at a branching point of a reinforcing fiber base materials changes in a longitudinal direction of the beam member, at a cross-sectional surface orthogonal to the longitudinal direction of the beam member. For the objective, a process for producing a beam member formed by a reinforcing fiber base material which has a web portion and at least a pair of flange portions extending to both sides via at least a branching point from the web portion, at a cross-sectional surface orthogonal to a longitudinal direction of the beam member, and by a shaped filler which fills a gap having a wedge shape formed at the branching point, is provided, wherein the shaped filler is produced by at least the following production processes (A) to (C): (A) a filler supply process for supplying a filler member configured by reinforcing fibers; (B) a preshaping process for providing a preshaped filler having at least a wedge projection portion, by pressurizing the filler member by a preshaping mold; and (C) a filler deforming process for providing a shaped filler by deforming the preshaped filler, by filling the preshaped filler into the gap and by pressurizing the preshaped filler such that a tip of the wedge projection portion is directed to a tip of the gap having a wedge shape.