Vibrating Forming Tool for Uniform Compression of 3D Fiber Parts
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Solution Overview
Problem
Existing methods for manufacturing three-dimensional products from fiber-containing materials face challenges in achieving consistent mechanical properties and surface quality, particularly at inclined portions, due to reduced pressing force and poor heat transfer with flexible tools.
Innovation Solution
A method involving a forming tool with movable tool components and introduced vibrations during the pressing process to uniformly compress fiber-containing materials, ensuring homogeneous strength and surface properties across the entire product geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a fixed forming tool is used for pressing fiber-containing material, then the structure is simple and heat transfer is good, but the pressing force on inclined portions is insufficient leading to poor compression and strength
Solution Approach 1:
The patent introduces vibrations by moving the forming tool components relative to the pressing direction during the pressing process. This vibration causes the fiber-containing material to be repeatedly moved between the inner and outer tool surfaces, enhancing compression on inclined portions and improving strength without requiring flexible tools.
Solution Approach 2:
The forming tool components are made movable relative to each other during the pressing process, transitioning from a static pressing operation to a dynamic one. This allows the tool to adapt to the material flow and apply consistent pressing force on inclined surfaces while maintaining the simplicity of the fixed tool structure.
2Force
If flexible tools with inflatable inner tools are used to improve pressing force distribution, then pressing force is improved, but heat transfer deteriorates and product properties worsen
Solution Approach 1:
Instead of using flexible inflatable tools, the patent employs vibrations generated by movable forming tool components. This approach achieves improved pressing force distribution on inclined surfaces while maintaining the heat transfer efficiency of fixed tools, as the vibration mechanism does not require flexible materials that would impede thermal conduction.
3Manufacturing precision
If the forming tool components are made movable to introduce vibrations, then compression consistency is improved, but device complexity increases
Solution Approach 1:
The forming tool incorporates movable components that can be actuated during the pressing process to generate vibrations. This dynamic capability allows the tool to achieve consistent compression across all product surfaces while adding only minimal complexity to the overall device structure, as the movable components work in conjunction with the existing pressing mechanism.
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 enables the production of three-dimensional products with uniform strength and surface properties by uniformly compressing fibers using vibrations, eliminating the need for flexible tools and improving mechanical properties at inclined surfaces.
Implementation Method 1
introducing vibrations by moving the at least one first tool component and/or the at least one second tool component relative to the pressing direction during the pressing
Implementation Method 2
pressing the fiber-containing material within the mold cavity
Implementation Method 3
the inflatable inner tool, which must be made of a flexible material, can provide significantly poorer heat transfer
Data Source
AI summary
A method for manufacturing three-dimensional products with at least one inclined product portion made of a fiber-containing material using at least one forming tool and a forming tool are described. Vibrations are introduced via a device and this results in an improved compression of fiber-containing material in the region of inclined portions.