• Journal of the Korean Society of Manufacturing Process Engineers
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• v.16 no.3
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• pp.24-29
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• 2017

In this study, a seat cross member was fabricated by optimizing the resin transfer molding processing of CFRP (Carbon Fiber Reinforced Plastics) materials. This seat cross member is used in automotive underbody parts and provides side impact support. The seat cross was manufactured via vacuum resin transfer molding. The process included 1min of resin injection, 8 mins of heating, and 1 min of cooling, for a total molding time of 10mins. Tensile test results showed an average breaking load of 21.50kN, a tensile strength of 404 MPa, and an elastic modulus of 46.2 GPa. As a result, the CFRP seat cross provides the same strength as a similar steel part, but weighs 42% less.

• Advanced Composite Materials
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• v.18 no.2
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• pp.135-152
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• 2009

Liquid molding processes, such as resin transfer molding, involve resin flow through a porous medium inside a mold cavity. Numerical analysis of resin flow and mold filling is a very useful means for optimization of the manufacturing process. However, the numerical analysis is quite time consuming and requires a great deal of effort, since a separate numerical calculation is needed for every set of material properties, part size and injection conditions. The efforts can be appreciably reduced if similarity solutions are used instead of repeated numerical calculations. In this study, the similarity relations for pressure, resin velocity and flow front propagation are proposed to correlate another desired case from the already obtained numerical result. In other words, the model gives a correlation of flow induced variables between two different cases. The model was verified by comparing results obtained by the similarity relation and by independent numerical simulation.

• Transactions of Materials Processing
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• v.11 no.8
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• pp.651-667
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• 2002

Overview of plastics processing is described and the research trend of the processing is also noted. The main manufacturing processes in the plastics industry are injection molding, blow molding, compression molding, transfer molding, extrusion and thermoforming. The principles of those processes have been discussed and molds for shaping operation have been mentioned. References for each process have also been presented.

• Proceedings of the Korean Society For Composite Materials Conference
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• 2001.05a
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• pp.189-192
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• 2001

Resin transfer molding process has been widely used in the automobile industry, because the product with large area can be manufactured easily and the cost for the manufacturing is lower than that of compression molding and hand lay up method. Since RTM process is suitable for large bus housing panels, in this work, the composite housing panel was manufactured by RTM process and the mechanical properties, surface quality and the condition of manufacturing process were studied.

• Advanced Composite Materials
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• v.16 no.3
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• pp.207-221
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• 2007

The filling process of resin injection/compression molding (I/CM) can be divided into injection and compression phases. During the resin injection the mold is kept only partially closed and thus a gap is present between the reinforcements and the upper mold. The gap results in preferential flow path. After the gap is filled with the resin, the compression action initiates and forces the resin to penetrate into the fiber preform. In the present study, the resin flow in the gap is simplified by using the Stokes approximation, while Darcy's law is used to calculate the flow field in the fiber mats. Results show that most of the injected resins enter into the gap during the injection phase. The resin injection time is extremely short so the duration of the filling process is determined by the final closing action of the mold cavity. Compared with resin transfer molding (RTM), I/CM process can reduce the mold filling time or injection pressure significantly.

• Proceedings of the Korean Vacuum Society Conference
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• 2013.02a
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• pp.634-634
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• 2013

Transfer molding methods have a problem that weak adhesion between nanostructures and substrates. It is important to make various nano scale applications, also the stability of nanostructure on substrate is related with device performance. We studied an effect of poly 4-vinylphenol (PVP) as the polymeric adhesion layer between organic nanowires and a Si substrate when the nanowires are transferred by liquid-bridge-mediated nanotransfer molding method (LB-nTM). Their structural stability was examined by optical microscopy, scanning electron microscopy as multiple transfer molding and washing process. Field-effect transistors were fabricated with organic semiconductor nanowires on a polymeric adhesion layer and their electrical properties showed no significant difference as the one without the adhesion layer. As a result, adhesion layer can be used in the washing process and making multi-layer nano-scale patterns.

• Composites Research
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• v.18 no.4
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• pp.35-43
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• 2005

In resin transfer molding(RTM), race-track effects and non-uniform fiber volume fraction may cause undesirable resin flow patterns and thus result in dry spots, which affect the mechanical properties of the finished parts. In this study, a real time RTM control strategy to reduce these unfavorable effects is proposed. This control rule is accomplished by means of the permeability mapping and pressure regulation. Through numerical simulations, the validity of the proposed scheme is demonstrated.

• Fibers and Polymers
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• v.4 no.3
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• pp.135-144
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• 2003

Permeability of the preform is one of key factors in design of RTM (Resin Transfer Molding) mold, determination of processing conditions, and modeling of flow in the mold. According to previous studies, permeability measured in the unsaturated fiber mats are higher than that in the saturated fiber mats by about 20% because of the capillary pressure. In this study, permeabilities of several fiber preforms are measured for both saturated and unsaturated flows. A saturated experiment of radial flow has been adopted to measure the permeability of anisotropic fiber preforms with high fiber content, i.e., circular braided preforms. In this method, four pressure transducers are used to measure the pressure distribution. Permeabilities in different directions are determined and the experimental results show a good agreement with the theory. Since permeability is affected by the capillary effect, permeability should be measured in the unsaturated condition for the textile composites to be manufactured under lower pressure as in the Vacuum Assisted Resin Transfer Molding (VARTM).

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.09a
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• pp.9-12
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• 2005

The rapid thermal response (RTR) molding is a novel process developed to raise the temperature of mold surface rapidly to the polymer melt temperature prior to the injection stage and then cool rapidly to the ejection temperature. The resulting filling process is achieved inside a hot mold cavity by prohibiting formation of frozen layer so as to enable thin wall injection molding without filing difficulty. The present work covers flow simulation of thin wall injection molding using the RTR molding process. In order to take into account the effects of thermal boundary conditions of the RTR mold, coupled analysis with transient heat transfer simulation is suggested and compared with conventional isothermal analysis. The proposed coupled simulation approach based on solid elements provides reliable thin wall flow estimation fur both the conventional molding and the RTR molding processes

• Proceedings of the Korean Society For Composite Materials Conference
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• 2001.05a
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• pp.176-179
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• 2001

When the preform is composed of more than two layers with different in-plane permeability in resin transfer molding, effective average permeability should be determined for the flow analysis in the mold. The most frequently used averaging scheme is the weighted average scheme, but it does not account for the transverse flow between adjacent layers. A new averaging scheme is proposed predicting the effective permeability of the multi-layered preform, which accounts for the transverse flow effect. The new scheme is verified by measuring the effective permeability of the multi-layered preforms and the difference in each flow front position.