Molding system for preparing an injection molded fiber reinforced composite article

A molding system for preparing an injection-molded fiber-reinforced composite article, comprising:

• a mold having a mold cavity;
• a molding machine configured to fill the mold cavity with a composite molding resin including a polymeric material having a plurality of fibers;
• a computing apparatus connected to the molding machine, wherein the computing apparatus is configured to generate a previous orientation distribution of the fibers in the mold cavity based on a molding condition for the molding machine, a rotary diffusional distribution of the fibers based on the previous orientation distribution of the fibers, and an updated orientation distribution of the fibers based on the rotary diffusional distribution of the fibers;
• and
• a controller connected to the computing apparatus and configured to control the molding machine with the molding condition to perform an actual molding for injecting the composite molding resin into at least a portion of the mold cavity;
• wherein the rotary diffusional distribution of the fibers is represented using an expression:
• Dr=CIR{circumflex over (d)}rRT
• R=[e1,e2,e3]
• d
• ^
• r
• =
• [
• d
• 1
• 0
• 0
• 0
• d
• 2
• 0
• 0
• 0
• d
• 3
• ]
• where CI represents an inter-fiber interaction, Dr represents the rotary diffusional distribution of the fibers, R represents eigenvalues of the previous orientation distribution of the fibers, RT represents a transpose of R, and d1, d2, d3 represents probability ratios of the fibers lying along three orthogonal directions.

A molding system for preparing an injection-molded fiber-reinforced composite article, comprising:

• a mold having a mold cavity;
• a molding machine configured to fill the mold cavity with a composite molding resin including a polymeric material having a plurality of fibers;
• a computing apparatus connected to the molding machine, wherein the computing apparatus is configured to generate a previous orientation distribution of the fibers in the mold cavity based on a molding condition for the molding machine, a rotary diffusional distribution of the fibers based on the previous orientation distribution of the fibers, and an updated orientation distribution of the fibers based on the rotary diffusional distribution of the fibers;
• and
• a controller connected to the computing apparatus and configured to control the molding machine with the molding condition to perform an actual molding for injecting the composite molding resin into at least a portion of the mold cavity;
• wherein the rotary diffusional distribution of the fibers is represented using an expression:
• Dr=CIR{circumflex over (d)}rRT
• d
• ^
• r
• =
• [
• 1
• 0
• 0
• 0
• Ω
• 0
• 0
• 0
• 1
• -
• Ω
• ]
• where CI represents an inter-fiber interaction, Dr represents the rotary diffusional distribution of the fibers, R represents eigenvalues of the previous orientation distribution of the fibers, RT represents a transpose of R, Ω is a constant, and 0.5≤Ω≤1.

A molding system for preparing an injection-molded fiber-reinforced composite article, comprising:

• a mold having a mold cavity;
• a molding machine configured to fill the mold cavity with a composite molding resin including a polymeric material having a plurality of fibers;
• a computing apparatus connected to the molding machine, wherein the computing apparatus is configured to generate a previous orientation distribution of the fibers in the mold cavity based on a molding condition for the molding machine, a rotary diffusional distribution of the fibers based on the previous orientation distribution of the fibers, and an updated orientation distribution of the fibers based on the rotary diffusional distribution of the fibers;
• and
• a controller connected to the computing apparatus and configured to control the molding machine with the molding condition to perform an actual molding for injecting the composite molding resin into at least a portion of the mold cavity;
• wherein the rotary diffusional distribution of the fibers is independent of a velocity distribution of the composite molding resin in the mold cavity.