CN112318895B - Spatial light high-rigidity porous grid carbon fiber honeycomb, and preparation method and application thereof - Google Patents
Spatial light high-rigidity porous grid carbon fiber honeycomb, and preparation method and application thereof Download PDFInfo
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
- B29C70/342—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using isostatic pressure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
- B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
- B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
- B29C70/543—Fixing the position or configuration of fibrous reinforcements before or during moulding
Abstract
The invention provides a space light high-rigidity porous grid carbon fiber honeycomb, a preparation method and application, wherein the honeycomb cells are hexagonal cells surrounded by hole wall materials; the hole wall material is a porous carbon fiber fabric composite material, and the holes in the hole wall material are square holes arranged in a matrix manner. The preparation method comprises the steps of preparing ultrathin high-modulus carbon fiber unidirectional prepreg based on a fiber thinning technology, cutting the ultrathin high-modulus carbon fiber unidirectional prepreg to an extremely narrow prepreg block, weaving porous grid carbon fiber prepreg fabric as a carbon fiber honeycomb preparation raw material, preparing a mold by combining an upper mold/a lower mold, a group hexagonal core column and a side limit block in a random concave-convex fluctuation mode, sequentially and repeatedly paving the prepreg block and the hexagonal core column on the mold until the required honeycomb width is achieved, applying specific curing pressure suitable for honeycombs with different widths to complete integral co-curing of the assembly, further realizing the preparation of the lightweight high-rigidity porous carbon fiber honeycomb, and meeting the technical index requirements of the honeycombs on rigidity, air escape, temperature-resistant alternating environment and the like.
Description
Technical Field
The invention belongs to the technical field of core material manufacturing, and particularly relates to a light high-rigidity porous grid carbon fiber honeycomb for a space, a preparation method and application thereof.
Background
The carbon fiber honeycomb is a light high-performance designable novel structural core material and can meet the high precision of a structural systemThe requirements of high stability, high reliability and the like are typical embodiment of the structural advancement of the high-performance light composite material. The European and American countries have mature preparation technology on the materials and realize engineering application. The American HECEL company and the ULTRACOR company have the technical capability of manufacturing carbon fiber honeycombs with different carbon fibers, resin systems and designable different structural forms, and can complete customized and generally-required carbon fiber honeycomb products. According to the GSTP project of Europe (ESA), the company INVENT and HPS of Germany jointly develop a porous carbon fiber honeycomb for space use, the density of which reaches 31kg/m 3 The flat compressive strength is 0.9MPa, and the use requirement of the space environment is met. The all-carbon interlayer composite material prepared based on the light carbon fibers is applied to structures such as ExoMars Mars detector antennas, PLANK detector reflectors, STANT antenna systems and the like which are jointly developed in Europe, and is widely applied to American X-series aerospace vehicles, F-series high-performance airplanes and the like.
At present, aluminum honeycomb, paper honeycomb and glass fiber reinforced plastic honeycomb core materials commonly used for aerospace equipment are combined with a carbon fiber panel to manufacture a light composite material sandwich structural member, and due to the fact that thermal expansion coefficients of heterogeneous materials are not matched, the size stability and the profile precision of the structural member are reduced under the change of a service environment, even microcracks inside the structural member are caused to expand to cause structural damage of the structural member, and the structural system can not meet the use requirements of a novel spacecraft carrier represented by an aerospace aircraft. The carbon fiber honeycomb is adopted to prepare the all-carbon homogeneous sandwich composite material of the carbon skin/carbon honeycomb core, has more remarkable weight reduction effect and higher specific strength and specific rigidity, and meets the requirements of development and development of a novel spacecraft. However, domestic related research is almost not available, the research foundation is poor, and no commercialized carbon fiber honeycomb is available at present.
Disclosure of Invention
In order to solve the problems of distortion deformation, stress expansion and even structural damage of a traditional composite material honeycomb sandwich component in a space environment due to mismatching of thermal expansion coefficients of heterogeneous materials, the inventor of the invention carries out intensive research and provides a light high-rigidity porous grid carbon fiber honeycomb for a space, a preparation method and application.
The technical scheme provided by the invention is as follows:
in the first aspect, the carbon fiber honeycomb with the light high-rigidity porous grids is characterized in that the cells of the carbon fiber honeycomb are hexagonal cells surrounded by hole wall materials; the porous wall material is a porous carbon fiber fabric composite material, the holes in the porous wall material are square holes arranged in a matrix manner, the side length of each square hole is less than or equal to 2mm, and the laying direction of the porous carbon fiber fabric composite material and the longitudinal angle of the honeycomb are 0-60 degrees.
In a second aspect, a method for preparing a lightweight high-rigidity porous grid carbon fiber honeycomb is used for preparing the carbon fiber honeycomb of the first aspect,
step (1), adopting an ultrasonic guided fiber expansion method to thin the high-modulus carbon fiber tows, and compounding the high-modulus carbon fiber tows with a resin film layer to prepare the ultrathin carbon fiber prepreg, wherein the surface density of the prepreg is less than or equal to 80g/m 2 The mass content of the resin is controlled between 38 percent and 44 percent;
step (2), cutting the ultrathin high-modulus carbon fiber prepreg obtained in the step (1) on prepreg cutting equipment until the carbon fiber prepreg extremely narrow belt is formed, wherein the bandwidth is controlled within the range of 2-6 mm;
step (3), weaving the carbon fiber pre-impregnated extremely narrow belt obtained in the step (2) in a two-dimensional orthogonal weaving mode at the temperature of-10 ℃ according to the proportion of the side length/the bandwidth of a hole being less than or equal to 0.5 to obtain a carbon fiber pre-impregnated fabric with a meshed grid;
step (4), cutting the porous grid carbon fiber prepreg fabric to a required length according to the length requirement of the prepared honeycomb, and cutting the required number of porous grid carbon fiber prepreg blocks according to the width requirement of the honeycomb;
step (5), the porous grid carbon fiber prepreg block is laid and attached to a concave-convex fluctuating lower die along with the shape, the concave-convex fluctuating lower die is provided with a concave-convex molded surface matched with the honeycomb cells, the hexagonal core columns are sequentially placed into the cavities of the molded surface, and then a layer of porous grid carbon fiber prepreg block is laid and attached; the diameter of the inscribed circle of the hexagonal core column is consistent with that of the inscribed circle of the honeycomb cell;
step (6), repeating the process of placing the hexagonal core column and carrying out random laying and pasting on the porous grid carbon fiber prepreg blocks until the required honeycomb width is achieved, and finishing honeycomb laying and pasting to obtain a honeycomb prefabricated body; preferably, 3-6 layers of the porous grid carbon fiber prepreg blocks are laid and adhered to each other, and the hexagonal core column and the porous grid carbon fiber prepreg blocks are compacted and adhered to each other;
step (7), pressing a concave-convex fluctuating upper die on the honeycomb prefabricated part, fixing two sides of the tool by using a limiting block, and fastening by using a positioning screw; the honeycomb prefabricated body is characterized in that the concave-convex fluctuating upper die structure is provided with a concave-convex surface matched with the honeycomb cells, fastening holes sleeved with positioning screws are machined in two ends of the concave-convex fluctuating upper die and the concave-convex fluctuating lower die, and limiting blocks are positioned on the inner sides of the positioning screws and matched with the concave-convex fluctuating upper die and the concave-convex fluctuating lower die to limit the honeycomb prefabricated body;
step (8), applying curing pressure required by honeycombs with different widths to the honeycomb assembly obtained in the step (7), and finishing honeycomb curing according to a curing process of a resin matrix;
and (9) removing the tooling on the cured carbon fiber honeycomb to obtain the light high-rigidity porous grid carbon fiber honeycomb.
In a third aspect, the light high-rigidity perforated grid carbon fiber honeycomb of the first aspect or the preparation method of the space-used light high-rigidity perforated grid carbon fiber honeycomb of the second aspect is applied to the manufacturing aspect of a light composite material sandwich structure in the aerospace environment.
According to the light high-rigidity porous grid carbon fiber honeycomb for the space, the preparation method and the application, the carbon fiber honeycomb has the following beneficial effects:
(1) In the light high-rigidity porous grid carbon fiber honeycomb for space and the preparation method thereof, the hole wall material of the honeycomb is an ultrathin porous high-modulus carbon fiber fabric composite material, an innovative high-efficiency preparation method which is completely different from the traditional honeycomb preparation is adopted, namely, a random porous pre-impregnated fabric paving and pasting + honeycomb body and shaping integrated co-curing preparation process is adopted, the preparation of the light high-rigidity porous carbon fiber honeycomb is realized, and the technical index requirements of the honeycomb on rigidity, gas escape, temperature-resistant alternating environment and the like are met;
(2) In the light high-rigidity porous grid carbon fiber honeycomb for the space and the preparation method thereof, the carbon fiber in the carbon fiber honeycomb is high-modulus carbon fiber, and the resin matrix is toughened thermosetting resin which can resist the requirements of temperature alternation, vacuum quality loss, condensable volatile matters and the like in the space environment, so that the use requirement of the space environment is met;
(3) In the light high-rigidity porous grid carbon fiber honeycomb for the space and the preparation method thereof, the laying direction of the porous carbon fiber fabric composite material and the longitudinal angle (L) of the honeycomb are designed to be 0-60 degrees, particularly 0-45 degrees, the longitudinal angles are different, the compression and shearing properties of the corresponding honeycomb are different, and the mechanical property of the honeycomb can be adjusted;
(4) According to the light high-rigidity porous grid carbon fiber honeycomb for the space and the preparation method thereof, the size and the spacing of the holes above the hole wall material of the honeycomb are specially designed, so that the stability of the carbon fiber honeycomb is ensured while the weight is reduced;
(5) In the preparation method of the light high-rigidity porous grid carbon fiber honeycomb for the space, the precision forming of the carbon fiber honeycomb is effectively ensured through tool design, profile precision requirements and setting of a curing process;
(6) The light high-rigidity porous grid carbon fiber honeycomb for the space and the preparation method thereof solve the bottleneck problem of the light porous carbon fiber honeycomb, can realize the manufacture of a light high-rigidity sandwich composite structural member in a space environment, can also be converted and applied to high-performance honeycomb sandwich structural members of structural systems in other fields such as aviation airplanes, engines, high-speed rails and the like, can meet the development requirements of increasingly high-rigidity full-carbon sandwich composite structural members in China, and have outstanding innovativeness, economic benefit and prospect.
Drawings
Fig. 1 shows a schematic structural diagram of a light-weight high-rigidity porous grid carbon fiber honeycomb, wherein the laying direction of a porous carbon fiber fabric composite material and the longitudinal angle of the honeycomb are 45 degrees;
FIG. 2 shows a schematic structural diagram of a carbon fiber honeycomb manufacturing tool;
FIG. 3 shows a side view of a carbon fiber honeycomb preparation tool structure.
Description of the reference numerals
1-concave-convex fluctuating upper die; 2-concave-convex fluctuating lower die; 3-hexagonal core column; 31-a threaded blind hole; 4-a limiting block; 5-positioning the screw rod; 6-edging block.
Detailed Description
The features and advantages of the present invention will become more apparent and apparent from the following detailed description of the invention.
According to the first aspect of the invention, a light high-rigidity porous grid carbon fiber honeycomb is provided, and the cells of the carbon fiber honeycomb are hexagonal cells surrounded by a hole wall material; the hole wall material is a porous carbon fiber fabric composite material, holes in the hole wall material are square holes arranged in a matrix manner, and the side length of each square hole is less than or equal to 2mm; the diameters of the inscribed circles of the honeycomb cells and the thicknesses of the cell walls are adjusted in a matching mode according to structural performance requirements.
In a preferred embodiment of the invention, the carbon fiber honeycomb has a bulk density of 64kg/m or less 3 The diameter of the inscribed circle of the carbon fiber honeycomb cell is less than or equal to phi 15mm, and the thickness of the cell wall material is less than or equal to 0.2mm.
In a preferred embodiment of the present invention, the laying direction of the porous carbon fiber fabric composite material is at an angle of 0 ° to 60 °, preferably 0 ° or 45 °, to the longitudinal direction (L direction) of the honeycomb. When the laying direction of the porous carbon fiber fabric composite material and the longitudinal angle of the honeycomb are 0 degree, the square holes in two adjacent rows in the longitudinal angle of the honeycomb are aligned and arranged; when the laying direction of the porous carbon fiber fabric composite material and the longitudinal angle of the honeycomb are 0 degree, two adjacent rows of square holes in the longitudinal angle of the honeycomb are arranged in a staggered mode, as shown in figure 1.
In the invention, the pore wall material of the carbon fiber honeycomb is prepared by curing the porous grid carbon fiber prepreg fabric, wherein in the porous grid carbon fiber prepreg fabric, the resin matrix is toughened thermosetting resin with the requirements of temperature alternation, vacuum quality loss, condensable volatile matters and the like in a space environment resistance; specifically, the vacuum quality loss of the resin matrix is less than or equal to 1.0 percent, the condensable volatile matter is less than or equal to 0.5 percent, the resin matrix is preferably any one or more of toughened epoxy resin or cyanate resin, and the carbon fiber is selected from any one or more of M40, M55 and M65-grade high-modulus carbon fiber.
Preferably, the porous grid carbon fiber prepreg fabric is prepared by the following steps:
step (1), adopting an ultrasonic guided fiber expansion method to thin the high-modulus carbon fiber tows, and compounding the high-modulus carbon fiber tows with a resin film layer to prepare the ultrathin carbon fiber prepreg, wherein the surface density of the prepreg is less than or equal to 80g/m 2 The resin mass content is controlled between 38 percent and 44 percent;
step (2), cutting the ultrathin high-modulus carbon fiber prepreg obtained in the step (1) on prepreg cutting equipment until the carbon fiber prepreg extremely narrow belt is formed, wherein the bandwidth is controlled within the range of 2-6 mm;
and (3) weaving the carbon fiber pre-impregnated extremely narrow belt obtained in the step (2) in a two-dimensional orthogonal weaving manner under a lower temperature condition (-10 ℃ temperature interval) according to the proportion of the side length/the bandwidth of the hole being less than or equal to 0.5, so as to obtain the carbon fiber pre-impregnated fabric with the porous grid.
Preferably, the perforated mesh carbon fiber prepreg weaving form comprises a plain weave, a twill weave, a satin weave, i.e. the weaving form of the perforated carbon fiber fabric composite material comprises a plain weave, a twill weave, a satin weave.
According to a second aspect of the invention, a preparation method of a lightweight high-rigidity meshed carbon fiber honeycomb is provided, which is used for preparing the lightweight high-rigidity meshed carbon fiber honeycomb, and comprises the following steps:
step (1), adopting an ultrasonic guide fiber expansion method to thin a high-modulus carbon fiber tow and compounding the high-modulus carbon fiber tow with a resin film layer to prepare an ultrathin carbon fiber prepreg, wherein the surface density of the prepreg is less than or equal to 80g/m 2 The mass content of the resin is controlled between 38 percent and 44 percent;
step (2), cutting the ultrathin high-modulus carbon fiber prepreg obtained in the step (1) on prepreg cutting equipment until the carbon fiber prepreg extremely narrow belt is formed, and controlling the bandwidth within the range of 2-6 mm;
step (3), weaving the carbon fiber pre-impregnated extremely narrow belt obtained in the step (2) in a two-dimensional orthogonal weaving manner under a lower temperature condition (-10 ℃ temperature interval) according to the proportion of the side length/the bandwidth of a hole being less than or equal to 0.5 to obtain a carbon fiber pre-impregnated fabric with a meshed grid;
step (4), cutting the porous grid carbon fiber prepreg fabric to the required length according to the length requirement of the prepared honeycomb, and cutting the required number of porous grid carbon fiber prepreg blocks according to the width (W) requirement of the honeycomb;
step (5), laying and pasting the porous grid carbon fiber prepreg block on a concave-convex lower die along with the shape, wherein the concave-convex lower die is provided with a concave-convex molded surface matched with the honeycomb cells, sequentially putting the hexagonal core column into a cavity of the molded surface, and then laying and pasting a layer of porous grid carbon fiber prepreg block; the diameter of the inscribed circle of the hexagonal core column is consistent with that of the inscribed circle of the honeycomb cell;
step (6), repeating the process of placing the hexagonal core column and carrying out random laying and pasting on the porous grid carbon fiber prepreg blocks until the required honeycomb width is achieved, and finishing honeycomb laying and pasting to obtain a honeycomb prefabricated body; preferably, 3-6 layers of the porous grid carbon fiber prepreg blocks are laid and adhered to each other, and the hexagonal core column and the porous grid carbon fiber prepreg blocks are compacted and adhered to each other;
step (7), pressing a concave-convex fluctuating upper die on the honeycomb prefabricated part, fixing two sides of the tool by using a limiting block, and fastening by using a positioning screw; the honeycomb prefabricated body is characterized in that the concave-convex fluctuating upper die structure is provided with a concave-convex surface matched with the honeycomb cell, two ends of the concave-convex fluctuating upper die and the concave-convex fluctuating lower die are provided with fastening holes sleeved with positioning screws, and limiting blocks are positioned on the inner sides of the positioning screws and matched with the concave-convex fluctuating upper die and the concave-convex fluctuating lower die to limit the honeycomb prefabricated body together;
step (8), applying curing pressure required by honeycombs with different widths on the honeycomb assembly obtained in the step (7), and finishing honeycomb curing according to a curing process of a resin matrix, so that the interface bonding performance of the cured honeycomb nodes is ensured, and the co-curing preparation of the light porous grid carbon fiber fabric honeycomb material body and shaping is realized;
and (9) removing the tooling on the cured carbon fiber honeycomb to obtain the light high-rigidity porous grid carbon fiber honeycomb which meets the use requirements of space environments such as rigidity, gas escape, temperature-resistant alternating environment and the like.
In a preferred embodiment of the present invention, in the step (5), the length of the working surface of the concave-convex undulating lower die is less than or equal to 2m, the accuracy of the length profile is less than or equal to 0.1mm, the accuracy of the width profile is less than or equal to 0.05mm, and the accuracy of the height of the concave-convex undulating lower die is less than or equal to 0.05mm.
In a preferred embodiment of the present invention, in step (5), edge-aligning stoppers are erected on the ends of the hexagonal pillars, and the edge-aligning stoppers are used to assist in aligning the ends of the hexagonal pillars in the group.
In a preferred embodiment of the invention, in the step (6), the length of the hexagonal core column is less than or equal to 300mm, the straightness is less than or equal to 0.05mm, and the corner angle R is less than or equal to R4; the length of the polygonal core column is not less than the width of the porous grid carbon fiber prepreg block.
Furthermore, threaded blind holes convenient to pull out are formed in two ends of the hexagonal core column.
In a preferred embodiment of the invention, in the step (7), the length of the working surface of the concave-convex fluctuating upper die is less than or equal to 2m, the precision of the length profile is less than or equal to 0.1mm, the precision of the width profile is less than or equal to 0.05mm, and the precision of the height of the concave-convex is less than or equal to 0.05mm.
In a preferred embodiment of the present invention, in the step (8), the curing process is performed in an autoclave or an oven, the curing temperature is 165-180 ℃, the curing time is 3-6 h, and the curing pressure is 0.2-1.2 MPa. Further, the curing pressure is adaptively adjusted according to the width (W) of the honeycomb, and when the W is less than or equal to 300mm, the curing pressure is 0.2 MPa-0.4 MPa; w is more than 300mm and less than or equal to 500mm, and the curing pressure is 0.3MPa to 0.6MPa; w is more than 500mm and less than or equal to 800mm, and the curing pressure is 0.5MPa to 0.8MPa; w is more than 800mm and less than or equal to 1000mm, and the curing pressure is 0.7MPa to 1.2MPa.
According to a third aspect of the invention, the application of the light high-rigidity meshed carbon fiber honeycomb in the first aspect or the preparation method of the light high-rigidity meshed carbon fiber honeycomb in the aspect of manufacturing a sandwich structure of a light composite material in a space environment is provided.
Examples
Example 1
A porous grid carbon fiber honeycomb with light weight and high rigidity for space is disclosed, wherein the honeycomb cells are porous grid hexagonal cells, and the side length of a square hole is 1mm; the hole wall material is a composite material prepared by curing a porous grid carbon fiber prepreg fabric, the carbon fiber of the honeycomb is M40-grade high-modulus carbon fiber, and the resin matrix is toughened epoxy resin which can resist the requirements of temperature alternation, vacuum quality loss, condensable volatile matters and the like in a space environment. The honeycomb density was 35kg/m 3 The diameter of the inscribed circle of the lattice is phi 10mm, and the thickness of the hole wall is 0.1mm; the porous carbon fiber fabric composite material is woven in a plain weave, and the laying direction of the porous carbon fiber fabric composite material and the longitudinal angle of the honeycomb are 45 degrees, as shown in figure 1.
The preparation method of the light high-rigidity porous grid carbon fiber honeycomb for the space comprises the following steps:
1) The high-modulus carbon fiber tows are thinned by adopting an ultrasonic guided fiber expansion method and are compounded with a resin film layer to prepare the ultrathin carbon fiber prepreg, and the surface density of the prepreg is 80g/m 2 The mass content of the resin is controlled between 38 percent and 44 percent;
2) Cutting the ultrathin high-modulus carbon fiber prepreg obtained in the step 1) on special prepreg cutting equipment until the carbon fiber prepreg extremely narrow belt bundle is obtained, wherein the bandwidth is 4mm;
3) Weaving the carbon fiber pre-impregnated extremely-narrow belt bundle obtained in the step 2) in a two-dimensional orthogonal weaving manner under a temperature condition (-10 ℃ -2 ℃) according to the proportion of the side length/the bandwidth of a hole being 0.25 to obtain a carbon fiber pre-impregnated fabric with a meshed grid;
4) As shown in fig. 2 and 3, the honeycomb preparation adopts a combined preparation tool of a conformal concave-convex fluctuation upper die 1, a concave-convex fluctuation lower die 2, a group hexagonal core column 3, a side limit block 4 and a positioning screw 5; the working surfaces of the concave-convex fluctuating upper die 1 and the concave-convex fluctuating lower die 2 have the length of 500mm, the length profile accuracy RMS of 0.05mm and the concave-convex height and width profile accuracy RMS of 0.05mm; the diameter of an inscribed circle of the hexagonal core column 3 is 10mm, the length is 160mm, the straightness is 0.03mm, and the corner R angle of the core column is R2; the limiting block 4 is fixed by a positioning screw, and threaded blind holes 31 convenient to pull and remove are formed in two ends of the hexagonal core column 3; the tool further comprises an edge aligning stop block 6, wherein the edge aligning stop block 6 is positioned at the tail end of the hexagonal core column 3 and used for aligning the tail ends of the hexagonal core columns 3 in groups;
5) Cutting the porous grid carbon fiber prepreg fabric obtained in the step 3) to a proper length according to the length requirement of honeycomb preparation, wherein the width of the prepreg fabric material block is 150mm; cutting the carbon fiber prepreg blocks with the meshes according with the honeycomb width requirement;
6) Laying and pasting the porous grid carbon fiber prepreg block obtained in the step 5) on the concave-convex fluctuating lower die manufactured in the step 4) along with the shape, sequentially placing the hexagonal core column into the concave cavity, and then laying and pasting a layer of prepreg cloth;
7) Placing a hexagonal core column in the newly formed cavity, repeating the process until the required honeycomb width W =200mm is achieved, and finishing honeycomb paving; each 3 layers of prepreg cloth are paved, and concave-convex up-and-down dies are adopted to compact and attach the hexagonal columns and the porous grid carbon fiber prepreg blocks;
8) Pressing the honeycomb prefabricated body obtained in the step 7) to a concave-convex fluctuating upper die, fixing two sides of the tool by using a limiting block, and fastening by using a positioning screw 5;
9) Putting the honeycomb assembly obtained in the step 8) into a hot-pressing tank for curing, wherein the curing temperature is 180 ℃, the curing time is 4 hours, and the curing pressure is 0.3MPa, so that co-curing preparation of the light porous grid carbon fiber fabric honeycomb material body and shaping is realized;
10 Removing the cured carbon fiber honeycomb tool to obtain the light high-rigidity porous grid carbon fiber honeycomb which meets the use requirements of space environments such as rigidity, gas escape, temperature-resistant alternating environment and the like. The honeycomb compression modulus reaches more than 100 MPa.
Example 2
A porous grid carbon fiber honeycomb with light weight and high rigidity for space is provided, the honeycomb cells are porous grid hexagonal cells, and the side length of a square hole is 0.5mm; the hole wall material is a composite material prepared by curing a porous grid carbon fiber prepreg fabric, the carbon fiber reinforcement of the honeycomb is M40-grade high-modulus carbon fiber, and the resin matrix isThe body is toughened epoxy resin which can resist the requirements of temperature alternation, vacuum quality loss, condensable volatile matters and the like in a space environment. The honeycomb density was 40kg/m 3 The diameter of the inscribed circle of the lattice is phi 8mm, and the thickness of the hole wall is 0.1mm; the porous carbon fiber fabric composite material is woven in a twill form, and the laying direction of the porous carbon fiber fabric composite material and the longitudinal angle of the honeycomb are 0 degrees.
The preparation method of the light high-rigidity porous grid carbon fiber honeycomb for the space comprises the following steps:
1) The high-modulus carbon fiber tows are thinned by adopting an ultrasonic guided fiber expansion method and are compounded with a resin film layer to prepare the ultrathin carbon fiber prepreg with the prepreg surface density of 75g/m 2 The resin mass content is controlled between 38% and 44%.
2) Cutting the ultrathin high-modulus carbon fiber prepreg obtained in the step 1) on special prepreg cutting equipment until the carbon fiber prepreg extremely narrow belt bundle is obtained, wherein the bandwidth is 3mm.
3) Weaving the carbon fiber pre-impregnated extremely narrow belt bundle obtained in the step 2) in a two-dimensional orthogonal weaving manner at a lower temperature of (-10 ℃ -0 ℃) according to the proportion of the side length/the bandwidth of a hole of 0.167 to obtain the carbon fiber pre-impregnated fabric with the mesh with the hole.
4) As shown in fig. 2 and 3, a combined preparation tool of a conformal concave-convex fluctuation upper die 1, a concave-convex fluctuation lower die 2, a group hexagonal core column 3 and a side limiting block 4 is adopted for honeycomb preparation; the working surfaces of the concave-convex fluctuating upper die 1 and the concave-convex fluctuating lower die 2 are 600mm in length, the length profile accuracy RMS is 0.05mm, and the concave-convex height and width profile accuracy RMS is 0.05mm; the diameter of an inscribed circle of the hexagonal core column 3 is 8mm, the length is 100mm, the straightness is 0.05mm, and the corner R angle of the core column is R2; the limiting block 4 is fixed by a positioning screw, and threaded blind holes 31 which are convenient to pull out are formed in two ends of the hexagonal core column 3; the tooling also comprises an edge aligning stop block 6, wherein the edge aligning stop block 6 is positioned at the tail end of the hexagonal core column 3 and is used for aligning the tail ends of the hexagonal core columns 3;
5) Cutting the porous grid carbon fiber prepreg fabric obtained in the step 3) to a proper length according to the length requirement of honeycomb preparation, wherein the width of the prepreg fabric material block is 100mm; cutting the carbon fiber prepreg blocks with the meshes according with the honeycomb width requirement;
6) Laying and pasting the porous grid carbon fiber prepreg block obtained in the step 5) on the concave-convex fluctuating lower die manufactured in the step 4) along with the shape, sequentially placing the hexagonal core column into the concave cavity, and then laying and pasting a layer of prepreg cloth;
7) Placing a hexagonal core column in the newly formed cavity, repeating the process until the required honeycomb width W =300mm is achieved, and finishing honeycomb paving; when 3 layers of prepreg cloth are paved, a concave-convex fluctuating upper die is adopted to compact and attach the hexagonal columns and the prepreg cloth;
8) Pressing the honeycomb prefabricated body obtained in the step 7) to a concave-convex fluctuating upper die, fixing two sides of the tool by using a limiting block, and fastening by using a positioning screw 5;
9) Putting the honeycomb assembly obtained in the step 8) into a hot-pressing tank for curing, wherein the curing temperature is 170 ℃, the curing time is 5 hours, and the curing pressure is 0.7MPa, so that the co-curing preparation of the light porous grid carbon fiber fabric honeycomb material body and the shaping is realized;
10 Removing the cured carbon fiber honeycomb tool to obtain the light high-rigidity porous grid carbon fiber honeycomb which meets the use requirements of space environments such as rigidity, gas escape, temperature alternating environment resistance and the like. The honeycomb compression modulus reaches more than 100 MPa.
The invention has been described in detail with reference to specific embodiments and illustrative examples, but the description is not intended to be construed in a limiting sense. Those skilled in the art will appreciate that various equivalent substitutions, modifications or improvements may be made to the embodiments and implementations of the invention without departing from the spirit and scope of the invention, and are within the scope of the invention. The scope of the invention is defined by the appended claims.
Those skilled in the art will appreciate that those matters not described in detail in the present specification are well known in the art.
Claims (12)
1. A light high-rigidity porous grid carbon fiber honeycomb is characterized in that the cells of the carbon fiber honeycomb are hexagonal cells surrounded by hole wall materials; the hole wall material is a porous carbon fiber fabric composite material, holes in the hole wall material are square holes arranged in a matrix mode, the side length of each square hole is less than or equal to 2mm, and the laying direction of the porous carbon fiber fabric composite material and the longitudinal angle of the honeycomb are 0-60 degrees;
the hole wall material of the carbon fiber honeycomb is prepared by curing a porous grid carbon fiber prepreg fabric, and the porous grid carbon fiber prepreg fabric is prepared by the following steps:
step (1), adopting an ultrasonic guided fiber expansion method to thin the high-modulus carbon fiber tows, and compounding the high-modulus carbon fiber tows with a resin film layer to prepare the ultrathin carbon fiber prepreg, wherein the surface density of the prepreg is less than or equal to 80g/m 2 The resin mass content is controlled between 38 percent and 44 percent;
step (2), cutting the ultrathin high-modulus carbon fiber prepreg obtained in the step (1) on prepreg cutting equipment until the carbon fiber prepreg extremely narrow belt is formed, and controlling the bandwidth within the range of 2-6 mm;
and (3) weaving the carbon fiber pre-impregnated extremely narrow belt obtained in the step (2) in a two-dimensional orthogonal weaving manner at the temperature of-10 ℃ according to the proportion of the side length/the bandwidth of the hole being less than or equal to 0.5, so as to obtain the carbon fiber pre-impregnated fabric with the porous grid.
2. The lightweight high-rigidity meshed carbon fiber honeycomb according to claim 1, wherein the laying direction of the meshed carbon fiber fabric composite material is at an angle of 0 ° or 45 ° to the longitudinal direction of the honeycomb.
3. The lightweight high-rigidity meshed carbon fiber honeycomb according to claim 1, wherein the carbon fiber honeycomb has a bulk density of 64kg/m or less 3 The diameter of an inscribed circle of the carbon fiber honeycomb cell is less than or equal to phi 15mm, and the thickness of a hole wall material is less than or equal to 0.2mm.
4. The lightweight high-rigidity perforated grid carbon fiber honeycomb according to claim 1, wherein in the perforated grid carbon fiber prepreg fabric, the resin matrix is a toughened thermosetting resin which is resistant to temperature alternation in a space environment, has a vacuum quality loss of not more than 1.0% and has a condensable volatile matter of not more than 0.5%.
5. The lightweight high-rigidity meshed carbon fiber honeycomb according to claim 4, wherein the toughened thermosetting resin is any one or more of toughened epoxy resin or cyanate resin, and the carbon fiber is selected from any one or more of M40, M55 and M65-grade high-modulus carbon fiber.
6. The lightweight high stiffness meshed carbon fiber honeycomb of claim 1, wherein the woven form of the meshed carbon fiber prepreg fabric comprises plain, twill, satin.
7. The preparation method of the light high-rigidity meshed carbon fiber honeycomb as claimed in claim 1, characterized by comprising the following steps:
step (1), adopting an ultrasonic guide fiber expansion method to thin a high-modulus carbon fiber tow and compounding the high-modulus carbon fiber tow with a resin film layer to prepare an ultrathin carbon fiber prepreg, wherein the surface density of the prepreg is less than or equal to 80g/m 2 The resin mass content is controlled between 38 percent and 44 percent;
step (2), cutting the ultrathin high-modulus carbon fiber prepreg obtained in the step (1) on prepreg cutting equipment until the carbon fiber prepreg extremely narrow belt is formed, and controlling the bandwidth within the range of 2-6 mm;
step (3), weaving the carbon fiber pre-impregnated extremely narrow belt obtained in the step (2) in a two-dimensional orthogonal weaving mode at the temperature of-10 ℃ according to the proportion of the side length/the bandwidth of a hole being less than or equal to 0.5 to obtain a carbon fiber pre-impregnated fabric with a meshed grid;
step (4), cutting the porous grid carbon fiber prepreg fabric to a required length according to the length requirement of the prepared honeycomb, and cutting the required number of porous grid carbon fiber prepreg blocks according to the width requirement of the honeycomb;
step (5), the porous grid carbon fiber prepreg block is laid and attached to a concave-convex fluctuating lower die along with the shape, the concave-convex fluctuating lower die is provided with a concave-convex molded surface matched with the honeycomb cells, the hexagonal core columns are sequentially placed into the cavities of the molded surface, and then a layer of porous grid carbon fiber prepreg block is laid and attached; the diameter of the inscribed circle of the hexagonal core column is consistent with that of the inscribed circle of the honeycomb cell;
step (6), repeating the process of placing the hexagonal core column and randomly paving and pasting the porous grid carbon fiber prepreg block until the required honeycomb width is achieved, and finishing honeycomb paving and pasting to obtain a honeycomb prefabricated body; each paving and pasting 3-6 layers of the porous grid carbon fiber prepreg blocks, and compacting and pasting the hexagonal core column and the porous grid carbon fiber prepreg blocks;
step (7), pressing a concave-convex fluctuating upper die on the honeycomb prefabricated part, fixing two sides of the tool by using a limiting block, and fastening by using a positioning screw; the honeycomb prefabricated body is characterized in that the concave-convex fluctuating upper die structure is provided with a concave-convex surface matched with the honeycomb cell, two ends of the concave-convex fluctuating upper die and the concave-convex fluctuating lower die are provided with fastening holes sleeved with positioning screws, and limiting blocks are positioned on the inner sides of the positioning screws and matched with the concave-convex fluctuating upper die and the concave-convex fluctuating lower die to limit the honeycomb prefabricated body together;
step (8), applying curing pressure required by honeycombs with different widths to the honeycomb assembly obtained in the step (7), and finishing honeycomb curing according to a curing process of a resin matrix;
and (9) removing the tool on the cured carbon fiber honeycomb to obtain the carbon fiber honeycomb with the porous grids.
8. The preparation method according to claim 7, wherein in the step (5), the length of the working surface of the concave-convex fluctuating lower die is less than or equal to 2m, the precision of the length profile is less than or equal to 0.1mm, the precision of the width profile is less than or equal to 0.05mm, and the precision of the height of the concave-convex is less than or equal to 0.05mm; and/or
In the step (7), the length of the working surface of the concave-convex fluctuating upper die is less than or equal to 2m, the precision of the length profile is less than or equal to 0.1mm, the precision of the width profile is less than or equal to 0.05mm, and the precision of the concave-convex height is less than or equal to 0.05mm.
9. The preparation method according to claim 7, wherein in the step (6), the hexagonal core column has a length of 300mm or less, a straightness of 0.05mm or less, and an angle R of R4 or less; the length of the hexagonal core column is not less than the width of the porous grid carbon fiber prepreg block; and/or
And threaded blind holes are formed in two ends of the hexagonal core column.
10. The preparation method according to claim 7, wherein in the step (8), the curing process is carried out in an autoclave or an oven, the curing temperature is 165-180 ℃, the curing time is 3-6 h, and the curing pressure is 0.2-1.2 MPa.
11. The preparation method of claim 10, wherein the curing pressure is adaptively adjusted according to the honeycomb width W, and when W is less than or equal to 300mm, the curing pressure is 0.2MPa to 0.4MPa; w is more than 300mm and less than or equal to 500mm, and the curing pressure is 0.3MPa to 0.6MPa; w is more than 500mm and less than or equal to 800mm, and the curing pressure is 0.5MPa to 0.8MPa; w is more than 800mm and less than or equal to 1000mm, and the curing pressure is 0.7MPa to 1.2MPa.
12. Use of a lightweight high stiffness meshed carbon fiber honeycomb according to one of claims 1 to 6 or a method of making a lightweight high stiffness meshed carbon fiber honeycomb according to one of claims 7 to 11 for the manufacture of lightweight composite sandwich structures in aerospace environments.
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