CN113910698A - 一种飞行员头盔壳体及制造方法 - Google Patents

一种飞行员头盔壳体及制造方法 Download PDF

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CN113910698A
CN113910698A CN202111219098.6A CN202111219098A CN113910698A CN 113910698 A CN113910698 A CN 113910698A CN 202111219098 A CN202111219098 A CN 202111219098A CN 113910698 A CN113910698 A CN 113910698A
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layer
shell
fiber
mould
inner cushion
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张福乐
张欣戎
李奇峰
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Shanghai Zitu New Material Technology Co ltd
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    • A—HUMAN NECESSITIES
    • A42—HEADWEAR
    • A42B—HATS; HEAD COVERINGS
    • A42B3/00—Helmets; Helmet covers ; Other protective head coverings
    • A—HUMAN NECESSITIES
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Abstract

本发明公开了一种飞行员头盔壳体及制造方法，包括壳体和内垫层，所述壳体包括从外向内依次设置的保护层、第一纤维增强层、吸能层和第二纤维增强层，所述第一纤维增强层和第二纤维增强层为碳纤维、芳纶、超高分子量聚乙烯纤维中的一种或多种，纤维存在形式为短切纤维或织物，所述吸能层为热塑性弹性体，所述保护层为热塑性膜，所述内垫层与壳体之间设置有拆装机构；本发明提供的头盔壳体，采用多层复合结构，充分发挥材料特性，壳体力学性能好；设置有热塑性弹性体吸能层，可有效吸收冲击能量，提高头盔抗冲击性；本发明的制造方法，保护层采用热塑性膜预成型后与壳体其他结构材料一体成型，成型后保护膜粘接强度高，壳体无需后续喷漆。

Description

一种飞行员头盔壳体及制造方法
技术领域
本发明属于军用头盔技术领域，具体涉及一种飞行员头盔壳体及制造方法。
背景技术
头盔是现代战斗机飞行员不可或缺的装备，我军于20世纪70年代开始配发飞行员头盔，经过数十年的发展，头盔已经发展成一个集视、听、说功能于一体，能快速装配，实现防护与信息处理功能的信息化、智能化综合系统。头盔壳体作为头盔系统的基本组成部分，已经从单一保护性要求到各项性能要求越来越高，如飞行速度提升，需要壳体能能够耐受更强的吹袭；飞行员弹射，要求壳体要有更高的抗冲击性和保护性；挂载附件增加要求壳体有更轻的质量。
目前飞行员头盔壳体采用单一的纤维增强复合材料制造而成，或为超高分子量聚乙烯复合材料，或为芳纶复合材料，虽然性能已经超过传统的玻璃钢壳体，但已然无法满足因日益增加的挂载附件和飞行速度提升等而对壳体提出的更高性能要求，对于目前头盔的结构形式，只能通过增加纤维层数来达到更高力学性能，由此也导致重量增加，佩戴舒适性差，为此本发明提出一种飞行员头盔壳体及制造方法。
发明内容
本发明的目的在于提供一种飞行员头盔壳体及制造方法，以解决上述背景技术中提出的问题。
为实现上述目的，本发明提供如下技术方案：一种飞行员头盔壳体，包括壳体和内垫层，所述壳体包括从外向内依次设置的保护层、第一纤维增强层、吸能层和第二纤维增强层，所述第一纤维增强层和第二纤维增强层为碳纤维、芳纶、超高分子量聚乙烯纤维中的一种或多种，纤维存在形式为短切纤维或织物，所述吸能层为热塑性弹性体，所述保护层为热塑性膜，所述内垫层与壳体之间设置有拆装机构，所述内垫层上设置有缓冲结构和透气结构。
优选的，所述拆装机构包括多个设置在内垫层外侧表面的卡块，所述壳体的内壁均匀开设有多个卡槽，所述卡块卡在卡槽内。
优选的，所述卡块与内垫层为一体式结构，且卡块和卡槽的截面均呈T形。
优选的，所述缓冲结构包括均匀设置在内垫层内侧表面的多个圆形隆起，所述圆形隆起与内垫层为一体式结构。
优选的，所述透气结构包括透气孔，所述内垫层的表面相对于每两个圆形隆起之间均开设有两个透气孔。
本发明提供所述的飞行员头盔壳体制造方法，包括下列步骤：
a.保护层预成型：利用真空吸塑，将热塑性膜吸塑成头盔形状；
b.纤维材料裁剪切割：将所需不同的纤维原料按要求裁剪备料；
c.壳体铺层：依次将保护层、第一纤维增强层、吸能层、第二纤维增强层铺叠在头盔模具腔体中；
d.合模：模具各组成部分安装完成后，利用螺栓将模具各部分拧紧，完成模具合模；
e.壳体成型：将模具加压加热，模具内部充气加压；
f.脱模：模具按照壳体材料成型工艺要求完成加热加压，待模具冷却后脱模；
g.修整打孔：对壳体边缘溢出部分进行修整，并按照壳体附件安装要求在壳体上打孔。
优选的，所述的模具为三瓣式结构结构，包括左瓣模、右瓣模，上盖模和充气橡胶袋，充气橡胶袋安装于上盖模处，外接充气口。
优选的，所述的壳体铺层过程，壳体上需要开孔部位在铺层时需要铺碳纤维加强片，加强片面积至少为孔面积的两倍。
与现有技术相比，本发明的有益效果是：
1、本发明提供的头盔壳体，采用多层复合结构，充分发挥材料特性，壳体力学性能好。
2、本发明提供的头盔壳体，设置有热塑性弹性体吸能层，可有效吸收冲击能量，提高头盔抗冲击性。
3、本发明的制造方法，保护层采用热塑性膜预成型后与壳体其他结构材料一体成型，成型后保护膜粘接强度高，壳体无需后续喷漆，有效降低壳体重量。
4、本发明的制造方法，除了对模具外部加热加压，对内部通过橡胶袋充气加压，制造的壳体材料之间粘接密实无气泡。
5、通过设置的内垫层可提高头盔整体的佩戴舒适度，并且在圆形隆起缓冲结构和透气结构的作用下，可起到一定的缓冲保护作用和透气作用，而通过设置的拆装机构，使得内垫层后期易于拆下进行清洗或更换，使用便捷性高。
附图说明
图1为本发明壳体的截面图；
图2为本发明壳体的铺层示意图；
图3为本发明内垫层与壳体连接时的剖视图；
图4为本发明图3中A区域的局部放大图；
图中：1、保护层；2、第一纤维增强层；21、碳纤维斜纹预浸布；22、芳纶斜纹预浸布；23、芳纶单向预浸布；3、吸能层；4、第二纤维增强层；41、芳纶平纹预浸布；42、碳纤维单向预浸布；5、内垫层；51、圆形隆起；52、卡块；53、透气孔。
具体实施方式
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
实施例
请参阅图1至图4，本发明提供一种技术方案：一种飞行员头盔壳体，包括壳体和内垫层5，壳体包括从外向内依次设置的保护层1、第一纤维增强层2、吸能层3和第二纤维增强层4，保护层1为聚氨酯膜，第一纤维增强层2依次由一层碳纤维斜纹预浸布21、一层芳纶斜纹预浸布22和四层-45°/0°/45°/90°交叉的芳纶单向预浸布组成，吸能层3为聚氨酯弹性体膜，第二纤维增强层4依次由一层芳纶平纹预浸布41和两层0°/90°交叉的碳纤维单向预浸布组成，内垫层5与壳体之间设置有拆装机构，内垫层5上设置有缓冲结构和透气结构。
本实施例中，优选的，拆装机构包括多个设置在内垫层5外侧表面的卡块52，壳体的内壁均匀开设有多个与卡块52相对应的卡槽，卡块52卡在卡槽内，卡块52与内垫层5为一体式结构，卡块52与内垫层5均为海绵材质构件，具有良好的弹性，且卡块52和卡槽的截面均呈T形，使得内垫层5易于拆装，缓冲结构包括均匀设置在内垫层5内侧表面的多个圆形隆起51，圆形隆起51与内垫层5为一体式结构，圆形隆起51为海绵材质构件，具有良好的弹性和一定的缓冲性能，透气结构包括透气孔53，内垫层5的表面相对于每两个圆形隆起51之间均开设有两个透气孔53，可提高内垫层5的透气性。
本实施例还提供了一种飞行员头盔壳体的制造方法，包括下列步骤：
1)保护层1制备：将聚氨酯膜置于吸塑机上，吸塑模按照头盔壳体最外层尺寸所开模具，将聚氨酯膜在135℃条加下加热5s开始吸塑，吸塑完成后利用水雾快速冷却，得到预成型的聚氨酯膜壳保护层1；
2)纤维材料裁剪切割：将铺层需要用的碳纤维斜纹预浸布21、芳纶斜纹预浸布22、芳纶单向预浸布23、芳纶平纹预浸布41、碳纤维单向预浸布42和吸能层3的聚氨酯弹性体膜按照用量和铺层方式裁剪好备用；
3)壳体铺层：依次将预成型的聚氨酯膜壳保护层1、一层碳纤维斜纹预浸布21、一层芳纶斜纹预浸布22、四层-45°/0°/45°/90°交叉的芳纶单向预浸布，一层聚氨酯弹性体膜吸能层3、一层芳纶平纹预浸布41、两层0°/90°交叉的碳纤维单向预浸布铺叠在由左瓣模、右瓣模组成的模腔中，接缝处采用搭接，搭接长度为5mm，壳体上需要打孔位置在碳纤维斜纹预浸布21和芳纶斜纹预浸布22之间贴一层碳纤维预浸布补片，补片面积为孔面积的3倍；
4)合模：头盔模具为三瓣式结构结构，除了左瓣模、右瓣模，还有上盖模，其中，上盖模设置有充气橡胶袋，上盖模外接充气口。拧紧左瓣模、右瓣模固定螺栓，并将上盖模安装到位后用固定螺栓拧紧；
5)壳体成型：将合模完成后的头盔模具置于热压机中，并将上盖模上的充气口外接气源，成型工艺参数设置为：热压压力3Mpa，温度130℃，气压2Mpa，时间2h；
6)脱模：热压完成后，关闭加热电源，在热压机上继续保压1h，1h后，取出模具，待模具冷却后将头盔壳体脱模；
7)修整打孔：对壳体边缘溢出部分进行修整，并按照壳体附件安装要求在壳体上打孔。
本发明的工作原理及使用流程：当需要内垫层5安装在壳体的内侧时，只需将内垫层5先贴合在壳体的内侧，并将对应位置的卡块52挤入壳体内壁上的卡槽中，致使卡块52发生弹性形变并最终卡在卡槽内，即可实现内垫层5的快速安装，在圆形隆起51的作用下，可一定程度对佩戴者的头部起到缓冲保护作用，而透气孔53可保证良好的透气性。
尽管已经示出描述了本发明的实施例，对于本领域的普通技术人员而言，可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种变化、修改、替换和变型，本发明的范围由所附权利要求及其等同物限定。

Claims (8)

1.一种飞行员头盔壳体，包括壳体和内垫层(5)，其特征在于：所述壳体包括从外向内依次设置的保护层(1)、第一纤维增强层(2)、吸能层(3)和第二纤维增强层(4)，所述第一纤维增强层(2)和第二纤维增强层(4)为碳纤维、芳纶、超高分子量聚乙烯纤维中的一种或多种，纤维存在形式为短切纤维或织物，所述吸能层(3)为热塑性弹性体，所述保护层(1)为热塑性膜，所述内垫层(5)与壳体之间设置有拆装机构，所述内垫层(5)上设置有缓冲结构和透气结构。
2.根据权利要求1所述的一种飞行员头盔壳体，其特征在于：所述拆装机构包括多个设置在内垫层(5)外侧表面的卡块(52)，所述壳体的内壁均匀开设有多个卡槽，所述卡块(52)卡在卡槽内。
3.根据权利要求2所述的一种飞行员头盔壳体，其特征在于：所述卡块(52)与内垫层(5)为一体式结构，且卡块(52)和卡槽的截面均呈T形。
4.根据权利要求1所述的一种飞行员头盔壳体，其特征在于：所述缓冲结构包括均匀设置在内垫层(5)内侧表面的多个圆形隆起(51)，所述圆形隆起(51)与内垫层(5)为一体式结构。
5.根据权利要求1所述的一种飞行员头盔壳体，其特征在于：所述透气结构包括透气孔(53)，所述内垫层(5)的表面相对于每两个圆形隆起(51)之间均开设有两个透气孔(53)。
6.一种如权利要求1至5任一项所述的飞行员头盔壳体制造方法，其特征在于：包括下列步骤：
a.保护层预成型：利用真空吸塑，将热塑性膜吸塑成头盔形状；
b.纤维材料裁剪切割：将所需不同的纤维原料按要求裁剪备料；
c.壳体铺层：依次将保护层(1)、第一纤维增强层(2)、吸能层(3)、第二纤维增强层(4)铺叠在头盔模具腔体中；
d.合模：模具各组成部分安装完成后，利用螺栓将模具各部分拧紧，完成模具合模；
e.壳体成型：将模具加压加热，模具内部充气加压；
f.脱模：模具按照壳体材料成型工艺要求完成加热加压，待模具冷却后脱模；
g.修整打孔：对壳体边缘溢出部分进行修整，并按照壳体附件安装要求在壳体上打孔。
7.根据权利要求6所述的一种飞行员头盔壳体制造方法，其特征在于：所述的模具为三瓣式结构结构，包括左瓣模、右瓣模，上盖模和充气橡胶袋，充气橡胶袋安装于上盖模处，外接充气口。
8.根据权利要求6所述的一种飞行员头盔壳体制造方法，其特征在于：所述的壳体铺层过程，壳体上需要开孔部位在铺层时需要铺碳纤维加强片，加强片面积至少为孔面积的两倍。
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CN104236393A (zh) * 2014-09-16 2014-12-24 山东大学 一种多功能复合材料防弹头盔及其制造方法
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CN108801055A (zh) * 2018-06-20 2018-11-13 张建春 一种减轻非贯穿性损伤的非金属防弹头盔及其制造方法

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102107440A (zh) * 2009-12-25 2011-06-29 王宏达 可保护孔洞的打孔方法
CN104236393A (zh) * 2014-09-16 2014-12-24 山东大学 一种多功能复合材料防弹头盔及其制造方法
CN205143609U (zh) * 2015-10-15 2016-04-13 深圳市威富多媒体有限公司 纳米碳纤维复合材料防护头盔
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