CN114055807A - Method for forming part made of composite material, formed part and aircraft - Google Patents
Method for forming part made of composite material, formed part and aircraft Download PDFInfo
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- CN114055807A CN114055807A CN202111339560.6A CN202111339560A CN114055807A CN 114055807 A CN114055807 A CN 114055807A CN 202111339560 A CN202111339560 A CN 202111339560A CN 114055807 A CN114055807 A CN 114055807A
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- 239000002131 composite material Substances 0.000 title claims abstract description 119
- 238000000034 method Methods 0.000 title claims abstract description 46
- 239000000463 material Substances 0.000 claims abstract description 29
- 238000010438 heat treatment Methods 0.000 claims abstract description 18
- 238000000465 moulding Methods 0.000 claims abstract description 11
- 239000010410 layer Substances 0.000 claims description 153
- 239000012790 adhesive layer Substances 0.000 claims description 33
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 27
- 239000004917 carbon fiber Substances 0.000 claims description 27
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 27
- 230000008569 process Effects 0.000 claims description 12
- 238000001723 curing Methods 0.000 claims description 10
- 239000003365 glass fiber Substances 0.000 claims description 9
- 238000003825 pressing Methods 0.000 claims description 7
- 239000006260 foam Substances 0.000 claims description 4
- 239000007787 solid Substances 0.000 claims description 4
- 238000009461 vacuum packaging Methods 0.000 claims description 3
- 238000013007 heat curing Methods 0.000 claims description 2
- 238000009413 insulation Methods 0.000 description 8
- 229920006231 aramid fiber Polymers 0.000 description 7
- 238000007493 shaping process Methods 0.000 description 7
- 239000000853 adhesive Substances 0.000 description 6
- 230000001070 adhesive effect Effects 0.000 description 6
- 230000009467 reduction Effects 0.000 description 6
- 239000004593 Epoxy Substances 0.000 description 4
- 230000008901 benefit Effects 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 239000003822 epoxy resin Substances 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 230000002093 peripheral effect Effects 0.000 description 4
- 229920000647 polyepoxide Polymers 0.000 description 4
- 239000000047 product Substances 0.000 description 4
- 239000002313 adhesive film Substances 0.000 description 2
- 230000032683 aging Effects 0.000 description 2
- 238000005452 bending Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 239000002657 fibrous material Substances 0.000 description 2
- 230000003014 reinforcing effect Effects 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 239000013589 supplement Substances 0.000 description 2
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 239000004760 aramid Substances 0.000 description 1
- 229920003235 aromatic polyamide Polymers 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000013329 compounding Methods 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000005538 encapsulation Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000011185 multilayer composite material Substances 0.000 description 1
- 229920001568 phenolic resin Polymers 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 238000004321 preservation Methods 0.000 description 1
- 238000005086 pumping Methods 0.000 description 1
- 229920006337 unsaturated polyester resin Polymers 0.000 description 1
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Classifications
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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
-
- 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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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Abstract
The application relates to a part molding method of a composite material, a molded part and an aircraft. The method comprises the following steps: placing the first composite material in a first mould, and preparing a first skin layer through the first mould; placing the second composite material in a second mould, and preparing a second skin layer through the second mould; bonding the first skin layer after demolding to one side of the intermediate structure layer to form a combined body; and adhering the assembly to the second skin layer in the second mold, and heating and curing to obtain the molded part. According to the scheme, the forming part with a complex actual structure can be manufactured, so that the composite material can meet the application requirements of different use scenes, the characteristics of the composite material can be fully utilized, and the characteristics of the composite material can be enhanced and more performances can be supplemented by increasing intermediate structure layers of different materials.
Description
Technical Field
The application relates to the technical field of composite materials, in particular to a part forming method, a formed part and an aircraft of a composite material.
Background
Because composite materials such as carbon fiber and the like have excellent characteristics of light weight, high strength and the like, molded parts made of the composite materials are often applied to cabin structures of aircrafts, so that the weight of the cabins is greatly reduced.
In the related art, the carbon fiber composite material generally adopts a single-plate structure as a component of the cabin, for example, as a back panel of the cabin. The impact strength of such structure is poor, yielding and sound insulation noise reduction effect is relatively poor. For this reason, when a multilayer structure is fabricated by compounding a carbon fiber composite material with other structural materials such as a honeycomb structure, although it is possible to improve impact resistance, reduce deformation rate, and insulate sound and reduce noise, such a multilayer structure is generally a flat plate type structure, and it is difficult to fabricate parts having a complicated structure, for example, a reliable curved structure having a stable structure.
Disclosure of Invention
In order to solve or partially solve the problems in the related art, the application provides a part forming method of a composite material, a formed part and an aircraft, which can compound a carbon fiber composite material and other structural materials and manufacture the formed part with a complex structure, stability and reliability.
In a first aspect, the present application provides a method of forming a part of a composite material, comprising
Placing a first composite material in a first mould, and preparing a first skin layer through the first mould;
placing a second composite material in a second mould, and preparing a second skin layer through the second mould;
bonding the first skin layer after demolding to one side of the intermediate structure layer to form a combined body;
and adhering the assembly to the second skin layer in the second mold, and curing by heating to obtain a molded part.
In one embodiment, the placing the first composite material in a first mold through which a first skin layer is made comprises:
and paving the prepreg of the first composite material in a first mould, and heating and curing the first composite material through a vacuum bag pressing process to obtain a first skin layer.
In one embodiment, the placing the second composite material in a second mold through which a second skin layer is made comprises:
and paving the prepreg of the second composite material in a second mould, and heating and curing the second composite material through a vacuum bag pressing process to obtain a second skin layer.
In one embodiment, the step of adhering the first skin layer after demolding to one side of the intermediate structure layer to form a combined body comprises:
and laying a first adhesive layer on one side of the first skin layer, and adhering one side of the intermediate structure layer to the first adhesive layer to form a combined body.
In one embodiment, the bonding the assembly to the second skin layer in the second mold to obtain a molded part by heat curing includes:
laying a second adhesive layer on one side of the second skin layer, and adhering the other side of the intermediate structure layer to the second adhesive layer to form a part to be formed;
and vacuum packaging the part to be molded, and heating and pressurizing the part to be molded through an autoclave process to obtain the molded part.
In an embodiment, the first composite material comprises a carbon fiber composite material or a glass fiber composite material; and/or
The second composite material comprises a carbon fiber composite material or a glass fiber composite material;
wherein the first composite material and the second composite material are the same material or different materials.
In one embodiment, the intermediate structural layer comprises a honeycomb structure or a foam solid structure.
In an embodiment, the second mold includes a mold body and a limiting member, the mold body is provided with a cavity, and the limiting member is detachably disposed on one side of the mold body along a height direction of the cavity to limit the height of the molding member.
In a second aspect, the present application provides a molded part produced by the method for molding a part made of a composite material according to any one of the above embodiments.
A third aspect of the present application provides an aircraft comprising a profiled section as described in any of the embodiments above.
The technical scheme provided by the application can comprise the following beneficial effects:
the utility model provides a scheme, can be with the quick machine-shaping of multilayer combined material, and can adjust the structure of first mould and second mould in a flexible way, thereby make the complicated shaping part of structure, then obtain not only to the straight board-like shaping part in plane, can also obtain curved surface structure and contain the more complicated shaping part of actual structure such as flange structure, make combined material can satisfy the application of different use scenes, both can make full use of combined material's characteristic, can also be through the middle structural layer that increases different materials with the characteristic of reinforcing combined material and the performance that supplements more.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the application.
Drawings
The foregoing and other objects, features and advantages of the application will be apparent from the following more particular descriptions of exemplary embodiments of the application as illustrated in the accompanying drawings wherein like reference numbers generally represent like parts throughout the exemplary embodiments of the application.
Fig. 1 is a schematic flow chart illustrating a method for forming a part of a composite material according to an embodiment of the present disclosure;
FIG. 2 is a schematic structural view of a molded part shown in an embodiment of the present application;
FIG. 3 is a schematic cross-sectional view of the molded part shown in FIG. 2 of the present application;
FIG. 4 is a schematic view of the honeycomb structure of the intermediate structural layer shown in FIG. 2 of the present application;
FIG. 5 is another schematic flow chart diagram illustrating a method for forming a part of a composite material according to an embodiment of the present disclosure;
FIG. 6 is a schematic view of the other orientation of the molded part shown in FIG. 2;
fig. 7 is a schematic partial sectional structure view of a second mold according to an embodiment of the present disclosure.
Reference numerals: a molded part 10; a first skin layer 110; an intermediate structural layer 120; a second skin layer 130; a first adhesive layer 140; a second adhesive layer 150; a flange structure 160; a curved surface structure 170; a second mold 20; a cavity 210; a bottom surface 211; a sidewall 212; a stopper 213; a stopper surface 2131; a bolt 214.
Detailed Description
Embodiments of the present application will be described in more detail below with reference to the accompanying drawings. While embodiments of the present application are illustrated in the accompanying drawings, it should be understood that the present application may be embodied in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. As used in this application and the appended claims, the singular forms "a", "an", and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It should also be understood that the term "and/or" as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items.
It should be understood that although the terms "first," "second," "third," etc. may be used herein to describe various information, these information should not be limited to these terms. These terms are only used to distinguish one type of information from another. For example, first information may also be referred to as second information, and similarly, second information may also be referred to as first information, without departing from the scope of the present application. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the present application, "a plurality" means two or more unless specifically limited otherwise.
In the related art, the single-plate structure made of the carbon fiber composite material has the problems of poor impact strength, easy deformation and poor sound insulation and noise reduction effects, but when the composite multi-layer structure combined by the carbon fiber and other structural materials is adopted, a stable and reliable complex curved surface structure is difficult to manufacture.
In view of the above problems, embodiments of the present application provide a method for forming a component of a composite material, which can combine a carbon fiber composite material with other structural materials to form a formed component with a complex structure, stability and reliability. The technical solutions of the embodiments of the present application are described in detail below with reference to the accompanying drawings.
Fig. 1 is a schematic flow chart illustrating a method for forming a part of a composite material according to an embodiment of the present disclosure; referring to fig. 1, an embodiment of the present application provides a method of forming a part of a composite material, the method comprising:
step S110, the first composite material is placed in a first mold, and a first skin layer is prepared through the first mold.
Wherein the first composite material may be a carbon fiber composite material or a glass fiber composite material. It will be appreciated that the selection may be made specifically depending on the characteristics of the carbon fiber composite material and the glass fiber composite material. The carbon fiber composite material and the glass fiber composite material may be commercially available composite materials or self-developed composite materials, and are not limited herein.
Further, the cavity of the first mold is arranged according to the structure of the molding part. As shown in fig. 2 and 3, taking the molding member in fig. 2 as an example, the molding member has a curved surface structure, i.e., a non-planar straight plate structure. The cavity of the first mold of the embodiment can be arranged along with the mold. The molding member 10 includes a first skin layer 110, an intermediate structure layer 120, and a second skin layer 130 stacked in sequence, which are tightly connected to form a multi-layer composite structure. In the step, the first composite material is firstly prepared into the first skin layer through the independent first mould.
And step S120, placing the second composite material in a second mold, and preparing a second skin layer through the second mold.
The second composite material comprises a carbon fiber composite material or a glass fiber composite material, and the carbon fiber composite material or the glass fiber composite material can be a composite material obtained from the market or a composite material developed by the user. The second composite material may be the same material as the first composite material or a different material depending on the desired characteristics of the molded part.
It will be appreciated that the second skin layer and the first skin layer are located on different sides of the profiled component, for example when the profiled component is a back panel of an aircraft, the second skin layer is located on the outside and the first skin layer is located on the inside, the peripheral profile dimension of the second skin layer may be different from the first skin layer, for example the peripheral profile dimension of the second skin layer may be slightly greater than the peripheral profile dimension of the first skin layer. And the cavity of the second die is arranged along with the shape according to the actual structure of the second skin layer.
It is understood that the above steps S110 and S120 may be performed sequentially or simultaneously.
Step S130, adhering the first skin layer after demolding to one side of the intermediate structure layer to form a combined body.
In order to combine the first skin layer with the second skin layer, the first skin layer prepared in step S110 is subjected to a mold release treatment. Wherein, the intermediate structure layer can be a honeycomb structure or a foam solid structure. As shown in fig. 4, when intermediate structure layer 120 is honeycomb, aramid fiber material can be selected for use to aramid fiber honeycomb has matter light and better impact strength intensity, through the intermediate structure layer that sets up aramid fiber honeycomb between first skin layer and second skin layer, can improve forming part's whole impact strength, reduces the deformation rate, and has the effect that gives sound insulation and insulate against heat and inhale the sound and fall the noise. Alternatively, the foam solid structure can be made of polyurethane material, and also has sound insulation and noise reduction properties, so that the overall impact strength and the sound insulation and noise reduction properties of the molded part can be improved.
Further, through bonding the intermediate structure layer with the first skin layer after the drawing of patterns in advance to be convenient for follow-up step directly combines assembly and second skin layer, then improve machining efficiency and equipment precision.
And step S140, bonding the assembly to a second skin layer in a second mold, and heating and curing to obtain a molded part.
After the second skin layer is formed in the second mold, the second skin layer is still placed in the cavity of the second mold, demolding is not performed, the combined body obtained in the step is directly bonded with the second skin layer in the second mold, and the first skin layer, the intermediate structure layer and the second skin layer form an integrated structure through heating and curing, and the first skin layer, the intermediate structure layer and the second skin layer are tightly connected with each other to ensure the stability and the reliability of the structure of the formed part. It will be appreciated that subsequent removal of the shaped part from the second mould will result in a finished product.
According to the scheme provided by the application, the multilayer composite material can be rapidly processed and molded, and the structures of the first mold and the second mold can be flexibly adjusted, so that the molded part with a complex structure is manufactured, the molded part which is not limited to a plane straight plate type is obtained, and the molded part with a curved surface structure, a flange-containing structure and other actual structures which are more complex can be obtained, so that the composite material can meet the application of different use scenes, the characteristics of the composite material can be fully utilized, and the characteristics of the composite material can be enhanced and more performances can be supplemented by adding intermediate structural layers of different materials.
FIG. 5 is another schematic flow chart diagram illustrating a method for forming a part of a composite material according to an embodiment of the present disclosure; in this embodiment, a carbon fiber composite material and an aramid fiber honeycomb structure are taken as examples, and a method for forming a part of the composite material of the present application is further described.
Referring to fig. 5, an embodiment of the present application provides a method of forming a part of a composite material, the method comprising:
step S210, the prepreg of the first composite material is laid in a first mould, and the first composite material is heated and cured through a vacuum bag pressing process to obtain a first skin layer.
The first composite material that has not yet been molded, that is, the prepreg of the carbon fiber composite material, may be laid in the cavity of the first mold. Further, the number of the paving layers of the first composite material is not limited herein, and is set according to the actual required thickness. In one embodiment, the first skin layer has a thickness of 1.00mm to 1.50mm, such as 1.00mm, 1.02mm, 1.05mm, 1.10mm, 1.30mm, 1.40mm, 1.50mm, and the like.
Further, after the prepreg of the first composite material is laid, according to a vacuum bag pressing process in the related art, the prepreg in the first mold is encapsulated by a vacuum bag, and the pressure in the vacuum bag is maintained at-0.15 MPa to-0.1 MPa, for example, -0.098MPa by vacuum pumping. And then the first die is integrally placed in a high-temperature furnace for heating. Taking a carbon fiber epoxy resin system composite material as an example, the temperature in a furnace is firstly raised to 120 ℃, the temperature is kept for 1 hour, then the temperature is raised to 180 ℃, the temperature is kept for 3 hours, and finally the prepreg is heated, cured and molded to obtain the first skin layer. It is understood that the heating temperatures of the resins of different systems can be different, and the heating temperature can be determined according to the actually selected resin system, and is not limited herein.
After the first skin layer is produced, cooling and demolding may be performed to obtain the first skin layer.
Step S220, the prepreg of the second composite material is laid in a second mould, and the second composite material is heated and cured through a vacuum bag pressing process to obtain a second skin layer.
The second composite material that has not yet been molded, that is, the prepreg of the carbon fiber composite material, may be laid in the cavity of the second mold. Further, the number of the paving layers of the second composite material is not limited herein, and is set according to the actual required thickness. In one embodiment, the second skin layer has a thickness of 1.00mm to 1.50mm, such as 1.00mm, 1.02mm, 1.05mm, 1.10mm, 1.30mm, 1.40mm, 1.50mm, and the like. Wherein the thickness of the second skin layer may be the same as or different from the first skin layer.
In this embodiment, in order to ensure structural reliability of the molded component, the second composite material is a carbon fiber composite material, such as a carbon fiber epoxy resin system composite material, as in the first composite material. And in the same way, the second skin layer is the same as the first skin layer in the steps, the prepreg in the second mould is packaged by adopting a vacuum bag, and the second skin layer after heating and curing can be obtained by vacuumizing and heating to the preset temperature for heat preservation. In this step, after the second skin layer is obtained, only the vacuum bag needs to be removed, and the second skin layer is continuously left in the cavity of the second mold without demolding, so that the subsequent steps can be conveniently assembled. It is understood that the second mold and the first mold are independent molds. It should be appreciated that by using a vacuum bagging process, the first and second molds are both monolithic molds, thereby saving tooling costs.
In this embodiment, as shown in fig. 6 and 7, the forming member 10 of this embodiment includes a curved surface structure 170 and a flange structure 160 perpendicular to the curved surface. Correspondingly, as shown in fig. 7, the second mold 20 includes a mold body and a limiting member 213, the mold body defines a cavity 210, and the limiting member 213 is detachably disposed on one side of the mold body along a height direction of the cavity 210 to limit a height of the molding part 10. The Z direction shown in fig. 7 is the height direction of the cavity 210. The cavity wall of the cavity 210 is defined by a bottom surface 211 of the second mold 20, a sidewall 212, and a limiting surface 2131 of the limiting member 213, wherein one end of the sidewall 212 is connected to the bottom surface 211, and the limiting member 213 is detachably connected to the other end of the sidewall 212, for example, by a bolt 214. The spacing distance between the limiting surface 2131 and the bottom surface 211 is the height dimension C of the forming member 10, i.e. the total height of the curved surface structure 170 and the flange structure 160. Further, the length a of the stopper surface 2131 of the stopper 213 positioned in the cavity 210 is the same as the thickness B of the molded component 10, and the thickness of the molded component is limited by the stopper surface 2131. It will be appreciated that the thickness of the molded component 10 is the sum of the thicknesses of the first skin 110, the first adhesive layer 140, the intermediate structural layer 120, the second adhesive layer 150, and the second skin layer 130. In order to obtain the molded part 10 conforming to the preset height dimension C and thickness dimension B, before processing, the limiting member 213 and the sidewall 212 of the second mold 20 are connected and fixed, so that the prepreg of the second composite material is laid on the bottom surface 211 and the sidewall 212 of the cavity 210. It will be appreciated that the bottom surface 211 of the second mold 20 is curved to form the second skin layer of the curved structure, and the sidewall 212 is perpendicular to the bottom surface 211 to facilitate the subsequent processing to form the flange structure 160 and the curved structure 170 in the molded component 10. In addition, by providing the stopper 213, it is possible to effectively assist in limiting the dimension of the prepreg in the height direction of the cavity 210, and to ensure the dimensional accuracy of the flange structure.
It is understood that step S210 and step S220 of the embodiment may be executed sequentially or simultaneously.
Step S230, laying a first adhesive layer on one side of the first skin layer, and bonding one side of the intermediate structure layer to the first adhesive layer to form a combined body.
Wherein, in order to ensure the reliability and compatibility of the whole structure, the first adhesive layer is the same as the material system of the first skin layer, for example, the first adhesive layer can be an epoxy structural adhesive. In other embodiments, the second adhesive layer may also be an unsaturated polyester resin structural adhesive, a phenolic resin structural adhesive, or the like, which may be selected according to the material system of the first composite material. Referring to fig. 3 again, by applying the adhesive film of the first adhesive layer 140 on the surface of the first skin layer 110, one side of the intermediate structure layer 120 can be tightly adhered to the first skin layer 110 by the first adhesive layer 140 to form a combined body.
Further, the intermediate structure layer of this embodiment may be an aramid honeycomb structure, and the thickness of the intermediate structure layer is 11mm to 12mm, and may be, for example, 11.00mm, 11.10mm, 11.30mm, 11.50mm, 11.89mm, 11.98mm, and 12.00 mm. By limiting the size, the strength of the molded part can be improved and the sound insulation and noise reduction performance can be improved while the light weight can be ensured as much as possible.
Step S240, laying a second adhesive layer on one side of the second skin layer, and adhering the other side of the intermediate structure layer to the second adhesive layer to form a part to be formed;
it is understood that the second adhesive layer is the same material system as the second composite, e.g. both epoxy systems. Referring to fig. 3 again, after the adhesive film of the second adhesive layer 150 is completely laid on the second skin layer 130, the intermediate structure layer 120 of the assembly can be aligned with the outer peripheral profile of the second skin layer 130, and the two are tightly adhered by the second adhesive layer 150 to form the part to be molded.
It will be appreciated that the assembly of multiple layers of different structures, how to ensure alignment and registration between the different layers, is critical and will directly affect the yield of the finished product. Especially when the flange structure that the shaping part still includes protruding establishing, in order to reduce the processing degree of difficulty, do benefit to the alignment, then will have the second skin layer and stay in the second mould, and with the first skin layer drawing of patterns processing of simple structure relatively, make first skin layer easily with the intermediate structure layer equipment, whole again assembles with the second skin layer, guarantees that the height and the thickness of flange structure accord with the accuracy of the whole profile size of the size requirement of predetermineeing of finished product and shaping part.
And S250, vacuum packaging the part to be molded, and heating and pressurizing the part to be molded through an autoclave process to obtain the molded part.
In order to ensure that the first skin layer and the second skin layer are respectively and reliably connected with the intermediate structure layer, in this embodiment, after the part to be molded is packaged in the second mold through the vacuum bag, according to an autoclave process in the related art, the whole packaged second mold is placed into an autoclave, according to the curing temperatures of the first adhesive layer and the second adhesive layer, taking epoxy resin structure adhesive as an example, the temperature is raised to 175 ℃, the pressure is increased to 0.6MPa, and the temperature and pressure are maintained for 3 to 4 hours, so that the first skin layer and the second skin layer are respectively adhered with the intermediate structure layer into a whole, and the reliability of the structure is ensured. It is understood that in other embodiments, the heating temperature is adjusted according to the material characteristics of each layer of the composite material and the adhesive layer material, and is not limited thereto. Meanwhile, the pressure setting is set according to the bearing capacity of the middle structural layer, and the middle structural layer is prevented from being damaged by overlarge pressure.
Referring back to fig. 6 and 7, the length a of the limiting surface 2131 of the limiting member 213 in the cavity is the same as the thickness of the molded part 10, when the assembly formed by the first skin layer 110 and the intermediate structure layer 120 is placed in the cavity 210 and bonded to the molded second skin layer 130, the total thickness is limited by the length a of the limiting surface 2131, and vacuum bag encapsulation is performed according to the length of the limiting surface 2131, so as to ensure that the wall thickness of the molded part 10 conforms to the set size. Meanwhile, the height dimension of the assembly is also limited by the spacing distance between the limiting surface 2131 and the bottom surface 211, so that the height of the molded part 10 after molding is ensured to be in accordance with the set dimension. After the molded part has been produced, the molded part can be released from the cavity of the second mold by removing the vacuum bag and the stopper 213, respectively.
Further, in other embodiments, if the molded part has a very complex curved structure, such as a curved structure with a wave-shaped cross section, the curved structure may be decomposed, for example, into a plurality of sub-curved structures. During processing, the multi-layer structure of each sub-curved surface is independently manufactured by adopting the sub-molds according to the steps, finally, the multi-layer structures of the sub-curved surfaces are sequentially and adjacently bonded and placed in a finished product mold, and the sub-curved surface structures are integrally heated and pressurized according to the step S250 to finally form an integrated forming part. The method of the present application is also applicable to multi-layer structures with gradually changing thickness, and can be made by the above method, which is not described herein again.
According to the scheme provided by the application, the first skin layer and the second skin layer are combined with the material intermediate structure layers of different types, wherein the carbon fiber composite material has the characteristics of high strength, high modulus, low density and fatigue resistance, the aramid fiber honeycomb structure in the intermediate structure layers has the effects of improving the rigidity of the carbon fiber composite material, insulating sound and heat, absorbing sound and reducing noise, and compared with a forming part made of a single carbon fiber composite material, the forming part made by the method has the advantages of being stable in size, not prone to deformation, large in bending strength and rigidity, resistant to fatigue and aging, high in instability resistance, insulating sound and heat, absorbing sound and reducing noise and the like. The method can be widely applied to manufacturing of the molded parts with complex structures and higher structural performance requirements.
Referring again to fig. 2 and 3, an embodiment of the present application further provides a molded part 10, which is manufactured according to the method for molding a part made of a composite material according to any one of the embodiments. The molded part comprises a first skin layer 110, a first adhesive layer 140, an intermediate structure layer 120, a second adhesive layer 150 and a second skin layer 130 which are stacked in sequence, wherein each layer is tightly connected to form a multi-layer composite structure. The first skin layer 110 and the second skin layer 130 are made of carbon fiber composite materials, such as carbon fiber epoxy resin composite materials. The first adhesive layer 140 is the same as the first skin layer 110, such as an epoxy structural adhesive; the second adhesive layer 150 is the same material system as the second skin layer 130, and is, for example, an epoxy structural adhesive. The intermediate structure layer 120 may be a honeycomb structure, and may be made of aramid fiber material to form an aramid fiber honeycomb structure.
Referring again to fig. 6, the formed part 10 of the present application may be a planar straight plate structure, a curved surface structure, or a hybrid of both. The molded part 10 of the present application may further include a flange structure 160, wherein the flange structure 160 is protruded on one side of the curved surface structure 170, and is vertically connected to the curved surface structure 170 to form an integrally molded structure. It is understood that the flange structure 160 is also a multi-layer composite structure composed of the first skin layer 110, the first adhesive layer 140, the intermediate structure layer 120, the second adhesive layer 150, and the second skin layer 130.
The utility model provides a shaping part can form abundant diversified complex structure, adopts combined material and intermediate structure layer to form multilayer composite construction, can satisfy the application of different use scenes, both can make full use of combined material's characteristic, can also be through the intermediate structure layer that increases different materials with the characteristic of reinforcing combined material and the performance that supplements more. The molded part prepared by the method has the characteristics of light weight and high strength, and also has the advantages of stable size, difficult deformation, high bending strength and rigidity, fatigue aging resistance, strong instability resistance, sound insulation, heat insulation, sound absorption, noise reduction and the like.
An embodiment of the present application further provides an aircraft including the molded part in any of the above embodiments. The forming part can be a back panel of the aircraft, and a flange structure of the forming part is connected with a main body frame of the aircraft.
In one embodiment, the aircraft of the present application may be an unmanned aircraft or a low-altitude manned aircraft, such as a flying automobile.
With regard to the shaped part and the aircraft in the above-described embodiments, the details of the relevant production have already been described in detail in the embodiments relating to the method and will not be explained in detail here.
Having described embodiments of the present application, the foregoing description is intended to be exemplary, not exhaustive, and not limited to the disclosed embodiments. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein is chosen in order to best explain the principles of the embodiments, the practical application, or improvements made to the technology in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein.
Claims (10)
1. A method of forming a composite material part, comprising:
placing a first composite material in a first mould, and preparing a first skin layer through the first mould;
placing a second composite material in a second mould, and preparing a second skin layer through the second mould;
bonding the first skin layer after demolding to one side of the intermediate structure layer to form a combined body;
and adhering the assembly to the second skin layer in the second mold, and curing by heating to obtain a molded part.
2. The method of claim 1, wherein said placing a first composite material in a first mold through which a first skin layer is made comprises:
and paving the prepreg of the first composite material in a first mould, and heating and curing the first composite material through a vacuum bag pressing process to obtain a first skin layer.
3. The method of claim 1, wherein said placing a second composite material in a second mold through which a second skin layer is made comprises:
and paving the prepreg of the second composite material in a second mould, and heating and curing the second composite material through a vacuum bag pressing process to obtain a second skin layer.
4. The method of claim 1, wherein said bonding said first skin layer after demolding to one side of an intermediate structural layer to form a composite comprises:
and laying a first adhesive layer on one side of the first skin layer, and adhering one side of the intermediate structure layer to the first adhesive layer to form a combined body.
5. The method of claim 1, wherein said adhering said combination to said second skin layer in said second mold to obtain a shaped part by heat curing comprises:
laying a second adhesive layer on one side of the second skin layer, and adhering the other side of the intermediate structure layer to the second adhesive layer to form a part to be formed;
and vacuum packaging the part to be molded, and heating and pressurizing the part to be molded through an autoclave process to obtain the molded part.
6. The method of claim 1, wherein:
the first composite material comprises a carbon fiber composite material or a glass fiber composite material; and/or
The second composite material comprises a carbon fiber composite material or a glass fiber composite material;
wherein the first composite material and the second composite material are the same material or different materials.
7. The method of claim 1, wherein:
the intermediate structural layer comprises a honeycomb structure or a foam solid structure.
8. The method according to any one of claims 1 to 7, characterized in that:
the second die comprises a die body and a limiting part, wherein the die body is provided with a cavity, and the limiting part is detachably arranged on one side of the die body along the height direction of the cavity so as to limit the height of the forming part.
9. A molded part produced by the part molding method of the composite material according to any one of claims 1 to 8.
10. An aircraft comprising the shaped part of claim 9.
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| CN117734184A (en) * | 2024-01-19 | 2024-03-22 | 湖北三江航天红阳机电有限公司 | Processing device of composite part and processing method of outer structural layer |
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