KR101806938B1 - Molding apparatus for composite structure using electromagnet and a method for forming the composite structure using the same - Google Patents

Abstract

The present invention relates to a molding device of a composite material structure using an electromagnet, and a molding method of the composite material structure using the molding device. An objective of the present invention is to provide the molding device of the composite material structure using the electromagnet. The molding device is capable of molding a composite material even in a limited space instead of an autoclave requiring a large space for installation, reduces installation costs, and improves safety of installation environment. The molding device of the present invention comprises: a magnetism transmission mold on which a bottom portion of a prepreg-stacked composite material structure is seated, and which transmits a magnetic force to a top portion of the composite material structure; an electromagnet which is attached to a bottom portion of the magnetism transmission mold, and which applies the magnetic force to the magnetism transmission mold; and a magnetism material mixture which contains magnetism materials enabling the magnetic force and attractive force transmitted from the magnetism transmission mold to be generated from the top portion of the composite material structure, and which evenly disperses the attractive force onto the surface of the composite material structure to apply a uniform pressure onto the surface of the composite material structure.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molding apparatus for molding a composite material using an electromagnet and a molding method for a composite material structure using the same.

The present invention relates to a composite material forming apparatus and a method of forming a composite material structure using the same, and more particularly, to a method of forming a composite material structure by providing an environment of high temperature and high pressure in a composite material structure without using an autoclave A composite material structure forming apparatus and a composite material structure forming method using the same.

In recent years, structures using composite materials have been increasingly utilized in the manufacture of transportation means such as air and automobiles because of their light weight and superior non-strength relative to metal. For example, in the railway sector, composite materials are increasingly utilized in the construction of facilities such as automobiles and infrastructures.

However, despite the excellent characteristics of the composite material, the molding process is complicated and the manufacturing cost is relatively high due to the space and size of the auxiliary equipment. Therefore, it is necessary to reduce the manufacturing cost to expand the application of composite materials.

Various techniques are being developed for the molding process for composites. In order to secure the physical properties of the composite material to an ideal maximum, among the various composite manufacturing techniques, a technique capable of uniformly applying heat and pressure has the most excellent physical properties.

Among them, typical molding method is a molding method using an autoclave and has the best physical properties. Unlike a general convection type oven curing method, a high pressure is applied not only to a temperature but also to a whole structure during molding, resulting in relatively high physical properties.

However, the autoclave process must be equipped with large-sized chamber equipment and peripheral equipment (compressor, pressurized gas, etc.) for heating and pressurization, regardless of the size of the structure. there is a problem.

In addition, strict control on safety matters is required because high pressure is applied, and there is a problem in cost because of operating a certain size of autoclave equipment irrespective of the structure size.

Korean Patent Publication No. 10-2013-0019635 Korean Patent Publication No. 10-2015-0090695

SUMMARY OF THE INVENTION Accordingly, the present invention has been made in view of the above problems, and it is an object of the present invention to provide a method and apparatus for molding a composite material in a limited space in place of an autoclave requiring a large space for installation, And more particularly, to a composite material structure molding apparatus using an electromagnet having improved safety.

It is another object of the present invention to provide a method of forming a composite material structure using the composite material structure molding apparatus.

According to one embodiment of the present invention for realizing the object of the present invention, a composite material structure molding apparatus includes a magnetic transfer mold, an electromagnet, and a magnetic material mixture. The magnetic transfer mold seats the lower portion of the composite structure in which the prepregs are stacked, and transmits the magnetic force toward the composite structure. The electromagnet is attached to a lower portion of the magnetic transmission mold and applies a magnetic force to the magnetic transmission mold. The magnetic material mixture contains a magnetic material at an upper portion of the composite material structure and acts on the magnetic force and attraction force transmitted from the magnetic transfer mold to disperse the attraction force on the upper surface of the composite material structure, do.

In one embodiment, the magnetic material mixture may comprise a silicone oil pack or a sol-gel composition containing a magnetic material.

In one embodiment, the controller may further include a controller for controlling the magnitude of the magnetic force of the electromagnet to adjust the magnitude of the pressure applied to the composite structure.

In one embodiment, the apparatus may further include a vacuum blank assembly attached to an upper surface of the composite work structure to seal the composite work structure.

In one embodiment, the vacuum assembly includes a hot blanket to raise the temperature of the composite structure.

In one embodiment, the magnetic transfer mold may comprise an iron metal.

In one embodiment, a vent hose is formed on one side of the magnetic transfer mold and capable of discharging interlayer air between the composite material structure and the magnetic transfer mold or interlayer air between the composite material structure and the magnetic material mixture .

According to another aspect of the present invention, there is provided a method of forming a composite material structure, the method comprising the steps of: placing a composite material structure in which prepregs are laminated on an upper portion of a magnetic transfer mold; Depositing an electromagnet to be transferred on a lower portion of the magnetic transfer mold; depositing a vacuum blank assembly on the composite structure in the order of a magnetic material mixture containing an appropriate amount of magnetic material; A step in which attraction is exerted between the magnetic transfer mold and the magnetic material mixture, and a step in which the attraction is uniformly dispersed in the composite material structure to apply pressure to the composite material structure.

According to the embodiments of the present invention, a composite material can be formed in a limited space instead of an autoclave requiring a large space for installing an autoclave. By simplifying equipment for molding a composite material, installation costs can be reduced, Can be increased.

In addition, the magnetic material mixture includes a silicone oil pack or a sol gel composition containing a magnetic material so that magnetic materials and magnetic force can be spread uniformly on the surfaces of various types of composite materials.

In addition, the magnetic force of the electromagnet can be adjusted in conjunction with the electromagnet through the controller, and the pressure applied to the composite structure can also be adjusted.

In addition, the vacuum blanking assembly can seal the composite structure and provide a hot blanket therein to raise the temperature of the composite structure, thereby providing a high temperature environment to the composite structure as a heat source.

Further, the vent hose can easily discharge the interlayer air between the composite structure and the magnetic transfer mold or the interlayer air between the composite structure and the magnetic material mixture, thereby making the inside of the composite structure molding apparatus into a vacuum state.

1 is an exploded perspective view showing a composite material structure forming apparatus according to an embodiment of the present invention.
2 is a sectional view taken along the line II 'in Fig.
3 is an exploded perspective view of a composite material structure molding apparatus according to another embodiment of the present invention.
FIG. 4 is a flowchart illustrating a method of molding a composite material structure using the composite material structure molding apparatus of FIG. 1 or FIG.

While the present invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not limited to the disclosed embodiments. It is to be understood, however, that the invention is not intended to be limited to the particular forms disclosed, but on the contrary, is intended to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention. Like reference numerals are used for like elements in describing each drawing. The terms first, second, etc. may be used to describe various elements, but the elements should not be limited by the terms. The terms are intended to distinguish one element from another Only. The terminology used in this application is used only to describe a specific embodiment and is not intended to limit the invention. The singular expressions include plural expressions unless the context clearly dictates otherwise. In the present application, the term "comprises" or "comprising ", etc. is intended to specify that there is a stated feature, figure, step, operation, component, But do not preclude the presence or addition of one or more other features, integers, steps, operations, components, parts, or combinations thereof.

Unless defined otherwise, all terms used herein, including technical or scientific terms, have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Terms such as those defined in commonly used dictionaries are to be interpreted as having a meaning consistent with the contextual meaning of the related art and are to be interpreted as either ideal or overly formal in the sense of the present application Do not.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

1 is an exploded perspective view showing a composite material structure forming apparatus according to an embodiment of the present invention. 2 is a cross-sectional view taken along the line I-I 'in Fig. 1 and 2, the apparatus for molding a composite material structure according to the present embodiment includes a magnetic transmission mold 120, an electromagnet 130, a magnetic material mixture 140, and a vent hose 190.

The composite work structure 110 is formed of a fibrous substrate and a matrix. The fibrous substrate may be carbon fiber, aramid fiber, glass fiber, or the like, and may include all those used as a composite material so far.

In the present embodiment, the term matrix refers to a thermosetting resin or a thermoplastic resin as a technical term used in the field of the composite material, and examples of the thermosetting resin include epoxy resin (EP), phenol resin (PF) And a polyester resin (UP). The thermoplastic resin includes, for example, a polypropylene resin (PP), a polyamide resin (PA), an ABS resin (ABS)

In this embodiment, the composite material structure 110 is formed by laminating prepregs impregnated with reinforcing fibers such as carbon fiber, glass fiber, aramid fiber, and a mixture thereof with a matrix of epoxy, polyester, phenol, or the like Curing, or curing by injecting a resin into a reinforced fiber preform, and then cutting it into a desired size and shape.

In addition, the composite material structure 110 may include injection, coating, lamination, etc. of a matrix in addition to impregnating the fibrous substrate with a matrix.

The magnetic transfer mold 120 is positioned below the composite work structure 110 to seat the composite work structure 110. The magnetic transmission mold 120 is made of a metal material including a ferrous metal having a strong magnetic property, and transmits the magnetic force to the composite material structure 110.

The electromagnet 130 is attached to the lower portion of the magnetic transmission mold 120 and transmits a magnetic force to the magnetic transmission mold 120. The magnetic force of the electromagnet 130 is adjustable in association with the controller (360 in Fig. 3).

The magnetic material mixture 140 is attached to the top of the composite structure 110 and contains magnetic particles. The magnetic particles may be at least one selected from the group consisting of a magnetic metal, an oxide thereof, a ferromagnetic metal, and an intermetallic compound containing a ferromagnetic metal.

Since the magnetic material mixture 140 is magnetized, the magnetic material mixture 140 acts on the magnetic force applied from the magnetic transfer mold 120 and disperses the attractive force evenly to the composite material structure 110 located at the lower portion. At this time, pressure is uniformly applied to the composite work structure 110 disposed between the magnetic transmission mold 120 and the magnetic material mixture 140 through the attraction action.

Accordingly, the magnetic transmission mold 120 and the magnetic material mixture 140 serve to apply pressure to the composite structure 110 as a pressure source, and can generate a high-pressure environment similar to an autoclave.

In this embodiment, the magnetic material mixture 140 may include a silicone oil pack or a sol-gel composition containing a magnetic material.

Due to the flow characteristics of silicon, the silicone oil pack can uniformly spread magnetic material on the surface of various types of composite material structures 110. Wherein the silicone oil pack contains silicon-containing crosslinked particles in a water-dispersed silicone oil droplet, wherein the silicone oil is an alkyl-modified silicone oil having at least a C4 alkyl group bonded to silicon.

The sol-gel composition may contain a magnetic material therein in a kneaded form to uniformly distribute the magnetic force to the composite structure 110. The sol-gel composition may comprise magnetic particles, gold particles, electrically conductive particles.

The composite material forming apparatus 100 according to the present embodiment may further include a vent hose 190 formed on one side of the magnetic transmission mold 120. When the composite material structure 110 is a flat plate, pressure can be uniformly applied to the composite material structure 110 by attraction between the magnetic transfer mold 120 and the magnetic material mixture 140, When the composite material structure 110 is curved, pressure may not be uniformly applied to the composite material structure 110.

In this case, when the composite material structure 110 is curved, the pressure acting on the curved surface is not uniform, so that a pressure difference occurs on the curved surface. Layer air between the composite material structure 110 and the magnetic transfer mold 120 through the vent hose 190 formed at one side of the magnetic transfer mold 120 using the pressure difference, ) And the magnetic material mixture 140 or the air inside the composite material structure molding apparatus 100 may be discharged to make the inside of the composite material structure molding apparatus 100 in a vacuum state.

The composite material forming apparatus 100 according to the present embodiment may further include a vacuum blanking assembly 150 between the magnetic material mixture 140 and the composite material structure 110.

The vacuum blanking assembly 150 is composed of a vacuum bag and a hot blanket and is attached on the composite work structure 110 to compactly seal the composite work structure 110. In addition, the vacuum blanking assembly 150 includes a hot blanket therein, thereby raising the temperature of the composite work structure 110 by the hot blanket. The hot blanket serves as a heat source to provide a high temperature environment for the composite structure 110.

In addition, the vacuum release assembly 150 may be attached to the upper portion of the composite material structure 110, but may be configured to surround the composite material structure 110. As the vacuum blank assembly 150, a material of a material already known in the autoclave may be used. For example, nylon, polyimide, and the like may be used as long as they have heat resistance and water resistance such as silicone rubber.

The vacuum assembly 150 may include a vacuum bag, a hot blanket, a peel ply, a porous film, a bleeder, and the like. The vacuum bag and the bleeder can be attached by disposing the double-sided adhesive tape strip between the vacuum bag and the bleeder

In this embodiment, the composite structure 110 is heated by a hot blanket within the vacuum blanking assembly 150 and pressurized by the magnetic transfer mold 120 and the magnetic material mixture 140. Therefore, as in the case of the autoclave process, there is no need to provide large-sized chamber equipments and peripheral equipments for increasing the temperature and pressurizing (compressor, pressurized gas, etc.), thus reducing the installation cost and replacing the autoclave So that the composite material can be formed even in a limited space.

3 is an exploded perspective view of a composite material structure molding apparatus according to another embodiment of the present invention.

The composite material structure molding apparatus 300 according to the present embodiment is the same as the composite material structure molding apparatus 100 described with reference to FIGS. 1 and 2 except that the molding apparatus further includes a controller 360 , Redundant explanations are omitted. 3, the composite material structure forming apparatus 310 according to the present embodiment includes a composite material structure 310, a magnetic transfer mold 320, an electromagnet 330, a magnetic material mixture 340, 350, a vent hose 390, and a controller 360.

In this case, the composite structure 310, the magnetic transmission mold 320, the electromagnet 330, the magnetic material mixture 340, and the vacuum blanking assembly 350 are the same as those described in FIGS. 1 and 2.

The controller 360 is electrically connected to the electromagnet 330.

Therefore, the magnetic force of the electromagnet 330 can be adjusted in conjunction with the electromagnet 330. The electromagnet 330 generates magnetic attraction force between the magnetic transfer mold 320 and the magnetic material mixture 340 by transmitting magnetic force to the magnetic transfer mold 320 so that pressure is applied to the composite work structure 310 Is applied.

At this time, as the magnetic force of the electromagnet 330 increases, the attracting force between the magnetic transmission mold 320 and the magnetic material mixture 340 becomes larger, and the magnitude of the pressure applied to the composite structure 310 also increases. As the magnetic force is smaller, the attracting force between the magnetic transmission mold 320 and the magnetic material mixture 340 becomes smaller, so that the magnitude of the pressure applied to the composite material structure 310 becomes smaller. Accordingly, the magnitude of the electromagnet 330 can be adjusted through the controller 360, so that the pressure applied to the composite structure 310 can be adjusted.

FIG. 4 is a flowchart illustrating a method of molding a composite material structure using the composite material structure molding apparatus of FIG. 1 or FIG.

Referring to FIG. 4, the composite structures 110 and 310 having the prepregs stacked thereon are placed on top of the magnetic transmission molds 120 and 320 (step S10). In the prepreg base material, it is preferable that the plurality of arranged reinforcing fibers are in close contact with the surface of a tape or sheet-like support. Examples of the support on the tape or sheet include paper such as kraft paper and release paper, resin films such as polyethylene and polypropylene resin, and metal foils such as aluminum foil.

Then, electromagnets 130 and 330 for transmitting a magnetic force to the magnetic transfer molds 120 and 320 are attached to the lower portion of the magnetic transfer mold (step S20).

In this embodiment, the mold may be manufactured by simply machining a bulk block of a magnetic material, machining a block of non-magnetic or non-metallic material, or by plating, plasma deposition, sputtering, Deposition of a layer of a magnetic material, or the like.

Next, the vacuum blank assemblies 150 and 350 are stacked on the composite material structures 110 and 310, and the magnetic material mixture 140 and 340 containing an appropriate amount of magnetic material are stacked in this order (step S30). The vacuum bag assemblies 150 and 350 are secured around the composite work structures 110 and 310. This fixation process may be performed manually by pressing the vacuum blanking assemblies 150, 350 toward the composite work structures 110, 310. However, according to the application example, it is also possible to use a mechanical structure or a tool (not shown), at least in part, to carry out the fixing process.

Further, the magnitude of the magnetic force of the electromagnet is adjusted by the controller 360 (step S40). The controller 360 may be attached to the electromagnets 130 and 330 and may be configured to transmit an input signal to the electromagnet by wire or wirelessly. That is, the controller 360 can be installed to transmit an input signal wirelessly by Bluetooth (not shown) or to transmit an input signal through a signal transmission cable 370 connected to a connector.

Next, an attractive force acts between the magnetic transfer molds 120 and 320 and the magnetic material mixture 140 and 340 (step S50), and the attractive force is uniformly dispersed in the composite material structures 110 and 310 Pressure is applied to the composite work structures 110 and 310 (step S60).

Therefore, the magnetic transfer molds 120 and 130 and the magnetic material mixture 140 and 340 serve to apply pressure to the composite material structures 110 and 310 as a pressure source, .

If the composite material structures 110 and 310 are curved surfaces other than flat plates after pressure is applied to the composite material structures 110 and 310 (step S60), the pressure is not uniformly applied to the curved surfaces A pressure difference occurs. Accordingly, the interlayer air between the composite material structure and the magnetic transfer mold or the interlayer air between the composite material structure and the magnetic material mixture can be discharged using the pressure difference.

According to the embodiments of the present invention, a composite material can be formed in a limited space instead of an autoclave requiring a large space for installing an autoclave. By simplifying equipment for molding a composite material, installation costs can be reduced, Can be increased.

In addition, the magnetic material mixture includes a silicone oil pack or a sol gel composition containing a magnetic material so that magnetic materials and magnetic force can be spread uniformly on the surfaces of various types of composite materials.

In addition, the magnetic force of the electromagnet can be adjusted in conjunction with the electromagnet through the controller, and the pressure applied to the composite structure can also be adjusted.

In addition, the vacuum blanking assembly can seal the composite structure and provide a hot blanket therein to raise the temperature of the composite structure, thereby providing a high temperature environment to the composite structure as a heat source.

Furthermore, the vent formed on one side of the magnetic transfer mold can easily discharge interlayer air between the composite material structure and the magnetic transfer mold or interlayer air between the composite material structure and the magnetic material mixture, thereby vacuuming the inside of the composite structure molding device .

It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the present invention as defined by the following claims. It can be understood that it is possible.

100: Composite structure forming device 110: Composite structure
120: Magnetic transmission mold 130: Electromagnet
140: magnetic material mixture 150: vacuum blank assembly
310: Composite material structure 320: Magnetic transmission mold
330: electromagnet 340: magnetic material mixture
350: Negative blank assembly 360: Controller

Claims (9)

A magnetic transmission mold on which a lower portion of the composite structure in which the prepregs are stacked is mounted and which transmits a magnetic force toward the composite structure;
An electromagnet attached to a lower portion of the magnetic transmission mold and applying a magnetic force to the magnetic transmission mold;
A magnetic material mixture containing a magnetic material at an upper portion of the composite material structure and acting as a magnetic force and attraction force transmitted from the magnetic transfer mold and distributing the attraction force to the upper surface of the composite material structure to apply a uniform pressure to the upper surface; And
And a vacuum blank assembly attached to an upper surface of the composite work structure to seal the composite work structure,
Wherein the vacuum blanking assembly includes a hot blanket to raise the temperature of the composite work structure. The method according to claim 1,
Wherein the magnetic material mixture comprises a silicone oil pack or a sol-gel composition containing a magnetic material. The method according to claim 1,
And a controller for adjusting the magnitude of the magnetic force of the electromagnet to adjust the magnitude of the pressure applied to the composite structure. delete delete The method according to claim 1,
Wherein the magnetic transfer mold comprises an iron metal. The method according to claim 1,
And a vent hose formed at one side of the magnetic transfer mold and capable of discharging interlayer air between the composite material structure and the magnetic transfer mold or interlayer air between the composite material structure and the magnetic material mixture. A composite structure forming device. Placing the composite structure having the prepregs stacked on top of the magnetic transmission mold;
Attaching an electromagnet for transmitting a magnetic force to the magnetic transmission mold to a lower portion of the magnetic transmission mold;
Stacking the composite blank structure in the order of a vacuum blank assembly and a magnetic material mixture containing an appropriate amount of magnetic material;
Adjusting a magnitude of the magnetic force of the electromagnet with a controller;
Applying a force between the magnetic transfer mold and the magnetic material mixture; And
Wherein the gravitational force is uniformly dispersed in the composite material structure to apply pressure to the composite material structure. 9. The method of claim 8,
Venting air between the composite material structure and the magnetic transmission mold or ventilating the interlayer air between the composite material structure and the magnetic material mixture through a vent hose.

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