Lightweight heat-insulating composite window frame component with electromagnetic shielding function and preparation method thereof

Abstract

This invention relates to a lightweight thermal insulation composite window frame component with electromagnetic shielding function and its preparation method. The window frame component is characterized by being divided into five functional layers: a main load-bearing layer (1), a fiberglass embedded part (3), a thermal insulation and weight reduction layer (4), an airtight layer (6), and an electromagnetic shielding layer (7). The electromagnetic shielding layer (7) is located on the outermost layer of the window frame component. The airtight layer (6) and the electromagnetic shielding layer (7) are adjacent layers, with the airtight layer (6) located inside the electromagnetic shielding layer (7) and bonded together. This invention achieves the integration of multiple functions such as lightweight, thermal insulation, electromagnetic shielding, and airtightness in the window frame component, as well as high-quality structural molding, through material design of the main load-bearing layer, thermal insulation and weight reduction layer, airtight layer, and electromagnetic shielding layer, interlayer interface reinforcement, and molding process design.

Description

Technical Field

[0001] This invention relates to the field of structural design and functional integration of composite material components, specifically to a lightweight thermal insulation composite window frame component with electromagnetic shielding function and its preparation method, which is used for the structural design and molding of components with requirements such as lightweight, thermal insulation, electromagnetic shielding, and airtightness. Background Technology

[0002] Composite window frame components are important components of storage and transportation equipment. They contain functional components. Due to the overall structural requirements, window frame components need to have multiple functions such as lightweight, heat insulation, electromagnetic shielding, and airtightness. Traditional window frames have single functions, difficult functional integration and matching, and difficult to control the molding quality between functional layers. Summary of the Invention

[0003] The purpose of this invention is to provide a multifunctional composite material window frame component and its preparation method, so as to solve the problem of limited functionality of window frame components in the prior art.

[0004] A lightweight, heat-insulating composite window frame component with electromagnetic shielding function is characterized in that the window frame component is mainly divided into five functional layers, including a main load-bearing layer 1, a fiberglass embedded part 3, a heat-insulating and weight-reducing layer 4, an airtight layer 6, and an electromagnetic shielding layer 7. The electromagnetic shielding layer 7 is the outermost layer of the window frame component. The airtight layer 6 is adjacent to the electromagnetic shielding layer 7, located inside the electromagnetic shielding layer 7 and bonded to it. The inner side of the airtight layer 6 is adjacent to the main load-bearing layer 1, which bears the main rigidity and strength of the window frame component. The heat-insulating and weight-reducing layer 4 is embedded inside the structure of the main load-bearing layer 1 to reduce the weight of the window frame component and insulate the temperature inside and outside the window frame. The fiberglass embedded part 3 is embedded in the pre-embedded hole 403 of the heat-insulating and weight-reducing layer 4. The steel sleeve 2 is cylindrical and is embedded in the pre-fabricated holes of the main load-bearing layer 1 and the fiberglass embedded part 3 to increase the structural connection strength.

[0005] The electromagnetic shielding layer 7 is a composite layer with a structure of adhesive film + high-density conductive metal mesh + adhesive film. The high-density conductive metal mesh enables overall conductivity on the outer surface of the window frame. The electromagnetic shielding layer 7 is divided into three parts: bottom shielding layer 701, side shielding layer 702, and top shielding layer 703. The three parts overlap by 3-5mm to achieve conductive connection. The adhesive film can enhance the composite strength between the high-density conductive metal mesh and the main load-bearing layer 1, and prevent defects such as insufficient adhesive, debonding, and air holes in the electromagnetic shielding layer and the main load-bearing layer from affecting the airtightness and structural strength of the window frame.

[0006] The main bearing layer 1 is made of high-strength glass fiber reinforced epoxy resin prepreg. An airtight layer 6 is designed between the main bearing layer 1 and the electromagnetic shielding layer 7. The airtight layer 6 is made of glass fiber felt + epoxy resin to form a resin-rich layer. The thickness of the main bearing layer 1 is not less than 3mm.

[0007] The heat insulation and weight reduction layer 4 is made of high-temperature resistant polyurethane foam, and the foam density is controlled at 0.03 g / m³ based on the weight index of the window frame. 3 ~0.3g / m 3 Between these elements, the low thermal conductivity of the foam ensures the overall thermal insulation performance of the window frame.

[0008] Inside the window frame, fiberglass embedded parts 3 are pre-embedded at the corresponding positions of the threaded holes. The fiberglass embedded parts 3 are installed in the corresponding pre-embedded holes of the heat insulation and weight reduction layer 4. They have a T-shaped structure to prevent relative rotation of the fiberglass embedded parts 3 when drilling and installing the window frame.

[0009] A method for preparing a lightweight thermally insulated composite window frame component with electromagnetic shielding function, characterized by comprising the following:

[0010] Step 1: Preparations before tiling the functional layer of the window frame components: (1) Before tiling, check the types and quantities of raw materials required for tiling to ensure that the raw materials are within their validity period and meet the usage requirements; check the mold cavity size, the surface quality of the tiling surface, and the pressure method to ensure that the tiling requirements are met.

[0011] (2) Wipe away grease and other dirt from the mold with a clean cotton cloth or absorbent cotton soaked in gasoline. Apply mold release agent evenly to the forming surface and parting surface of the mold with a clean cotton cloth or absorbent cotton soaked in gasoline. Repeat the application of mold release agent at least three times after 15-minute intervals.

[0012] Step 2: Pre-forming of the heat insulation and weight reduction layer 4:

[0013] (1) The heat insulation and weight reduction layer 4 is made of high temperature resistant polyurethane foam material. The foam blank is formed by resin heating and foaming molding process. After the foam blank is completed, it is processed into the required structural size by mechanical processing. Foam 401 and foam 402 are processed on the heat insulation and weight reduction layer 4. After the heat insulation and weight reduction layer 4 is processed, the excess material on the surface is blown off with an air gun. (2) A layer of epoxy resin film is laid on the foam surface, and then 2-3 layers of glass fiber prepreg are laid. After the laying is completed, vacuum heating is performed. After curing, the surface and edges are polished and cleaned.

[0014] (3) The pre-embedded hole 403 of the fiberglass embedded part 3 is processed again on the upper surface of the heat insulation and weight reduction layer 4. The pre-embedded hole is a T-shaped stepped hole. The fiberglass embedded part 3 is pre-embedded into the pre-embedded hole 403 and is ready for internal assembly and use.

[0015] Step 3: Pre-forming of electromagnetic shielding layer 7:

[0016] (1) The electromagnetic shielding layer 7 is a composite structure of adhesive film + high-density conductive metal mesh + adhesive film. Cut two adhesive films and one piece of metal copper mesh, pre-form the electromagnetic shielding layer on a clean and flat metal plate, and lay them in the order of adhesive film-metal copper mesh-corner. After laying, vacuum bag is used to pre-press at 60°C for 1 hour to fully pre-impregnate the metal copper mesh with adhesive liquid.

[0017] (2) Expel the air between the copper mesh and the adhesive film, and after cooling to room temperature, cut the blank of the electromagnetic shielding layer 7 on the cutting machine; the electromagnetic shielding layer 7 is divided into three parts, namely the bottom shielding layer 701, the side shielding layer 702, and the upper shielding layer 703.

[0018] Step 4: Apply electromagnetic shielding layer 7 to the mold surface.

[0019] (1) First, apply the bottom shielding layer 701 to the mold laying surface, and then apply the side shielding layer 702. The two parts overlap by 3-5mm to achieve conductive connection.

[0020] (2) A layer of glass fiber surface felt is laid on the electromagnetic shielding layer 7, and then a layer of epoxy resin is evenly brushed on the surface felt as an airtight layer 6. Then the inner layer of the main bearing layer 1 is laid 5mm, and the joints of each layer are staggered. During the laying process, the gas between the layers is discharged by scraping with a scraper and vacuum pre-pressing.

[0021] (3) After the inner 5mm layer is laid, hot-pressing is carried out at 60℃. After the temperature drops to room temperature after pre-pressing, the sealing material is removed and the material is cleaned and repaired.

[0022] Step 5, Pre-embedding of heat insulation and weight reduction layer 4: After the inner layer is hot-extracted and cooled, the pre-formed heat insulation and weight reduction layer 4 is placed on the main load-bearing layer 1 using special tooling. Then, the outer 5mm layer of the main load-bearing layer 1 is laid, with the joints of each layer staggered. During the laying process, the interlayer gas is discharged by means of scraping and vacuum pre-pressing. After the inner layer is laid, it is hot-extracted and pre-pressed at 60℃. After the temperature drops to room temperature after pre-pressing, the encapsulation material is removed and the layer is cleaned and repaired.

[0023] Step 6, Fabrication of electromagnetic shielding layer 7: After the main support layer is laid, fold the higher part of the side shielding layer 702 90° and lay it on the upper surface of the main support layer 1. Finally, lay the upper shielding layer 703 on the upper surface of the main support layer 1 and overlap it with the folded part of the side shielding layer 702 to make it conductive.

[0024] Step 7, Mold Closure and Curing: After all the tiling is completed, assemble the outer mold and the upper mold. After the mold is closed, hoist the mold onto the hot press for mold closure and curing. The gap between the molds should not exceed 0.1mm.

[0025] Step 8: After the window frame has cured, demold, clean and trim it. Then, process the pre-processed holes for the steel sleeve 2. After the holes are processed, apply glue to the external thread of the processed steel sleeve 2 and screw it into the hole. The upper end of the steel sleeve 2 should not protrude from the upper surface of the window frame. Curing takes 3 hours at room temperature.

[0026] Beneficial effects

[0027] This invention achieves a high-quality integrated structure and multiple functions for window frame components, including lightweight construction, thermal insulation and weight reduction, airtightness, and electromagnetic shielding, through material design of the main load-bearing layer, thermal insulation and weight reduction layer, airtight layer, and electromagnetic shielding layer, as well as interlayer interface reinforcement and molding process design. The invention is ingeniously designed, structurally simple, low-cost, and integrates multiple functions into one. Attached Figure Description

[0028] Figure 1 , are schematic diagrams of the structure of the present invention;

[0029] (a) Schematic diagram of the window frame components of the present invention;

[0030] (b) is the AA section view of (a);

[0031] Figure 2 ,yes Figure 1 Enlarged view of point B in (b);

[0032] Figure 3 1 is a schematic diagram of the steel sleeve structure of the present invention;

[0033] (a) Top view of the steel sleeve structure of the present invention;

[0034] (b) is the AA section view of (a);

[0035] Figure 4 1 is a schematic diagram of the fiberglass embedded part of the present invention;

[0036] (a) Front view of the fiberglass embedded part of the present invention;

[0037] (b) A perspective view of the fiberglass embedded part of the present invention;

[0038] Figure 5 1. This is a schematic diagram of the electromagnetic shielding layer of the present invention;

[0039] Figure 6 The diagram shows the heat insulation and weight reduction layer of this invention. Detailed Implementation

[0040] A lightweight, thermally insulated composite window frame component with electromagnetic shielding function and its manufacturing method are disclosed. The window frame component mainly consists of five functional layers: a main load-bearing layer 1, a fiberglass embedded part 3, a thermal insulation and weight-reducing layer 4, an airtight layer 6, and an electromagnetic shielding layer 7. The multi-functional layers of the window frame are compositely formed using a molding process. The electromagnetic shielding layer 7 is the outermost layer of the window frame component and is conductive to other structural circuits, achieving the overall electromagnetic shielding performance of the structure. The airtight layer 6 is adjacent to the electromagnetic shielding layer 7 and is a resin-rich layer, ensuring airtightness. The main load-bearing layer 1 is adjacent to the airtight layer 6 and mainly serves to ensure the rigidity and strength of the entire window frame, guaranteeing the airtightness of the product. The thermal insulation and weight-reducing layer 3 is embedded inside the main load-bearing structure, reducing the weight of the window frame component, isolating the temperature inside and outside the window frame, and maintaining the relative stability of the internal temperature of the window frame component. The fiberglass embedded part 3 is embedded inside the thermal insulation and weight-reducing layer 3, and a steel sleeve 2 is embedded in the pre-drilled holes in the main load-bearing layer and the fiberglass embedded part 3, mainly increasing the structural connection strength. The composite material window frame component of the present invention has functions such as lightweight, heat insulation, and electromagnetic shielding.

[0041] The electromagnetic shielding layer 7 is a composite layer with a structure of adhesive film + high-density conductive metal mesh + adhesive film. The conductive metal mesh enables overall conductivity on the outer surface of the window frame, and the adhesive film enhances the composite strength between the conductive metal mesh and the main load-bearing layer 1, thus preventing defects such as insufficient adhesive, debonding, and air holes in the electromagnetic shielding layer and the main load-bearing layer from affecting the airtightness and structural strength of the window frame.

[0042] The main bearing layer 1 is made of high-strength glass fiber reinforced epoxy resin prepreg. An airtight layer 6 is designed between the main bearing layer 1 and the electromagnetic shielding layer 7. The airtight layer is made of glass fiber felt + epoxy resin to form a resin-rich layer. The thickness of the main bearing layer is not less than 3mm.

[0043] The heat insulation and weight reduction layer 4 is made of high-temperature resistant polyurethane foam, with a foam density of 0.03 g / m³ based on the weight of the window frame. 3 ~0.3 g / m 3 Density control and low thermal conductivity of the foam ensure the overall thermal insulation performance of the window frame.

[0044] Inside the window frame, fiberglass embedded parts 3 are pre-embedded at the corresponding positions of the threaded holes. The embedded parts are installed in the corresponding pre-embedded holes of the insulation foam. The fiberglass embedded parts 3 have a T-shaped structure to prevent relative rotation of the embedded parts when drilling holes in the window frame and during installation.

[0045] The window frame's mounting threaded holes adopt a structure where steel sleeves 2 are installed on fiberglass embedded parts. The bottom holes for installing steel sleeves 2 are machined on the embedded parts, and the steel sleeves 2 are then glued in place to improve the strength and reliability of the window frame's threaded connection.

[0046] The window frame mold is designed as a modular assembly, with a sloping pressure structure and simultaneous pressure on the sides and top. The outer mold is designed as a double-layer structure to prevent material clamping during mold closure and ensure the net dimensions of the components are formed.

[0047] The window frame components are formed through a process of functional layer laying and molding. The laying sequence is electromagnetic shielding layer 5 - airtight layer 6 - main load-bearing layer 1 - thermal insulation and weight reduction layer 4 - main load-bearing layer 1. During the laying process, vacuum pre-compaction is used to improve the quality between functional layers and inside the window frame. The thermal insulation and weight reduction layer 4 is a structure of a solidified glass fiber thin-walled hard shell with an outer layer of thermal insulation foam. Before the thermal insulation and weight reduction layer 4 is embedded, 2-3 layers of prepreg are laid on its outer surface, and then vacuum curing is performed to enhance the strength and rigidity of the thermal insulation and weight reduction layer 4. This avoids the problem of insufficient molding pressure of the main load-bearing layer due to the weak compressive strength of the low-density foam of the thermal insulation and weight reduction layer 3, and ensures sufficient molding pressure during the molding process of the window frame.

[0048] A lightweight, thermally insulated composite window frame component with electromagnetic shielding function and its manufacturing method are disclosed. The window frame component mainly consists of five functional layers: a main load-bearing layer 1, a fiberglass embedded part 3, a thermal insulation and weight reduction layer 4, an airtight layer 6, and an electromagnetic shielding layer 7. The multi-functional layers of the window frame are compositely formed using a molding process. The electromagnetic shielding layer 7 is the outermost layer of the window frame component and is electrically connected to other structural components outside the window frame component, achieving the electromagnetic shielding performance of the overall structure. The airtight layer 6 is adjacent to the electromagnetic shielding layer 7 and is a resin-rich layer, ensuring airtightness. The main load-bearing layer 1 is adjacent to the airtight layer 6 and mainly serves to ensure the rigidity and strength of the entire window frame, guaranteeing the airtightness of the product. The heat insulation and weight reduction layer 3 is embedded inside the main load-bearing structure to reduce the weight of the window frame components, insulate the temperature inside and outside the window frame, and maintain a relatively stable temperature inside the window frame components. Fiberglass embedded parts 3 are embedded in the pre-embedded holes 403 of the heat insulation and weight reduction layer 3. Steel sleeves 2 are embedded in the pre-drilled holes of the main load-bearing layer and the fiberglass embedded parts 3, mainly serving to increase the structural connection strength. The composite material window frame components of this invention possess functions such as lightweight, heat insulation, and electromagnetic shielding.

[0049] The electromagnetic shielding layer 7 is a composite layer with a structure of adhesive film + high-density conductive metal mesh + adhesive film. The conductive metal mesh enables overall conductivity on the outer surface of the window frame. The electromagnetic shielding layer 7 is divided into three parts: bottom shielding layer 701, side shielding layer 702, and top shielding layer 703. The three parts overlap by 3-5mm to achieve conductive connection. The adhesive film enhances the composite strength between the conductive metal mesh and the main load-bearing layer 1, preventing defects such as insufficient adhesive, delamination, and air holes in the electromagnetic shielding layer and the main load-bearing layer from affecting the airtightness and structural strength of the window frame.

[0050] The main bearing layer 1 is made of high-strength glass fiber reinforced epoxy resin prepreg. An airtight layer 6 is designed between the main bearing layer 1 and the electromagnetic shielding layer 7. The airtight layer is made of glass fiber felt + epoxy resin to form a resin-rich layer. The thickness of the main bearing layer is not less than 3mm.

[0051] The heat insulation and weight reduction layer 4 is made of high-temperature resistant polyurethane foam, with a foam density of 0.03 g / m³ based on the weight of the window frame. 3 ~0.3g / m 3 Density control and low thermal conductivity of the foam ensure the overall thermal insulation performance of the window frame.

[0052] Inside the window frame, fiberglass embedded parts 3 are pre-embedded at the corresponding positions of the threaded holes. The embedded parts are installed in the corresponding pre-embedded holes of the insulation foam. The fiberglass embedded parts 3 have a T-shaped structure to prevent relative rotation of the embedded parts when drilling holes in the window frame and during installation.

[0053] The window frame's mounting threaded holes adopt a structure where steel sleeves 2 are installed on fiberglass embedded parts. The bottom holes for installing steel sleeves 2 are machined on the embedded parts, and the steel sleeves 2 are then glued in place to improve the strength and reliability of the window frame's threaded connection.

[0054] The window frame mold is designed as a modular assembly, with a sloping pressure structure and simultaneous pressure on the sides and top. The outer mold is designed as a double-layer structure to prevent material clamping during mold closure and ensure the net dimensions of the components are formed.

[0055] The window frame components are formed through a process of functional layer laying and molding. The laying sequence is electromagnetic shielding layer 5 - airtight layer 6 - main load-bearing layer 1 - thermal insulation and weight reduction layer 4 - main load-bearing layer 1. During the laying process, vacuum pre-compaction is used to improve the quality between functional layers and inside the window frame. The thermal insulation and weight reduction layer 4 is a structure of a solidified glass fiber thin-walled hard shell with an outer layer of thermal insulation foam. Before the thermal insulation and weight reduction layer 4 is embedded, 2-3 layers of prepreg are laid on its outer surface, and then vacuum curing is performed to enhance the strength and rigidity of the thermal insulation and weight reduction layer 4. This avoids the problem of insufficient molding pressure of the main load-bearing layer due to the weak compressive strength of the low-density foam of the thermal insulation and weight reduction layer 3, and ensures sufficient molding pressure during the molding process of the window frame.

[0056] This embodiment discloses a lightweight thermal insulation composite window frame component with electromagnetic shielding function and its preparation method. In order to make the structure and molding process of the present invention more obvious and easy to understand, specific embodiments are provided and described in detail with reference to the accompanying drawings.

[0057] Example:

[0058] The main structure of the component of this invention includes a main load-bearing layer 1, a steel sleeve 2, a fiberglass embedded part 3, a heat insulation and weight reduction layer 4, an airtight layer 6, and an electromagnetic shielding layer 7. These components are composite molded by laying them on a metal forming mold and then heating and curing them in a hot press. This achieves functional integration of the composite material window frame component.

[0059] 1. Before installation, check the types and quantities of raw materials required for installation, ensuring that the materials are within their expiration date and meet the usage requirements. Check that the mold cavity dimensions, the surface quality of the installation surface, and the pressure application method meet the installation requirements.

[0060] 2. Wipe away grease and other dirt from the mold with a clean cotton cloth or absorbent cotton soaked in gasoline. Apply mold release agent (55-NC) evenly to the forming surface and parting surface of the mold with a clean cotton cloth or absorbent cotton soaked in gasoline. Repeat the application of mold release agent at least three times, with an interval of 15 minutes between applications.

[0061] 3. Machining of steel sleeves 2 and fiberglass embedded parts 3, structure as follows Figure 3 , Figure 4 .

[0062] 4. Pre-forming of heat insulation and weight reduction layer 4: The heat insulation and weight reduction layer 4 is made of high-temperature resistant polyurethane foam material. The foam blank is formed through a resin heating and foaming process. After the foam blank is completed, it is machined to the required structural dimensions. The structural form of the heat insulation and weight reduction layer 4 is as follows: Figure 3 After the foams 401 and 402 shown are processed, the excess material on the surface is blown away with an air gun. A layer of epoxy resin film is laid on the foam surface, and then 2-3 layers of glass fiber prepreg are laid. After laying, vacuum heating is applied and cured. After curing, the surface and edges are polished and cleaned. Then, the pre-embedded holes 403 of the fiberglass embedded parts 3 are processed on the upper surface of the thermal insulation and weight reduction layer 4. The pre-embedded holes are T-shaped stepped holes. The fiberglass embedded parts 3 are pre-embedded into the pre-embedded holes 403 for internal assembly and use.

[0063] 5. Electromagnetic shielding layer 7 preforming: Electromagnetic shielding layer 7 is a composite structure of adhesive film + high-density conductive metal mesh + adhesive film. Two 2m*1m adhesive films and one piece of copper metal mesh are cut and preformed on a clean and flat metal plate. The adhesive film-copper metal mesh-corner film are laid in the order of adhesive film-copper metal mesh-corner film. After laying, the metal mesh is vacuum-packed and pre-pressed at 60℃ for 1 hour to fully pre-impregnate the copper metal mesh with adhesive and remove the air between the copper metal mesh and the adhesive film. After cooling to room temperature, the blank of electromagnetic shielding layer 7 is cut on a cutting machine. Electromagnetic shielding layer 7 is divided into three parts: bottom shielding layer 701, side shielding layer 702, and top shielding layer 703.

[0064] 6. Lay the electromagnetic shielding layer 7 on the mold surface. First, lay the bottom shielding layer 701 and the side shielding layer 702, overlapping the two parts by 3-5mm to achieve conductive connection. Lay a layer of fiberglass surface felt on the electromagnetic shielding layer 7, and then evenly brush a layer of epoxy resin on the surface felt as an airtight layer 6. Then lay the inner 5mm of the main load-bearing layer 1, with the joints of each layer staggered. During the laying process, the interlayer gas is discharged by means of scraping with a scraper and vacuum pre-compression. After the inner 5mm is laid, it is hot-pressed at 60℃. After the pre-compression reaches room temperature, the encapsulation material is removed and the surface is cleaned and repaired.

[0065] 7. Pre-embedding of heat insulation and weight reduction layer 4: After the inner layer is hot-extracted and cooled, the pre-formed heat insulation and weight reduction layer 4 is placed on the main load-bearing layer 1 using special tooling. Then, the outer 5mm layer of the main load-bearing layer 1 is laid. The joints of each layer are staggered. During the laying process, the gas between the layers is discharged by means of scraping and vacuum pre-pressing. After the inner 5mm layer is laid, it is hot-extracted and pre-pressed at 60℃. After the pre-pressing reaches room temperature, the encapsulation material is removed and the layers are cleaned and repaired.

[0066] 8. After the main load-bearing layer is laid, fold the higher part of the side facade shielding layer 702 90° and lay it on the upper surface of the main load-bearing layer 1. Finally, lay the upper end shielding layer 703 on the upper surface of the main load-bearing layer 1 and overlap it with the folded part of the side facade shielding layer 702 to make it conductive.

[0067] 9. After all the tiling is completed, assemble the outer mold and the upper mold. After the mold is closed, hoist the mold onto the hot press for mold closing and curing. The gap between the molds should not be greater than 0.1mm.

[0068] 10. After the window frame has cured, demolding, cleaning and trimming are carried out. Then, the steel sleeve 2 is processed into the inlay hole. After the inlay hole is processed, the outer thread of the processed steel sleeve 3 is coated with glue and screwed into the hole. The upper end face of the steel sleeve 2 should not protrude from the upper surface of the window frame. Curing is carried out at room temperature for 3 hours.

[0069] This invention discloses a lightweight thermal insulation composite window frame component with electromagnetic shielding function and its preparation method. The lightweight design of the window frame structure is achieved through material selection, functional layer design, and composite processes. The entire window frame is made of fiberglass, with a pre-embedded thermal insulation and weight reduction layer 4 in the middle to achieve both lightweight design and high thermal insulation performance. Electromagnetic shielding performance is achieved through the design of an electromagnetic shielding layer 7, and the airtightness of the window frame is ensured by using epoxy resin pre-impregnated on the surface of fiberglass mat as an airtight layer 6. This invention employs a functional layer lamination and molding process to achieve high-quality molding and composite of the main load-bearing layer 1, the thermal insulation and weight reduction layer 4, the airtight layer 6, and the electromagnetic shielding layer 7.

Claims

1. A lightweight, heat-insulating composite material window frame component with electromagnetic shielding function, characterized in that, The window frame components are mainly divided into five functional layers, including the main load-bearing layer (1), fiberglass embedded parts (3), heat insulation and weight reduction layer (4), airtight layer (6), and electromagnetic shielding layer (7). Among them, the electromagnetic shielding layer (7) is the outermost layer of the window frame components, the airtight layer (6) and the electromagnetic shielding layer (7) are adjacent layers, the airtight layer (6) is inside the electromagnetic shielding layer (7) and is attached to the electromagnetic shielding layer (7); the airtight layer (6) is adjacent to the main load-bearing layer (1) on the inside, and the main load-bearing layer (1) bears the main rigidity and strength of the window frame components; the heat insulation and weight reduction layer (4) is embedded in the structure of the main load-bearing layer (1) to reduce the weight of the window frame components and isolate the temperature inside and outside the window frame; the fiberglass embedded parts (3) are embedded in the pre-embedded holes (403) of the heat insulation and weight reduction layer (4); the steel sleeve (2) is cylindrical and is embedded in the pre-made holes of the main load-bearing layer (1) and the fiberglass embedded parts (3) to increase the structural connection strength.

2. A lightweight thermal insulation composite window frame component with electromagnetic shielding function according to claim 1, characterized in that, The electromagnetic shielding layer (7) is a composite layer with a structure of adhesive film + high-density conductive metal mesh + adhesive film. The high-density conductive metal mesh enables overall conductivity on the outer surface of the window frame. The electromagnetic shielding layer (7) is divided into three parts: bottom shielding layer (701), side shielding layer (702), and top shielding layer (703). The three parts overlap by 3-5mm to achieve conductive connection. The adhesive film can enhance the composite strength of the high-density conductive metal mesh and the main bearing layer 1, and avoid defects such as insufficient adhesive, debonding, and air holes in the electromagnetic shielding layer and the main bearing layer, which would affect the airtightness and structural strength of the window frame.

3. A lightweight thermal insulation composite window frame component with electromagnetic shielding function according to claim 1, characterized in that, The main bearing layer (1) is made of high-strength glass fiber reinforced epoxy resin prepreg. An airtight layer (6) is designed between the main bearing layer (1) and the electromagnetic shielding layer (7). The airtight layer (6) is made of glass fiber felt + epoxy resin to form a resin-rich layer. The thickness of the main bearing layer (1) is not less than 3mm.

4. A lightweight thermal insulation composite window frame component with electromagnetic shielding function according to claim 1, characterized in that, The heat insulation and weight reduction layer (4) is made of high-temperature resistant polyurethane foam. The foam density is controlled at 0.03 g / m³ according to the weight index of the window frame. 3 ~0.3g / m 3 Between these elements, the low thermal conductivity of the foam ensures the overall thermal insulation performance of the window frame.

5. A lightweight thermal insulation composite window frame component with electromagnetic shielding function according to claim 1, characterized in that, Inside the window frame, fiberglass embedded parts (3) are pre-embedded at the corresponding positions of the threaded holes. The fiberglass embedded parts (3) are installed in the corresponding pre-embedded holes of the heat insulation and weight reduction layer (4) and are T-shaped to prevent relative rotation of the fiberglass embedded parts (3) when drilling and installing the window frame.

6. A method for preparing a lightweight thermally insulated composite window frame component with electromagnetic shielding function, characterized in that, Includes the following: Step 1: Preparations before tiling the functional layers of the window frame components: (1) Before laying, check the types and quantities of raw materials required for laying to ensure that the raw materials are within the validity period and meet the usage requirements; check that the mold cavity size, the surface quality of the laying surface, and the pressure method meet the laying requirements. (2) Wipe away the grease and other dirt on the mold with a clean cotton cloth or degreased cotton soaked in gasoline. Apply the release agent evenly to the forming surface and parting surface of the mold with a clean cotton cloth or degreased cotton. Repeat the application of the release agent at least three times after 15 minutes. Step 2, Pre-forming of the heat insulation and weight reduction layer (4): (1) Heat insulation and weight reduction layer (4) Select high temperature resistant polyurethane foam material, form foam blank by resin heating foaming molding process, after the foam blank is completed, process it into the required structural size by mechanical processing, process foam (401) and foam (402) on heat insulation and weight reduction layer (4), after the heat insulation and weight reduction layer (4) is processed, blow off the excess on the surface with an air gun; (2) Lay a layer of epoxy resin film on the foam surface, and then lay 2-3 layers of glass fiber prepreg, after laying, vacuum heat curing, after curing, grind and clean the surface and edges; (3) The pre-embedded hole (403) of the fiberglass embedded part (3) is processed again on the upper surface of the heat insulation and weight reduction layer (4). The pre-embedded hole is a T-shaped stepped hole. The fiberglass embedded part (3) is pre-embedded into the pre-embedded hole (403) and is ready for internal assembly and use. Step 3, Electromagnetic shielding layer (7) preforming: (1) The electromagnetic shielding layer (7) is a composite structure of adhesive film + high-density conductive metal mesh + adhesive film. Cut two adhesive films and one piece of metal copper mesh, and pre-form the electromagnetic shielding layer on a clean and flat metal plate. Lay them in the order of adhesive film-metal copper mesh-corner. After laying, vacuum bag is used to pre-press at 60°C for 1 hour so that the metal copper mesh is fully pre-impregnated with adhesive liquid. (2) Expel the air between the copper mesh and the adhesive film, and after cooling to room temperature, cut the blank of the electromagnetic shielding layer (7) on the cutting machine; the electromagnetic shielding layer (7) is divided into three parts, namely the bottom shielding layer (701), the side shielding layer (702), and the top shielding layer (703). Step 4: Apply the electromagnetic shielding layer (7) to the mold surface: (1) First, lay the bottom shielding layer (701) on the mold laying surface, and then lay the side shielding layer (702). The two parts overlap by 3-5mm to achieve conductive connection. (2) A layer of glass fiber surface felt is laid on the electromagnetic shielding layer (7), and then a layer of epoxy resin is evenly brushed on the surface felt as an airtight layer (6). Then, the inner layer of the main bearing layer (1) is laid 5mm. The joints of each layer are staggered. During the laying process, the gas between the layers is discharged by scraping with a scraper and vacuum pre-pressing. (3) After the inner 5mm layer is laid, hot-pressing is carried out at 60℃. After the temperature drops to room temperature after pre-pressing, the sealing material is removed and the material is cleaned and repaired. Step 5, Pre-embedding of heat insulation and weight reduction layer (4): After the inner layer is hot-extracted and cooled down, the pre-formed heat insulation and weight reduction layer (4) is placed on the main bearing layer (1) using special tools. Then, the outer layer of the main bearing layer (1) is laid 5mm. The joints of each layer are staggered. During the laying process, the gas between the layers is discharged by means of scraping with a scraper and vacuum pre-pressing. After the inner layer is laid, it is hot-extracted and pre-pressed at 60℃. After the temperature drops to room temperature after pre-pressing, the encapsulation material is removed and cleaned and repaired. Step 6, Fabrication of electromagnetic shielding layer (7): After the main bearing layer is laid, the side shielding layer (702) is folded 90° and laid on the upper surface of the main bearing layer (1). Finally, the upper shielding layer (703) is laid on the upper surface of the main bearing layer (1) and overlapped with the folded part of the side shielding layer (702) to conduct electricity. Step 7, Mold Closure and Curing: After all the tiling is completed, assemble the outer mold and the upper mold. After the mold is closed, hoist the mold onto the hot press for mold closure and curing. The gap between the molds should not exceed 0.1mm. Step 8: After the window frame has been cured, demolding, cleaning and trimming are carried out. Then, the steel sleeve (2) with the pre-processed inlay hole is processed. After the inlay hole is processed, the outer thread of the processed steel sleeve (2) is coated with glue and screwed into the hole. The upper end face of the steel sleeve (2) should not protrude from the upper surface of the window frame. Curing is carried out at room temperature for 3 hours.

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