A spin pot wind sail injection molding mold and method

Abstract

The application belongs to the technical field of novel ship boosting, and discloses a spinning cylinder wind sail injection molding die and method, realizes integrated injection molding of the spinning cylinder wind sail, eliminates the interface weak area, lap discontinuity and stress concentration problems generated by traditional segmentation splicing, and improves the axial and ring structure continuity of the cylinder body. The flow guide assembly and the vacuum injection assembly cooperate to establish a vacuum environment, so that the resin uniformly penetrates into the composite material layer along the preset flow channel; the temperature control heating layer is arranged on the surface of the outer cylinder mold, realizes the rapid and uniform heating and curing process, reduces the temperature difference and curing thermal gradient stress inside and outside the thick wall structure, improves the curing consistency and yield; the compressible elastic layer is controlled to shrink through the vacuum pumping assembly, the inner cylinder mold is actively demolded, and the demolding resistance is reduced. The whole closed vacuum injection process reduces the dependence on personal protection of workers, improves the production safety and environmental protection.

Description

Technical Field

[0001] This invention relates to the field of new ship propulsion technology, and in particular to a rotary sail injection molding mold and method. Background Technology

[0002] A rotary sail is a marine auxiliary propulsion device that generates thrust based on the Magnus effect. It has been engineered and applied to various commercial vessels, primarily to reduce fuel consumption and carbon emissions. It has significant practical value and potential for widespread adoption in energy conservation, emission reduction, and improving ship energy efficiency. Due to the high specific strength and high specific stiffness of composite materials, it can significantly reduce the structural weight while meeting the strength and stiffness requirements of large, slender cylindrical structures, thereby improving ship stability and reducing deck loads. Currently, rotary sail hulls are mostly made of composite materials and manufactured using a vacuum injection molding process for integral molding.

[0003] However, existing injection molding processes for rotary sails still have several shortcomings: First, due to the large length and thick walls of the cylinder, the resin flow path is long, making it prone to defects such as dry spots, local resin accumulation, uneven flow, and air bubbles during injection, affecting structural density and mechanical properties. Second, the thick-walled structure takes a long time to cure, and the uneven temperature distribution of traditional heating methods can easily lead to localized insufficient curing or overheating defects. Third, demolding large-sized integral cylinders is difficult, and high interfacial frictional resistance or inconsistent shrinkage can easily cause surface damage and dimensional deviations. Fourth, if segmented injection is used followed by splicing, the structural strength and long-term fatigue reliability of the splicing interface are difficult to guarantee, and interface peeling or damage is likely to occur, thereby reducing the overall structural safety. In addition, workers are often exposed to harmful gases generated by resin volatilization during construction, so additional personnel protection measures must be taken, which also increases the safety costs in the production process. Summary of the Invention

[0004] The purpose of this invention is to solve or at least alleviate some or all of the aforementioned problems. Therefore, the purpose of this invention is to provide a vortex sail casting mold and method that effectively achieves continuous, integrated vacuum casting of the vortex sail, as well as precise temperature control and uniform curing during the curing process. This effectively overcomes the structural continuity issues caused by existing segmented molding methods, improves the uneven resin flow during thick-walled casting, and solves the problem of difficult demolding of large integral cylinders. It significantly improves the overall structural performance, molding quality stability, and large-scale production efficiency of vortex sail products, while protecting workers from harmful substances in the environment and effectively reducing the need for personal protective equipment.

[0005] To achieve this objective, the present invention adopts the following technical solution: A rotary sail casting mold includes: The outer mold assembly includes at least two rigid outer cylinder mold segments that can be assembled along the cylinder axial direction and a sealing locking component. Each of the outer cylinder mold segments is assembled along the cylinder axial direction through the sealing locking component to form an outer cylinder mold and encloses a mold cavity. Inner cylinder mold, including any of the following forms: An integral straight-cylinder structure for forming the rotor outer cylinder of a rotary sail; or, The modular structure consists of two separate parts arranged along the axial direction of the cylinder. When the two ends are clamped together, they form a tapered mold part that matches the shape of the inner component of the tapered disc at the end of the rotary sail. The outer wall of the inner cylinder mold is sequentially covered with a first flexible vacuum layer, a compressible elastic layer, a second flexible vacuum layer, and a composite material layer; wherein, the first flexible vacuum layer and the inner wall of the outer cylinder mold form a first sealed space, and the compressible elastic layer is located within the first sealed space; the second flexible vacuum layer and the inner wall of the outer cylinder mold form a second sealed space, and the composite material layer is located within the second sealed space; The vacuum infusion assembly is in sealed communication with the second enclosed space through the second flexible vacuum layer; A flow guiding component is disposed within the second sealed space and is connected to the infusion end of the vacuum infusion component; A vacuuming assembly, connected to the first sealed space, can selectively evacuate the first sealed space to compress or release the compressible elastic layer. A temperature-controlled heating layer covers the surface of the outer cylinder mold.

[0006] In some optional embodiments, the temperature-controlled heating layer includes multiple sets of temperature control components, each of which is partitioned and disposed on the inner wall surface of the outer cylinder mold, for independently and synchronously heating and curing each area of ​​the outer cylinder mold and monitoring temperature changes in real time.

[0007] In some alternative embodiments, the temperature control component includes a heating channel and a temperature monitoring element, wherein the heating channel is laid in sections between the inner surface of the outer cylinder mold and the composite material layer, and the temperature monitoring element is mounted on the surface of the outer cylinder mold.

[0008] In some optional embodiments, the flow guiding assembly includes a flow guiding pipe, a flow guiding net, a perforated film, and an adhesive-absorbing felt. The perforated film, the flow guiding net, and the flow guiding pipe are sequentially laid on the side of the composite material layer facing the inner cylinder mold. The adhesive-absorbing felt is arranged at intervals between the flow guiding net and the flow guiding pipe along the cylinder axial direction. The flow guiding pipe is connected to the filling end of the vacuum filling assembly.

[0009] In some alternative embodiments, the vacuum assembly includes a vacuum pump and a vacuum gauge, and the first flexible vacuum layer is provided with a first interface and a second interface, the first interface being sealed to the vacuum pump and the second interface being sealed to the vacuum gauge.

[0010] In some optional embodiments, the outer cylinder mold includes an upper outer cylinder mold section and a lower outer cylinder mold section, which are spliced ​​together along the cylinder axial direction by the sealing and locking member to form the outer cylinder mold. The assembly gap at the splice is less than 2mm, and the relative misalignment in the chord and axial directions at the splice is not greater than 1mm.

[0011] In some alternative embodiments, a first release layer is laid between the inner wall of the outer cylinder mold and the composite material layer; a second release layer is laid between the compressible elastic layer and the second flexible vacuum layer.

[0012] In some alternative embodiments, sealing strips are provided between the first flexible vacuum layer and the outer cylinder mold, and between the second flexible vacuum layer and the outer cylinder mold.

[0013] A method for casting a rotary sail using a rotary sail casting mold includes the following steps: S1: The composite material layer is laid in the forming area of ​​the outer cylinder mold, rolled flat and fixed layer by layer; the flow guiding component and the second flexible vacuum layer are laid on the composite material layer in sequence, so that the second flexible vacuum layer and the outer cylinder mold form a second sealed space. S2: The vacuum infusion assembly is sealed and connected to the second sealed space, and the infusion end of the vacuum infusion assembly is connected to the input end of the flow guiding assembly to uniformly supply resin to the flow guiding assembly. S3: The first flexible vacuum layer and the compressible elastic layer are sequentially wrapped around the outer wall of the inner cylinder mold, so that the first flexible vacuum layer and the outer cylinder mold enclose a first sealed space; and the inner cylinder mold is placed inside the mold cavity of the outer cylinder mold; S4: The vacuum assembly is sealed and connected to the first enclosed space through the first flexible vacuum layer; S5: Start the vacuum infusion assembly to inject resin into the second sealed space, and at the same time extract the air from the second sealed space and the pores of the composite material layer, so that a negative pressure environment is formed inside the second sealed space, and the resin is uniformly permeated into the composite material layer under the guidance of the flow guiding assembly until the second sealed space is filled, thus completing the infusion. S6: After the injection is completed, the composite material layer is heated and cured by the temperature-controlled heating layer set on the surface of the outer cylinder mold; S7: After curing, the first sealed space is evacuated by the vacuuming component to compress the compressible elastic layer, and then the inner cylinder mold is removed along the cylinder axis to complete the demolding of the swivel sail.

[0014] In some optional embodiments, when the inner cylinder mold is the integral straight cylinder structure, the forming area of ​​the composite material layer in step S1 is the annular space between the inner wall of the outer cylinder mold and the outer wall of the inner cylinder mold; When the inner cylinder mold is the combined structure, the forming area of ​​the composite material layer in step S1 is the annular space between the inner wall of the outer cylinder mold and the outer wall of the inner cylinder mold, and the clamping space formed by the clamping of each component of the combined structure along the cylinder axis, and the annular space and the clamping space formed by clamping are interconnected.

[0015] The beneficial effects of this invention are: This invention provides a casting mold and method for a rotary sail. A continuous mold cavity is formed by axially assembling outer cylinder mold sections, and various types of inner cylinder molds are used to create a continuous molding space between them. This achieves integrated casting molding of the rotor's outer cylinder and end tapered disc structure, avoiding the interface weakening and stress concentration problems caused by traditional segmented splicing, thus improving structural continuity and mechanical properties. Through the synergistic action of the flow guiding component and the vacuum casting component, the resin is directionally and uniformly spread and fully impregnated, improving molding density and quality stability. The temperature-controlled heating layer reduces curing thermal stress and improves curing consistency. A first flexible vacuum layer and a compressible elastic layer are set outside the inner cylinder mold, providing uniform radial support and compaction during the molding stage. During the demolding stage, active shrinkage and separation are achieved through vacuuming, effectively reducing demolding resistance and enabling reuse. This effectively solves the problems of uneven casting of thick-walled structures and difficulty in demolding large cylinders, significantly improving product performance, molding quality, and production efficiency. Attached Figure Description

[0016] Figure 1 This is a cross-sectional view of the rotary sail casting mold described in this invention; Figure 2 This is a diagram showing the pouring state of the rotary sail pouring mold in Embodiment 1 of the present invention; Figure 3 This is a demolding diagram of the rotary sail casting mold in Embodiment 1 of the present invention; Figure 4 This is a diagram showing the pouring state of the rotary sail pouring mold in Embodiment 2 of this invention; Figure 5 This is a diagram showing the pouring state of the rotary sail pouring mold in Embodiment 2 of the present invention.

[0017] In the picture: 1. Outer mold assembly; 11. Outer cylinder mold; 111. Upper outer cylinder mold section; 112. Lower outer cylinder mold section; 12. First demolding layer; 2. Composite material layer; 21. Fiber cloth layer; 22. Core material layer; 3. Temperature-controlled heating layer; 4. First flexible vacuum layer; 5. Flow guiding component; 51. Perforated membrane; 6. Inner cylinder mold; 61. Integral straight cylinder structure; 62. Modular structure; 7. Compressible elastic layer; 8. Second flexible vacuum layer; 9. Second release layer; 10. Sealing and locking component. Detailed Implementation

[0018] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar components or components having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0019] In this invention, the terms "comprising," "including," "having," or any other variations thereof are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element.

[0020] In this invention, the term "and / or" describes the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent three cases: A alone, A and B simultaneously, and B alone. Additionally, in this invention, the character " / " generally indicates that the preceding and following related objects have an "and / or" relationship.

[0021] In the description of this invention, unless otherwise explicitly specified and limited, the terms "connected," "linked," "fixed," "combined," "coupled," and "installed" should be interpreted broadly. For example, they can refer to a fixed connection or a detachable connection; a direct connection or an indirect connection via an intermediate medium; or the internal communication of two components or the interaction between two components. As examples, a direct connection refers to two parts or components being connected together without the need for an intermediate medium, while an indirect connection refers to two parts or components each being connected to at least one intermediate medium, with the connection achieved through the intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances. Furthermore, "connected" and "coupled" are not limited to physical or mechanical connections or couplings, but can also include electrical connections or couplings.

[0022] In this invention, those skilled in the art will understand that relative terms (e.g., “about,” “approximately,” “basically,” etc.) used in conjunction with quantities or conditions are to include the value and have the meaning indicated by the context. For example, such relative terms include at least the degree of error associated with the measurement of a particular value, tolerances associated with the particular value due to manufacturing, assembly, use, etc. Such terms should also be considered as disclosing a range defined by the absolute values ​​of the two endpoints. Relative terms may refer to a certain percentage (e.g., 1%, 5%, 10% or more) of the indicated value. Numerical values ​​not using relative terms should also be disclosed as specific values ​​with tolerances. Furthermore, “basically” when expressing relative angular relationships (e.g., substantially parallel, substantially perpendicular) may refer to a certain degree (e.g., 1 degree, 5 degrees, 10 degrees or more) added to or subtracted from the indicated angle.

[0023] In this invention, those skilled in the art will understand that the function performed by a component can be performed by one component, multiple components, one part, or multiple parts. Similarly, the function performed by a part can also be performed by one part, one component, or a combination of multiple parts.

[0024] In this invention, the terms "upper," "lower," "left," "right," "front," and "rear," etc., refer to the orientations or positional relationships shown in the accompanying drawings. They are used solely for ease of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention. Furthermore, in the context, it should be understood that when an element is mentioned as being "upper" or "lower" than another element, it can be directly connected to the other element "upper" or "lower," or indirectly connected through an intermediate element. It should also be understood that directional terms such as "upper side," "lower side," "left side," "right side," "front side," and "rear side" not only represent positive orientation but can also be understood as lateral orientation. For example, "above," "on top of," "upper side of," and "above" the first feature "above" or "on the second feature" includes the first feature being directly above, to the upper left, to the upper right, to the upper front, and to the upper rear of the second feature, or simply indicating that the first feature is at a higher horizontal level than the second feature. The terms "below," "under," "below," and "below" for "first feature" and "second feature" include situations where the first feature is directly below, to the lower left, to the lower right, in front of, or behind the second feature, or simply indicate that the first feature is at a lower horizontal level than the second feature. Furthermore, the terms "first" and "second" are used merely for descriptive distinction and have no specific meaning.

[0025] Please refer to Figures 1 to 5As shown, this embodiment provides a rotary sail injection molding mold, including an outer mold assembly 1, an inner cylinder mold 6, a vacuum injection assembly, a flow guiding assembly 5, a vacuum extraction assembly, and a temperature control heating layer 3; the outer mold assembly 1 includes at least two rigid outer cylinder mold sections that can be assembled along the cylinder axial direction and a sealing locking member 10. Each outer cylinder mold section is assembled along the cylinder axial direction by the sealing locking member 10 to form an outer cylinder mold 11, and encloses to form a mold cavity; the inner cylinder mold 6 includes any of the following forms: an integral straight cylinder structure 61, used to form the rotor outer cylinder of the rotary sail; a combined structure 62, consisting of two parts that are separately arranged along the cylinder axial direction, and the two ends are clamped together to form a tapered disk mold part that matches the shape of the tapered disk inner component at the end of the rotary sail; the outer wall of the inner cylinder mold 6 is sequentially The covering includes a first flexible vacuum layer 4, a compressible elastic layer 7, a second flexible vacuum layer 8, and a composite material layer 2; wherein, the first flexible vacuum layer 4 and the inner wall of the outer cylinder mold 11 enclose a first sealed space, and the compressible elastic layer 7 is located in the first sealed space; the second flexible vacuum layer 8 and the inner wall of the outer cylinder mold 11 enclose a second sealed space, and the composite material layer 2 is located in the second sealed space; the vacuum injection assembly and the second sealed space are sealed and connected through the second flexible vacuum layer 8; the flow guiding assembly 5 is disposed in the second sealed space and is connected to the injection end of the vacuum injection assembly; the vacuum pumping assembly is connected to the first sealed space and can selectively evacuate the first sealed space to compress or release the compressible elastic layer 7; and the temperature-controlled heating layer 3 covers the surface of the outer cylinder mold 11.

[0026] Each outer cylinder mold segment is assembled axially through sealing and locking parts 10 to form a complete outer cylinder mold 11 and enclose a continuous mold cavity. With the cooperation of different types of inner cylinder molds 6, the composite material layer 2 can form a continuous molding space between the outer cylinder mold 11 and the inner cylinder mold 6. This allows the composite material layer 2 to not only integrally cast the rotor outer cylinder of the rotary sail, but also integrally cast the cylinder with the tapered disc internal component at the end of the rotary sail. This achieves integrated casting molding of the rotor outer cylinder and the end tapered disc structure of the rotary sail, effectively avoiding the problems of overlapping interfaces, weak bonding areas and stress concentration caused by splicing after traditional segmented manufacturing, and improving the axial continuity and circumferential strength of the product cylinder.

[0027] The flow guiding component 5 constructs a controllable flow channel network on the surface of the composite material layer 2, automatically guiding the resin to spread evenly and gradually penetrate along a predetermined path. The vacuum infusion component implements vacuum negative pressure control on the second sealed space and simultaneously infuses the resin, forming a stable pressure difference drive to ensure full resin wetting, reduce stagnation and air bubble inclusions, and improve molding density and quality stability. The temperature-controlled heating layer 3 uniformly heats the composite material layer 2, reducing the curing thermal gradient stress, producing high-curing-quality rotary sail composite material products, and improving curing consistency and yield.

[0028] By covering the outer wall of the inner cylinder mold 6 with a first flexible vacuum layer 4 and a compressible elastic layer 7, the first flexible vacuum layer 4 and the inner wall of the outer cylinder mold 11 form a first sealed space. With the help of a vacuum pumping component, controllable adjustment is achieved: during the molding stage, the first sealed space is kept at normal pressure or pressurized, so that the compressible elastic layer 7 expands outward and provides uniform radial support and compaction to the composite material layer 2, thereby improving the interlayer bonding quality, inner wall density and wall thickness uniformity; during the demolding stage, the first sealed space is evacuated, so that the compressible elastic layer 7 shrinks and retracts, actively separating from the inner cylinder mold 6, reducing the demolding resistance of the inner cylinder mold 6, avoiding structural damage, improving demolding efficiency and reducing labor costs. After the vacuum is removed, it can be reused.

[0029] Meanwhile, closed vacuum infusion is used instead of open hand lay-up process, and the entire construction process is sealed and controlled to reduce the escape of volatile organic compounds from the resin, improve the safety of the working environment and reduce protection costs.

[0030] Therefore, the rotary sail injection molding mold effectively realizes the overall continuous integrated vacuum injection molding of rotary sails, effectively overcoming the problem of insufficient structural continuity caused by the existing segmented molding method, improving the uneven resin flow during thick-walled injection, and solving the problem of difficult demolding of large integral cylinders. This significantly improves the overall structural performance, molding quality stability and large-scale production efficiency of rotary sail products, while protecting workers from harmful substances in the environment and effectively reducing the need for personal protective equipment.

[0031] The compressible elastic layer 7 can be, but is limited to, using porous polyurethane foam elastic material, which facilitates compression and release, allows for repeated use, and reduces costs. Both the inner cylinder mold 6 and the outer cylinder mold 11 can be made of rigid composite materials or formed from metal.

[0032] like Figure 1 , Figure 2 and Figure 4 As shown, in order to facilitate a smooth and complete surface of the finished product after molding and easy demolding, in some embodiments, a first demolding layer 12 is laid between the inner wall of the outer cylinder mold 11 and the composite material layer 2; the first demolding layer 12 can be made of polyester film. In addition, a second demolding layer 9 is laid between the compressible elastic layer 7 and the second flexible vacuum layer 8, and the second demolding layer 9 can be made of polyester film.

[0033] In addition, sealing strips are provided between the first flexible vacuum layer 4 and the outer cylinder mold 11, and between the second flexible vacuum layer 8 and the outer cylinder mold 11, to ensure that the first flexible vacuum layer 4 and the second flexible vacuum layer 8 form a reliable closed space with the outer cylinder mold 11, thereby achieving airtightness and negative pressure stability during the vacuum suction process.

[0034] Specifically, the vacuum infusion assembly includes multiple vacuum pumps, a vacuum gauge, and a resin injection device. The second flexible vacuum layer 8 has multiple resin injection ports and at least one air extraction port arranged alternately along the axial direction of the cylinder. The vacuum pumps are sealed to the air extraction ports to establish and maintain a stable negative pressure in the second sealed space, enabling uniform resin penetration within the composite material layer 2. The resin injection device is sealed to each injection port to distribute the resin to each area according to the designed flow rate. The multiple port spacing shortens the resin spreading path, optimizes the flow front, prevents local stagnation and air bubble entrainment, and facilitates real-time monitoring of the negative pressure. The vacuum gauge provides feedback to adjust the air extraction intensity, thereby ensuring the integrated infusion and molding quality of the thick-walled rotary sail.

[0035] like Figure 1 As shown, specifically, the composite material layer 2 includes a fiber layer and a core layer 22, wherein the fiber layer includes at least one of carbon fiber and glass fiber; the core layer 22 includes at least one of polyvinyl chloride foam, polyethylene foam, polyethylene terephthalate foam, and polystyrene foam structures to maintain the rigidity of the product while reducing its weight. The infused resin includes at least one of polyester, vinyl, and epoxy resins.

[0036] During the laying process, the fiber cloth layer 21 is first laid layer by layer according to the designed layering sequence, and is rolled and vented layer by layer to make it flat and secure. If necessary, a small amount of adhesive is sprayed for temporary positioning. Then, the core material layer 22 is laid according to the structural design requirements. The gaps between adjacent splices are filled with core material of the same thickness as the area to eliminate the splice steps and ensure the overall flatness and thickness continuity. After the core material layer 22 is laid, the subsequent fiber cloth layers 21 can be laid on it to form a stable sandwich composite structure.

[0037] Specifically, the flow guiding component 5 includes a flow guiding pipe, a flow guiding net, a perforated membrane 51, and an adhesive-absorbing felt. The perforated membrane 51, the flow guiding net, and the flow guiding pipe are sequentially laid on the side of the composite material layer 2 facing the inner cylinder mold 6. The adhesive-absorbing felt is arranged at intervals between the flow guiding net and the flow guiding pipe along the axial direction of the cylinder. The flow guiding pipe is connected to the injection end of the vacuum injection component. Among them, the flow guiding pipe serves as the main resin delivery channel, quickly introducing the resin into the first sealed space and distributing it to each area along the axial direction, establishing a stable resin supply path, and ensuring synchronous filling of the thick-walled structure. The flow guiding net constructs a planar flow network, allowing the resin to spread rapidly in the surface and then penetrate into the thickness direction, improving flow uniformity and reducing stagnation and dry spots. The perforated membrane 51 is used to regulate the gradual penetration of resin into the thickness direction of the composite material layer 2, preventing local instantaneous resin enrichment, and acting as an isolation function after curing, facilitating the overall removal of the flow guiding layer. The adhesive-absorbing felt is used to absorb excess resin, preventing local accumulation and helping to control the resin content and wall thickness consistency. It is understandable that the absorbent felt can be evenly spaced along the axial direction of the cylinder (for example, one absorbent felt is placed every 400mm).

[0038] In some embodiments, the temperature control component includes heating channels and temperature monitoring elements. The heating channels are laid in sections between the inner surface of the outer cylinder mold 11 and the composite material layer 2, enabling direct heating of the composite material layer 2 to achieve rapid and uniform curing temperature rise and reduce the temperature difference between the inside and outside of the thick-walled structure. The temperature monitoring elements are disposed on the surface of the outer cylinder mold 11 to collect temperature data of each temperature zone in real time and feed it back to the control system; when the temperature of a certain area is abnormal, the heating parameters can be adjusted in time, thereby improving curing stability and yield. The first demolding layer 12 is laid between the heating channels and the composite material layer 2.

[0039] Specifically, the temperature-controlled heating layer 3 includes multiple temperature control components, each of which is partitioned on the inner wall surface of the outer cylinder mold 11. These components are used to independently and synchronously heat and cure each area of ​​the outer cylinder mold 11 and monitor temperature changes in real time. The multiple temperature control components are partitioned on the inner wall surface of the outer cylinder mold 11 to form an axial and circumferential independent temperature control structure. This structure can directly and uniformly heat the composite material layer 2 and monitor its temperature in real time, ensuring uniform curing, reducing the curing thermal gradient stress, producing high-quality cyclone sail composite material products, and improving curing consistency and yield.

[0040] Optionally, the heating channel can be a water-heated circulating heating channel or an electric heating tube; the temperature monitoring device can be a thermocouple, and the temperature change can be monitored in real time through a computer system. After the pouring is completed, the heating temperature and holding time of each area can be set separately, and the heating program can be started simultaneously to ensure the consistency and controllability of the overall curing process.

[0041] In some embodiments, the vacuum assembly includes a vacuum pump and a vacuum gauge. The first flexible vacuum layer 4 has a first interface and a second interface. The first interface is sealed to the vacuum pump, and the second interface is sealed to the vacuum gauge. The vacuum pump can selectively evacuate air from the first sealed space, causing the compressible elastic layer 7 to contract uniformly under pressure or support the composite material layer 2, thereby achieving radial compaction during the molding stage or active separation during the demolding stage. The vacuum gauge displays the vacuum level in the first sealed space in real time, facilitating monitoring and adjustment by operators to ensure that the vacuum is maintained within a set range (e.g., ≤-0.09MPa), avoiding local air leakage or insufficient negative pressure from affecting the compaction effect.

[0042] In some optional embodiments, the outer cylinder mold 11 includes an upper outer cylinder mold section 111 and a lower outer cylinder mold section 112. The two are spliced ​​together along the cylinder axial direction by a sealing locking member 10 to form the outer cylinder mold 11. The assembly gap between the splicing ends is less than 2mm, and the relative misalignment of the splicing ends in the chord and axial directions is not greater than 1mm. This effectively ensures the concentricity and sealing of the splicing of the outer layer mold, forming a continuous and smooth mold cavity. This facilitates the overall laying and vacuum injection of the composite material layer 2, avoids resin leakage or uneven local thickness, and improves the structural continuity of the cylinder in the axial and circumferential directions as well as the precision of the final product.

[0043] like Figure 1 As shown, specifically, the sealing and locking component 10 includes bolts and nuts. The upper outer cylinder mold section 111 and the lower outer cylinder mold section 112 have radially arranged mating flanges at their splicing ends. The bolts pass through the upper and lower flanges and are threadedly connected to the nuts, achieving rigid positioning and reliable sealing. This structure not only ensures the coaxiality and stability of the mold splice but also ensures the continuity of the mold cavity and the overall sealing performance, which is beneficial for the overall laying of the composite material layer 2 and the uniform penetration during the vacuum infusion process.

[0044] This embodiment also provides a method for casting a rotary sail, using the rotary sail casting mold from any of the above embodiments, including the following steps: S1: The composite material layer 2 is laid in the forming area of ​​the outer cylinder mold 11, and rolled flat and fixed layer by layer; the flow guiding component 5 and the second flexible vacuum layer 8 are laid on the composite material layer 2 in sequence, so that the second flexible vacuum layer 8 and the outer cylinder mold 11 enclose the second sealed space. S2: The vacuum filling assembly is sealed and connected to the second sealed space, and the filling end of the vacuum filling assembly is connected to the input end of the flow guiding assembly 5 so as to uniformly supply resin to the flow guiding assembly 5. S3: The first flexible vacuum layer 4 and the compressible elastic layer 7 are sequentially wrapped around the outer wall of the inner cylinder mold 6, so that the first flexible vacuum layer 4 and the outer cylinder mold 11 enclose and form a first sealed space; and the inner cylinder mold 6 is placed in the mold cavity of the outer cylinder mold 11. S4: The vacuum assembly is sealed and connected to the first enclosed space through the first flexible vacuum layer 4; S5: Start the vacuum infusion assembly to inject resin into the second sealed space, and at the same time extract the air from the second sealed space and the pores of the composite material layer 2, so that a negative pressure environment is formed inside the second sealed space, and the resin is evenly permeated into the composite material layer 2 under the guidance of the flow guiding assembly 5 until the second sealed space is filled, thus completing the infusion. S6: After the injection is completed, the composite material layer 2 is heated and cured by the temperature-controlled heating layer 3 set on the surface of the outer cylinder mold 11; S7: After curing, the first sealed space is evacuated by the vacuum assembly to compress the compressible elastic layer 7, and then the inner cylinder mold 6 is removed along the cylinder axis to complete the demolding of the swivel sail.

[0045] This method constructs and coordinates two sealed spaces. During the injection stage, the second sealed space, under the action of vacuum negative pressure and the flow guiding component 5, allows resin to uniformly penetrate the composite material layer 2 along a predetermined path, achieving continuous and integrated vacuum injection molding of the composite material layer 2. This effectively overcomes the structural continuity issues caused by existing segmented molding methods, improves the uneven resin flow during thick-walled injection, and solves the problem of difficult demolding of large integral cylinders. This significantly improves the overall structural performance, molding quality stability, and large-scale production efficiency of the cyclone sail product. Simultaneously, workers are protected from harmful substances in the environment, effectively reducing the need for personal protective equipment. Meanwhile, the first sealed space, in a non-vacuum or pressurized state, allows the compressible elastic layer 7 to provide uniform radial support and compaction to the composite material layer 2, improving interlayer bonding quality and wall thickness uniformity. During the curing stage, temperature-controlled heating reduces thermal stress and ensures uniform curing. During the demolding stage, vacuuming the first sealed space causes the elastic layer to actively shrink, achieving low-resistance separation between the inner cylinder mold 6 and the product, significantly reducing demolding difficulty and the risk of structural damage. Overall, it balances high-quality molding with efficient demolding, improving product performance stability and large-scale production efficiency.

[0046] like Figure 3 and Figure 5 As shown, it should be noted that when the inner cylinder mold 6 is an integral straight cylinder structure 61, the molding area of ​​the composite material layer 2 in step S1 is the annular space between the inner wall of the outer cylinder mold 11 and the outer wall of the inner cylinder mold 6. This is beneficial for the uniform flow and stable wetting of resin in the circumferential and axial directions, and is suitable for conventional cylinder structures, resulting in products with uniform wall thickness and high density. When the inner cylinder mold 6 is a combined structure 62, the molding area of ​​the composite material layer 2 in step S1 is the annular space between the inner wall of the outer cylinder mold 11 and the outer wall of the inner cylinder mold 6, as well as the clamping space formed by the clamping of each component of the combined structure 62 along the cylinder axis. The annular space and the clamping space formed by clamping are interconnected. By connecting the clamping space formed by the clamping of the components with the annular space, the resin can not only fill the conventional annular area, but also simultaneously enter complex structural areas such as the end tapered plate, realizing the integrated injection molding of complex internal components and cylinder, avoiding the interface weakening and stress concentration problems caused by local secondary molding or splicing. Meanwhile, this interconnected design helps eliminate dead zones in the flow, reduces the risk of air bubble retention, and improves the sufficiency of wetting and the consistency of molding in complex structural areas, thereby enhancing the overall structural integrity and mechanical properties of the product.

[0047] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art will be able to make various obvious changes, readjustments, and substitutions without departing from the scope of protection of the present invention. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A rotary sail casting mold, characterized in that, include: The outer mold assembly (1) includes at least two rigid outer cylinder mold sections that can be assembled along the cylinder axis and a sealing locking member (10). Each of the outer cylinder mold sections is assembled along the cylinder axis through the sealing locking member (10) to form an outer cylinder mold (11) and encloses a mold cavity. Inner cylinder mold (6), including any of the following forms: An integral straight cylindrical structure (61) is used for the outer cylinder of the rotor in the formation of a rotary sail; or, The combined structure (62) consists of two parts that are separated along the axial direction of the cylinder. After the two ends are clamped together, a tapered plate mold part that matches the shape of the inner component of the tapered plate at the end of the rotary sail is formed. The outer wall of the inner cylinder mold (6) is sequentially covered with a first flexible vacuum layer (4), a compressible elastic layer (7), a second flexible vacuum layer (8), and a composite material layer (2); wherein, the first flexible vacuum layer (4) and the inner wall of the outer cylinder mold (11) enclose a first sealed space, and the compressible elastic layer (7) is located within the first sealed space; the second flexible vacuum layer (8) and the inner wall of the outer cylinder mold (11) enclose a second sealed space, and the composite material layer (2) is located within the second sealed space; The vacuum infusion assembly is in sealed communication with the second sealed space through the second flexible vacuum layer (8); The flow guiding component (5) is disposed in the second sealed space and is connected to the infusion end of the vacuum infusion component; The vacuum assembly is connected to the first sealed space and can selectively evacuate the first sealed space to compress or release the compressible elastic layer (7). A temperature-controlled heating layer (3) is applied to the surface of the outer cylinder mold (11).

2. The rotary sail casting mold according to claim 1, characterized in that, The temperature-controlled heating layer (3) includes multiple temperature control components. Each temperature control component is partitioned and arranged on the inner wall surface of the outer cylinder mold (11) to independently and synchronously heat and solidify each area of ​​the outer cylinder mold (11) and monitor temperature changes in real time.

3. The rotary sail casting mold according to claim 2, characterized in that, The temperature control component includes a heating channel and a temperature monitoring element. The heating channel is laid in sections between the inner surface of the outer cylinder mold (11) and the composite material layer (2). The temperature monitoring element is installed on the surface of the outer cylinder mold (11).

4. The rotary sail casting mold according to claim 1, characterized in that, The flow guiding component (5) includes a flow guiding pipe, a flow guiding net, a perforated film (51) and an adhesive-absorbing felt. The perforated film (51), the flow guiding net and the flow guiding pipe are sequentially laid on the side of the composite material layer (2) facing the inner cylinder mold (6). The adhesive-absorbing felt is arranged at intervals between the flow guiding net and the flow guiding pipe along the cylinder axial direction. The flow guiding pipe is connected to the injection end of the vacuum injection component.

5. The rotary sail casting mold according to claim 1, characterized in that, The vacuum assembly includes a vacuum pump and a vacuum gauge. The first flexible vacuum layer (4) is provided with a first interface and a second interface. The first interface is sealed to the vacuum pump, and the second interface is sealed to the vacuum gauge.

6. The rotary sail casting mold according to claim 1, characterized in that, The outer cylinder mold (11) includes an upper outer cylinder mold section (111) and a lower outer cylinder mold section (112). The two are spliced ​​together along the cylinder axial direction by the sealing locking member (10) to form the outer cylinder mold (11). The assembly gap at the splice is less than 2mm, and the relative misalignment of the chord and axial directions at the splice is not greater than 1mm.

7. The rotary sail casting mold according to any one of claims 1-6, characterized in that, A first release layer (12) is laid between the inner wall of the outer cylinder mold (11) and the composite material layer (2); a second release layer (9) is laid between the compressible elastic layer (7) and the second flexible vacuum layer (8).

8. The rotary sail casting mold according to any one of claims 1-6, characterized in that, Sealing strips are provided between the first flexible vacuum layer (4) and the outer cylinder mold (11), and between the second flexible vacuum layer (8) and the outer cylinder mold (11).

9. A method for casting a rotary sail, characterized in that, The method of using the vortex sail casting mold as described in any one of claims 1-8 includes the following steps: S1: The composite material layer (2) is laid in the molding area of ​​the outer cylinder mold (11) and rolled flat and fixed layer by layer; the flow guiding component (5) and the second flexible vacuum layer (8) are laid on the composite material layer (2) in sequence, so that the second flexible vacuum layer (8) and the outer cylinder mold (11) enclose a second sealed space. S2: The vacuum infusion assembly is sealed and connected to the second sealed space, and the infusion end of the vacuum infusion assembly is connected to the input end of the flow guiding assembly (5) to uniformly supply resin to the flow guiding assembly (5). S3: The first flexible vacuum layer (4) and the compressible elastic layer (7) are sequentially wrapped around the outer wall of the inner cylinder mold (6) so that the first flexible vacuum layer (4) and the outer cylinder mold (11) enclose and form a first sealed space; and the inner cylinder mold (6) is placed in the mold cavity of the outer cylinder mold (11); S4: The vacuum pumping assembly is sealed and connected to the first sealed space through the first flexible vacuum layer (4); S5: Start the vacuum injection assembly to inject resin into the second sealed space, and at the same time extract the air from the second sealed space and the pores of the composite material layer (2), so that a negative pressure environment is formed inside the second sealed space, and the resin is uniformly permeated into the composite material layer (2) under the guidance of the flow guide assembly (5) until the second sealed space is filled, and the injection is completed. S6: After the injection is completed, the composite material layer (2) is heated and cured by the temperature-controlled heating layer (3) set on the surface of the outer cylinder mold (11); S7: After curing, the first sealed space is evacuated by the vacuuming component to compress the compressible elastic layer (7), and then the inner cylinder mold (6) is removed along the cylinder axis to complete the demolding of the cyclone sail.

10. The method for casting and molding a rotary sail according to claim 9, characterized in that, When the inner cylinder mold (6) is the integral straight cylinder structure (61), the forming area of ​​the composite material layer (2) in step S1 is the annular space between the inner wall of the outer cylinder mold (11) and the outer wall of the inner cylinder mold (6); When the inner cylinder mold (6) is the combined structure (62), the forming area of ​​the composite material layer (2) in step S1 is the annular space between the inner wall of the outer cylinder mold (11) and the outer wall of the inner cylinder mold (6), and the clamping space formed by the clamping of each component of the combined structure (62) along the cylinder axis, and the annular space and the clamping space formed by clamping are interconnected.

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