One-step bonding and curing molding method for mosaic structure and shell assembly

Abstract

The present invention provides a one-step adhesive bonding and curing molding method and shell assembly for a mosaic structure. While ensuring adhesive bonding and curing quality and post-bonding part dimensions, this method achieves one-step adhesive bonding and curing molding of a honeycomb mosaic structure composite material. This reduces the number of assembly and adhesive bonding and curing steps required, allowing the production of a honeycomb sandwich mosaic structure to be completed with only one assembly and one adhesive bonding. This method is simple to operate and the process is easily controllable. This method solves the problems of prior art methods requiring at least two steps of assembly, adhesive bonding, and curing molding for a hyperbolic honeycomb mosaic structure composite material, resulting in difficulty in controlling deformation.

Description

Technical Field

[0001] The present invention relates to the field of composite materials for aviation engines, and in particular to a one-time gluing and curing molding method for an inlaid structure and a shell assembly. Background Art

[0002] A thrust reverser is a device that redirects engine thrust, primarily serving to decelerate and shorten taxiing distance. The duct housing of a thrust reverser is constructed from aluminum honeycomb composite material, reducing weight by 40% and meeting the requirements for duct internal surface smoothness, structural specific stiffness, and specific strength. Currently, adhesively bonded and cured components made of honeycomb composite materials are widely used in various types of aerospace. As a secondary load-bearing component, the aluminum honeycomb composite housing assembly of an aircraft engine thrust reverser requires many mounting components to be interposed based on load-bearing requirements.

[0003] The existing technology has the following problems: the inlays need to be glued and cured multiple times, which prolongs the production cycle, increases the operation risk and increases the cost; the sandwich inlays are easy to move out of position, causing the inner skin to warp and the parts to be scrapped. Summary of the Invention

[0004] In view of this, an embodiment of the present invention provides a method for forming a mosaic structure by one-step adhesive bonding and curing, to solve the technical problem in the prior art that mosaic structure composite materials require at least two steps of assembly, adhesive bonding and curing, and deformation is difficult to control. The method comprises:

[0005] Form the inner skin, outer skin and other parts into sheet metal, perform phosphoric acid anodizing on all sheet metal parts after sheet metal forming, and spray primer on the bonding and curing surface;

[0006] prefabricated honeycombs and inlays;

[0007] The outer skin is mounted on the tooling mold and fixed, and the outer skin is laid through the prefabricated honeycomb and film to form a laid-up part;

[0008] Digging out the position of the prefabricated inlay piece on the paving piece according to the prefabricated template;

[0009] Placing the prefabricated inlay piece at a preset position on the paving piece, and filling the interface between the prefabricated inlay piece and the paving piece with adhesive;

[0010] An adhesive film is placed on the honeycomb of the paving piece, and an inner skin is installed to obtain an assembled shell component.

[0011] Furthermore, the prefabricated honeycomb comprises:

[0012] Use CNC numerical control to form the honeycomb surface and roll-bend it to obtain a prefabricated honeycomb;

[0013] or

[0014] The honeycomb is cut using a template and roll-bent to obtain a prefabricated honeycomb.

[0015] Furthermore, the prefabricated inlay comprises:

[0016] Laying a layer of adhesive film on the bottom plate of the inlay and placing a prefabricated honeycomb, and pouring foam glue into the holes of the prefabricated honeycomb;

[0017] The prefabricated honeycomb surface is paved with adhesive film, and the upper backing plate of the inlay is placed to obtain the prefabricated inlay.

[0018] Furthermore, the prefabricated inlay is clamped with a clamp, and an air gun is used to blow the upper and lower pads of the prefabricated inlay, so that there is a fitting force between the lower pad, the adhesive film, the prefabricated honeycomb and the upper pad of the prefabricated inlay.

[0019] Furthermore, the outer skin is loaded onto a tooling mold and fixed, and the outer skin is paved using prefabricated honeycombs and adhesive films to form a paved piece, including:

[0020] The outer skin is installed on the tooling mold and the size of the outer skin is limited and fixed by the positioning block;

[0021] Press the outer skin tightly and lay the adhesive film on it;

[0022] Laying prefabricated honeycomb on the outer skin after laying the film;

[0023] A vacuum bag is made and vacuumed to ensure adhesion between the prefabricated honeycomb, the film and the outer skin.

[0024] Furthermore, after the adhesive is filled into the interface between the prefabricated inlay piece and the paving piece, foam glue is poured into the area of ​​the paving piece where the foam glue needs to be poured.

[0025] Furthermore, an assembled housing assembly is obtained, comprising:

[0026] Making a vacuum bag for the assembled shell assembly and performing vacuum treatment;

[0027] Transferring the vacuum-treated housing assembly into an autoclave for curing according to preset process parameters;

[0028] The shell assembly after the curing process is removed from the tooling mold.

[0029] Furthermore, the shell component is a double curvature component.

[0030] Furthermore, after the shell assembly that has completed the curing treatment is removed from the tooling mold, the shell assembly is subjected to ultrasonic C-scan testing and mechanical property testing.

[0031] Compared with the prior art, the beneficial effects that can be achieved by at least one of the above-mentioned technical solutions adopted in the embodiments of this specification include at least the following: the present invention provides a one-time assembly, gluing and curing process method for a large-diameter honeycomb mosaic structure composite material component with a hyperbolic curvature. Through the one-time gluing and curing molding of the honeycomb sandwich mosaic, the positioning of the mosaic can be well solved, while reducing the number of assembly and gluing and curing times. Only one assembly and one gluing and curing are required to complete the production of the honeycomb sandwich mosaic structure, with low cost and high efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0033] Figure 1 This is a schematic flow chart of a one-step bonding molding method according to an embodiment of the present invention;

[0034] Figure 2 is a schematic structural diagram of a housing assembly according to an embodiment of the present invention;

[0035] Figure 3 This is a schematic diagram of the structure of a prefabricated inlay according to an embodiment of the present invention;

[0036] Figure 4 Schematic diagram of the dimensions of the housing assembly according to an embodiment of the present invention.

[0037] Reference numerals in the figures: 1, inner skin; 2, outer skin; 3, prefabricated honeycomb; 4, prefabricated inlay; 5, upper pad; 6, lower pad. DETAILED DESCRIPTION

[0038] The embodiments of the present application are described in detail below with reference to the accompanying drawings.

[0039] The following describes the embodiments of the present application through specific examples, and those skilled in the art can easily understand other advantages and effects of the present application from the contents disclosed in this specification. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. The present application can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed in various ways based on different viewpoints and applications without departing from the spirit of the present application. It should be noted that, in the absence of conflict, the features in the following embodiments and embodiments can be combined with each other. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without making creative work are within the scope of protection of this application.

[0040] In an embodiment of the present invention, a method for forming a mosaic structure by one-step bonding and curing is provided, such as Figure 1 As shown, the method includes: step S100: forming the inner skin 1, the outer skin 2 and the remaining parts into sheet metal, performing phosphoric acid anodizing treatment on all the sheet metal parts after the sheet metal forming, and spraying primer on the bonding and curing surface; step S200: prefabricating the honeycomb 3 and the prefabricated inlay 4; step S300: installing the outer skin 2 on the tooling mold and fixing it, and paving the outer skin through the prefabricated honeycomb 3 and the adhesive film to form a paving part; step S400: digging out the position of the prefabricated inlay 4 on the paving part according to the prefabricated template; step S500: placing the prefabricated inlay 4 at a preset position on the paving part, and filling the adhesive at the interface between the prefabricated inlay 4 and the paving part; step S600: placing the adhesive film on the honeycomb of the paving part, and installing the inner skin 1 to obtain an assembled shell component.

[0041] The present invention provides a one-time assembly, gluing and curing process method for a composite material component of a hyperbolic large-diameter honeycomb mosaic structure. By forming the honeycomb sandwich mosaic piece through one-time gluing and curing, the positioning of the mosaic piece can be well solved, while reducing the number of assembly and gluing and curing times. Only one assembly and one gluing and curing are required to complete the production of the honeycomb sandwich mosaic structure, with low cost and high efficiency.

[0042] Depend on Figure 1 As can be seen from the process shown, the first embodiment of the present invention specifically includes the following steps:

[0043] Step S100: forming the inner skin 1, the outer skin 2 and the remaining components into sheet metal, performing phosphoric acid anodizing treatment on all sheet metal parts after the sheet metal forming, and spraying primer on the bonding and curing surface;

[0044] Specifically, the assembled shell assembly structure is as follows Figure 2 As shown, it includes an inner skin 1, an outer skin 2 and the remaining components. In the one-time bonding and curing molding assembly method of the hyperbolic honeycomb mosaic structure composite material provided by the present invention, the inner and outer skins and the remaining components are first subjected to sheet metal forming. Sheet metal forming is a method of applying external force to the metal wool to cause it to undergo plastic deformation or shearing, thereby becoming a part processing method with the expected shape and performance. After the sheet metal processing, all sheet metal parts are subjected to phosphoric acid anodizing treatment to improve the bonding performance, and then the bonding and curing surface is sprayed with primer. Preferably, the primer used in this embodiment is J-117 primer. The bonding and curing surface is the surface of the outer skin 2 where the prefabricated honeycomb 2 is to be laid. In addition, all adhesives to be used must be taken out from the freezer 6 hours in advance to prevent the adhesive film from failing and debonding due to condensed water on the surface.

[0045] Step S200: prefabricating a honeycomb 3 and a mosaic 4;

[0046] In specific implementation, the prefabricated honeycomb 3 includes:

[0047] Step S210a: using CNC numerical control to form a honeycomb surface and then roll-bending it to obtain a prefabricated honeycomb 3;

[0048] or

[0049] Step S220a: Using a template to cut a honeycomb and roll-bending it to obtain a prefabricated honeycomb 3.

[0050] Specifically, the honeycomb structure is a sandwich structure, the core layer of which is composed of a series of hexagonal, quadrilateral or other shaped honeycomb-like cells, and thinner panels / skins are glued (or brazed) on the upper and lower surfaces of the sandwich layer. The honeycomb structure has higher strength and rigidity than other forms of sandwich structures. In this embodiment, CNC numerical control machining or manual cutting is used to use raw material honeycombs to process prefabricated honeycombs 3 for the bonding molding of the shell components in this application. Among them, CNC (Computerized Numerical Control) numerical control machining is used to process the honeycomb surface, and roll-bending is used to obtain the prefabricated honeycomb 3; manual cutting is to use a preset template to cut the raw material honeycomb, and roll-bending is used to obtain the prefabricated honeycomb 3. The preset template is a template made according to the honeycomb shape required for the bonding molding of the inner skin 1 and the outer skin 2.

[0051] In specific implementation, the prefabricated inlay 4 includes:

[0052] Step S210b: laying a layer of adhesive film on the lower base plate 6 of the inlay and placing the prefabricated honeycomb 3, and pouring foam glue into the holes of the prefabricated honeycomb 3;

[0053] Step S220b: Laying adhesive film on the three surfaces of the prefabricated honeycomb, placing the upper backing plate 5 of the inlay, and obtaining the prefabricated inlay 4.

[0054] During the specific implementation, the prefabricated inlay 4 is clamped with a clamp, and the upper pad 5 and the lower pad 6 of the prefabricated inlay 4 are blown with an air gun, so that there is a fitting force between the lower pad 6 of the prefabricated inlay 4, the adhesive film, the prefabricated honeycomb 3 and the upper pad 5.

[0055] Specifically, after obtaining the prefabricated honeycomb 3, the prefabricated inlay 4 is manufactured. The structure of the prefabricated inlay 4 is as follows: Figure 3As shown, the assembly comprises an upper plate 5, a prefabricated honeycomb 3, and a lower plate 6. First, a layer of adhesive film is applied to the lower plate 6, followed by the prefabricated honeycomb 3. The holes of the prefabricated honeycomb 3 are then filled with foam. Adhesive film is then applied to the surface of the prefabricated honeycomb 3, followed by the upper plate 5 of the prefabricated inlay 4. The prefabricated inlay 4 is then clamped securely in place with a clamp. A hot air gun is then used to blow on the plate of the prefabricated inlay 4 to achieve a certain degree of adhesion between the lower plate 6, adhesive film, honeycomb, and upper plate 5, thus completing the fabrication of the prefabricated inlay 4.

[0056] Step S300: The outer skin 2 is mounted on the tooling mold and fixed, and the outer skin is paved through the prefabricated honeycomb 3 and the adhesive film to form a paved piece;

[0057] In specific implementation, step S300 further includes:

[0058] Step S310: The outer skin 2 is mounted on the tooling mold, and the outer skin 2 is dimensioned and fixed by positioning blocks;

[0059] Step S320: pressing the outer skin 2 and laying an adhesive film on the outer skin 2;

[0060] Step S330: laying the prefabricated honeycomb 3 on the outer skin 2 after laying the adhesive film;

[0061] Step S340: preparing a vacuum bag and evacuating the bag to ensure adhesion between the prefabricated honeycomb 3 , the adhesive film and the outer skin 2 .

[0062] Specifically, the outer skin 2 is placed on the tooling mold, and the outer skin 2 is fixed and pressed tightly with positioning blocks to ensure that the outer skin 2 is in close contact with the tooling mold. A layer of adhesive film is then applied to the outer skin 2. Preferably, in this embodiment, J-116A adhesive film is applied to the outer skin 2. The prefabricated honeycomb 3 is then applied to the outer skin 2 with the adhesive film applied, and a vacuum bag is prepared and evacuated to ensure a certain degree of adhesion between the prefabricated honeycomb 3 and the outer skin 2, thereby improving the bonding quality.

[0063] Step S400: Digging out the position of the prefabricated inlay 4 on the paving piece according to the prefabricated template;

[0064] Step S500: placing the prefabricated inlay 4 at a preset position on the paving piece, and filling adhesive at the interface between the prefabricated inlay 4 and the paving piece;

[0065] Preferably, the adhesive is J-118 adhesive.

[0066] During specific implementation, after the adhesive is filled into the interface between the prefabricated inlay 4 and the paving piece, the foam glue is poured into the area of ​​the paving piece that needs to be sealed with the foam glue.

[0067] Preferably, the foaming glue is J-60 foaming glue.

[0068] Step S600: placing an adhesive film on the honeycomb of the paving piece and installing the inner skin 1 to obtain an assembled shell assembly.

[0069] Specifically, in this embodiment, the shell assembly is a shell with a large diameter and a double curvature. Typical parts of the shell assembly are as follows: Figure 4 As shown, the maximum diameter is 2 meters, the height is 1 meter, and the opening arc is about 150 degrees.

[0070] In a specific implementation, after obtaining the assembled housing assembly, the following steps are further included:

[0071] Step S610: making a vacuum bag for the assembled housing assembly and performing vacuum treatment;

[0072] Step S620: transferring the vacuum-treated housing assembly into an autoclave for curing according to preset process parameters;

[0073] Step S630: removing the shell assembly after the curing process from the tooling mold.

[0074] Specifically, the assembled shell components are vacuumed and then transferred into an autoclave for curing according to pre-set process parameters. The shell components are then removed from the mold, completing the one-step bonding and curing of the large-diameter, double-curvature honeycomb mosaic composite material.

[0075] In a specific implementation, after the shell assembly that has completed the curing treatment is removed from the tooling mold, the shell assembly is subjected to ultrasonic C-scan testing and mechanical property testing.

[0076] The embodiments of the present invention achieve the following technical effects:

[0077] The present invention provides an assembly method for a large-diameter, hyperbolic honeycomb mosaic structure composite material. While ensuring both bonding and curing quality and post-bonding part dimensions, the method achieves single-step bonding and curing molding of the hyperbolic honeycomb mosaic structure composite material. This reduces the number of assembly and curing steps required, allowing the production of the honeycomb sandwich mosaic structure to be completed with only one assembly and one curing step. The method is simple to operate and the process is easily controllable. This method overcomes the problems of prior art, whereby hyperbolic honeycomb mosaic structure composite materials require at least two steps of assembly, curing, and molding, resulting in difficult-to-control deformation.

[0078] The foregoing description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will readily appreciate that various modifications and variations of the present invention are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention are intended to be within the scope of protection of the present invention.

Claims

1. A method for one-step bonding and curing of an inlaid structure, wherein the assembled shell assembly comprises an inner skin (1), an outer skin (2) and other components, characterized in that: The one-step bonding and curing molding method of the mosaic structure comprises: Forming the inner skin (1), the outer skin (2) and the remaining parts into sheet metal, performing phosphoric acid anodizing treatment on all sheet metal parts after the sheet metal forming, and spraying primer on the bonding and curing surface; Prefabricated honeycomb (3) and prefabricated inlay (4); The outer skin (2) is mounted on the tooling mold and fixed, and the outer skin is paved through the prefabricated honeycomb (3) and the adhesive film to form a paved piece; Digging out the position of the prefabricated inlay (4) on the paving piece according to the prefabricated template; Placing the prefabricated inlay (4) at a preset position on the paving piece, and filling the interface between the prefabricated inlay (4) and the paving piece with adhesive; Placing a film on the honeycomb of the paving member and installing an inner skin (1) to obtain an assembled shell assembly; The outer skin (2) is loaded onto a tooling mold and fixed, and the outer skin is paved through a prefabricated honeycomb (3) and a film to form a paved piece, comprising: The outer skin (2) is mounted on the tooling mold, and the outer skin (2) is dimensioned and fixed by a positioning block; Pressing the outer skin (2) tightly and laying a film on the outer skin (2); Laying the prefabricated honeycomb (3) on the outer skin (2) after the adhesive film is laid; Making a vacuum bag and evacuating the bag so that the prefabricated honeycomb (3), the adhesive film and the outer skin (2) have a bonding force; Obtain assembled housing components, including: Making a vacuum bag for the assembled shell assembly and performing vacuum treatment; Transferring the vacuum-treated housing assembly into an autoclave for curing according to preset process parameters; The shell component after the curing process is removed from the tooling mold; the shell component is a double curvature component.

2. The one-step adhesive bonding and curing molding method for a mosaic structure according to claim 1, characterized in that: The prefabricated honeycomb (3) comprises: Using CNC numerical control to form a honeycomb surface and roll-bending it to obtain a prefabricated honeycomb (3); or The honeycomb is cut using a template and roll-bent to obtain a prefabricated honeycomb (3).

3. The one-step adhesive bonding and curing molding method for a mosaic structure according to claim 1, characterized in that: The prefabricated inlay (4) comprises: Laying a layer of adhesive film on the lower pad (6) of the inlay and placing a prefabricated honeycomb (3), and pouring foam glue into the holes of the prefabricated honeycomb (3); The prefabricated honeycomb (3) is laid with adhesive film, and the upper pad (5) of the inlay is placed to obtain the prefabricated inlay (4).

4. The one-step adhesive bonding and curing molding method for a mosaic structure according to claim 3, characterized in that: The prefabricated inlay (4) is clamped with a clamp, and an air gun is used to blow the upper pad (5) and the lower pad (6) of the prefabricated inlay (4) so ​​that there is a bonding force between the lower pad (6) of the prefabricated inlay (4), the adhesive film, the prefabricated honeycomb (3) and the upper pad (5).

5. The one-step adhesive bonding and curing molding method for mosaic structures according to claim 1, characterized in that: After the interface between the prefabricated inlay piece (4) and the paving piece is filled with adhesive, foam glue is poured into the area of ​​the paving piece where the foam glue needs to be poured.

6. The one-step adhesive bonding and curing molding method for mosaic structures according to claim 1, characterized in that: After the shell assembly that has been cured is removed from the tooling mold, an ultrasonic C-scan test and a mechanical property test are performed on the shell assembly.

7. A shell assembly, wherein the shell assembly is manufactured using the one-step gluing and curing molding method for mosaic structures according to any one of claims 1 to 6.

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