A carbon fiber composite material electrical conduction structure and its manufacturing method

Abstract

The present invention discloses a structure for realizing electrical conduction of carbon fiber composite materials and a method for manufacturing the same, belonging to the field of carbon fiber technology. The conductive body includes a plurality of metal blocks and metal wires, wherein the metal blocks have a groove structure or a hole structure; the metal wires are used to connect adjacent metal blocks, and the metal wires are embedded in the groove structure or the hole structure of the metal blocks; the conductive body is laid on the inner skin of the surface of the forming mold; the metal support layer is located at the bottom of the metal wires and is used to support the metal wires; the metal wire coating layer is located at the top of the metal wires, and the upper surface of the metal coating layer and the metal blocks are located in the same plane; the outer skin is provided on the metal wire coating layer and the upper surface of the metal blocks. The present invention solves the problem of electrical conduction of carbon fiber, has a good mold-mounting effect, a high material utilization rate, and a flexible and changeable structural form.

Description

Technical Field

[0001] The present invention relates to the technical field of carbon fiber, and in particular to an electrical conduction structure of a carbon fiber composite material and a manufacturing method thereof. Background Art

[0002] Carbon fiber reinforced resin-based composites have excellent specific strength, specific stiffness, high chemical stability, corrosion resistance, fatigue resistance and designability, and are widely used in many fields such as aerospace, shipbuilding, ocean, transportation and electronics industries.

[0003] Carbon fiber reinforced resin-based composites (CFRPs) are increasingly used in the marine and offshore sectors due to their excellent corrosion resistance. In particular, carbon fiber operating consoles are becoming increasingly popular. These consoles consist of multiple control modules, each requiring good electrical continuity between any connection holes. CFRPs, however, are composed of carbon fiber reinforcements and a resin matrix. While carbon fiber is conductive, the resin matrix is ​​typically an insulator. This poor conductivity of the resulting CFRPs severely restricts their application in this sector.

[0004] Currently, the methods for achieving electrical conductivity in carbon fiber reinforced resin-based composite materials include: spraying a conductive coating on the carbon fiber surface, but the resistance of the conductive coating is too high to meet the requirements; connecting a metal plate layer on the carbon fiber surface, which is too heavy and has poor corrosion resistance; for complex carbon fiber parts, the metal plate has a complex shape, the processing cost is expensive, and there is serious material waste. Summary of the Invention

[0005] The purpose of the present invention is to provide a carbon fiber composite material electrical conduction structure and a manufacturing method thereof, which solves the problem of carbon fiber electrical conduction, has good mold bonding effect, high material utilization rate, and flexible and changeable structural form.

[0006] The technical solution of the present invention is achieved in this way:

[0007] A carbon fiber composite material electrical conduction structure, comprising a conductor c, an outer skin 1, an inner skin 2, a metal wire support layer 3-1 and a metal wire covering layer 3-3;

[0008] The conductive body c includes multiple metal blocks a and metal wires b, and the metal block a has a groove structure or a hole structure; the metal wires b are used to connect adjacent metal blocks a, and the metal wires b are embedded in the groove structure or hole structure of the metal block a; the conductive body c is laid on the inner skin 2 on the surface of the forming mold e; the metal wire support layer 3-1 is located at the bottom of the metal wire b and is used to support the metal wire; the metal wire coating layer 3-3 is located on the top of the metal wire b, and the upper surface of the metal coating layer and the metal block are located in the same plane; the outer skin is provided on the metal wire coating layer 3-3 and the upper surface of the metal block a.

[0009] Furthermore, the metal block covering layer 3 - 2 is used to fill the outer space of the metal block, and the height of the metal block covering layer is consistent with the height of the metal block.

[0010] A method for manufacturing a carbon fiber composite material electrically conductive structure, for manufacturing the above-mentioned carbon fiber composite material electrically conductive structure, specifically comprising the following steps:

[0011] Step 1: Determine the mathematical model of the metal block a and the metal wire b, and design the positioning and connection tooling d of the conductive body c based on the mathematical model;

[0012] Step 2: Design a positioning and connecting tool d according to the size requirements of the carbon fiber frame unit window connection hole, and use the positioning tool d to ensure the position of the metal block a;

[0013] Step 3: Conduct a continuity test on the conductive body c composed of the metal block a and the metal wire b, and adjust the series and parallel relationships of the conductive circuits to meet the conductivity value requirements;

[0014] Step 4: Lay the inner skin onto the carbon fiber frame unit forming mold e, and lay a metal wire support layer at the corresponding position of the inner skin; remove the conductive body c that has passed the conductivity test from the positioning tool d, and place the conductive body c on the inner skin, wherein the metal wire is facing the metal wire support layer and is located on the upper surface of the metal wire support layer;

[0015] Step 5: When laying the conductor c on the inner skin 2, it is necessary to adjust the positioning on the mold e, then lay the metal wire coating layer 3-3 and the metal block coating layer 3-2 at the corresponding positions, and fill the rest of the entire surface with carbon fiber prepreg; finally, lay the outer skin 1, and completely sandwich the conductor between the inner and outer skins. The carbon fiber prepreg is cured to form a carbon fiber frame unit 4;

[0016] Step 6: Use mold marking or machining to make connection holes with conductivity requirements, completing the manufacture of the entire carbon fiber conductive frame unit 4.

[0017] Furthermore, the positioning tooling includes a substrate, a first positioning assembly and a second positioning assembly; the first positioning assembly and the second positioning assembly are both fixed to the upper surface of the substrate, and the top of the first positioning assembly is provided with a slot for fixing the metal block; the top of the second positioning assembly is provided with a strip groove for constraining the metal wire, and the width of the strip groove is the same as the diameter of the metal wire.

[0018] Furthermore, step 1 is specifically as follows: determining the shape and size of the top slot of the first positioning component according to the shape and size of the metal block a, and determining the width of the top strip slot of the second positioning component according to the diameter of the metal wire b.

[0019] Furthermore, step 2 is specifically as follows: determining the positions of the first positioning component and the second positioning component on the substrate according to the size requirements of the carbon fiber frame unit window connection hole; and installing the metal block and the metal wire on the top of the corresponding first positioning component and the top of the second positioning component.

[0020] Compared with the prior art, the present invention has the following beneficial effects:

[0021] 1. This invention utilizes a co-curing process for carbon fiber and conductors, allowing for simple and convenient tooling. The effective combination of flexible metal wire and rigid metal blocks allows for easy attachment of the conductor to the product's outer skin. Once bonded to the outer skin, the conductor maintains a minimal rigid surface area, minimizing internal stress and achieving high mold placement accuracy.

[0022] 2. The present invention overcomes the shortcomings of traditional manufacturing processes. When manufacturing large-scale, non-planar conductive parts, traditional processes have disadvantages such as many hollow positions and poor conformability. Even through correction and trimming, it is difficult to achieve high film-mounting accuracy. The process scheme of metal wire plus metal block conductor is adopted. Through the pre-embedded process, the easy bendability of the metal wire can maximize the release of internal stress caused by the change from a flat surface to a curved surface / inclined surface, thereby realizing a conductive structure with good mold-mounting effect.

[0023] 3. The conductor composed of metal wire and metal block designed by the present invention can be controlled in size by positioning tooling, and the conductivity requirements can be achieved by mechanical or welding methods. The metal wire can also be bent by calculating the angles of different surfaces. This process is simple and convenient, with low molding stress, and can achieve the higher conductivity requirements of the carbon fiber frame.

[0024] 4. The present invention is based on a mold and adopts a vacuum negative pressure process, through carbon fiber wrapping and filling; the inner skin serves as the working surface of the conductor, and is bonded and solidified with the conductor to form a carbon fiber conductor frame unit, which constitutes the core technical features of the present invention. The conductor technology composed of metal wires and metal blocks in the present invention can achieve good mold adhesion and conduction effect. At the same time, the thickness of the layers is relatively uniform during the implementation process, and the internal stress is minimized in all links, providing a good foundation for the realization of the carbon fiber conductor frame unit. Compared with the metal plate pasting process, not only is the process implementation simple, but the manufacturing cost is also greatly reduced. The carbon fiber frame unit not only has good electrical conductivity and high reliability, but also has a simple operating procedure and an easy-to-implement environment. It is very suitable for mass production and has a wide range of engineering application value. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 Schematic diagram of the structure of the connection part of the metal block and the metal wire in an embodiment of the present invention.

[0026] Figure 2 yes Figure 1 Schematic cross-section of .

[0027] Figure 3 Schematic diagram of the structure of a conductive body according to an embodiment of the present invention.

[0028] Figure 4 1 is a structural diagram of a conductive body located on a positioning tool in an embodiment of the present invention.

[0029] Figure 5 yes Figure 4 Schematic diagram of part of the structure.

[0030] Figure 6 It is a cross-sectional schematic diagram of a carbon fiber composite material electrical conduction structure according to an embodiment of the present invention.

[0031] Figure 7 Schematic diagram of a carbon fiber frame unit that meets electrical conductivity requirements in an embodiment of the present invention.

[0032] Explanation of the figure marks: a is a metal block, b is a metal wire, c is a conductor, d is a positioning tool, e is a mold, 1 is an outer skin, 2 is an inner skin, 3-1 is a metal wire supporting layer, 3-2 is a metal block wrapping layer, 3-3 is a metal wire covering layer, 4 is a frame unit, d-1 is a substrate, d-2 is a second positioning component, and d-3 is a first positioning component. DETAILED DESCRIPTION

[0033] The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0034] A carbon fiber composite material electrical conduction structure, comprising a conductor c, an outer skin 1, an inner skin 2, a metal wire support layer 3-1 and a metal wire covering layer 3-3;

[0035] The conductive body c includes multiple metal blocks a and metal wires b, and the metal block a has a groove structure or a hole structure; the metal wires b are used to connect adjacent metal blocks a, and the metal wires b are embedded in the groove structure or hole structure of the metal block a; the conductive body c is laid on the inner skin 2 on the surface of the mold e; the metal wire support layer 3-1 is located at the bottom of the metal wire b and is used to support the metal wire; the metal wire coating layer 3-3 is located on the top of the metal wire b, and the upper surface of the metal coating layer and the metal block are located in the same plane; the outer skin is provided on the metal wire coating layer 3-3 and the upper surface of the metal block a.

[0036] Furthermore, the metal block covering layer 3 - 2 is used to fill the outer space of the metal block, and the height of the metal block covering layer is consistent with the height of the metal block.

[0037] A method for manufacturing a carbon fiber composite material electrically conductive structure, for manufacturing the above-mentioned carbon fiber composite material electrically conductive structure, specifically comprising the following steps:

[0038] Step 1: Determine the mathematical model of the metal block a and the metal wire b, and design the positioning and connection tooling d of the conductive body c based on the mathematical model;

[0039] Step 2: Design a positioning and connecting tool d according to the size requirements of the carbon fiber frame unit window connection hole, and use the positioning tool d to ensure the position of the metal block a;

[0040] Step 3: Conduct a continuity test on the conductive body c composed of the metal block a and the metal wire b, and adjust the series and parallel relationships of the conductive circuits to meet the conductivity value requirements;

[0041] Step 4: Lay the inner skin onto the carbon fiber frame unit forming mold e, and lay a metal wire support layer at the corresponding position of the inner skin; remove the conductive body c that has passed the conductivity test from the positioning tool d, and place the conductive body c on the inner skin, wherein the metal wire is facing the metal wire support layer and is located on the upper surface of the metal wire support layer;

[0042] Step 5: When laying the conductor c on the inner skin 2, it is necessary to adjust the positioning on the mold e, then lay the metal wire coating layer 3-3 and the metal block coating layer 3-2 at the corresponding positions, and fill the rest of the entire surface with carbon fiber prepreg; finally, lay the outer skin 1, and completely sandwich the conductor between the inner and outer skins. The carbon fiber prepreg is cured to form a carbon fiber frame unit 4;

[0043] Step 6: Use mold marking or machining to make connection holes with conductivity requirements, completing the manufacture of the entire carbon fiber conductive frame unit 4.

[0044] Furthermore, the positioning tooling includes a substrate, a first positioning assembly and a second positioning assembly; the first positioning assembly and the second positioning assembly are both fixed to the upper surface of the substrate, and the top of the first positioning assembly is provided with a slot for fixing the metal block; the top of the second positioning assembly is provided with a strip groove for constraining the metal wire, and the width of the strip groove is the same as the diameter of the metal wire.

[0045] Furthermore, step 1 is specifically as follows: determining the shape and size of the top slot of the first positioning component according to the shape and size of the metal block a, and determining the width of the top strip slot of the second positioning component according to the diameter of the metal wire b.

[0046] Furthermore, step 2 is specifically as follows: determining the positions of the first positioning component and the second positioning component on the substrate according to the size requirements of the carbon fiber frame unit window connection hole; and installing the metal block and the metal wire on the top of the corresponding first positioning component and the top of the second positioning component.

[0047] The following is a more specific embodiment:

[0048] Reference Figures 1 to 7 This embodiment consists of a metal block a, a metal wire b, a conductor c composed of the metal block a and the metal wire b, an outer skin 1, an inner skin 2, a metal wire support layer 3-1, a metal block coating layer 3-2, and a metal wire coating layer 3-3. The metal block a is a slotted or open-hole structure, and the metal wire b is reliably embedded in the slot or hole structure of the metal block a. The metal block a and the metal wire b are connected to form a conductor c by a positioning tool d. The conductor c is laid on the inner skin 2 on the surface of the mold e. The metal wire support layer 3-1, the metal block coating layer 3-2, and the metal wire coating layer 3-3 press the conductor c onto the inner skin 2. The carbon fiber outer skin 1 covers the conductor c and its coating layer. The carbon fiber outer skin 1, the carbon fiber inner skin 2, the conductor c and the metal wire support layer 3-1, the metal block coating layer 3-2, and the metal wire coating layer 3-3 are bonded and cured by high temperature and negative pressure to form a conductive carbon fiber frame unit 4.

[0049] A manufacturing method for achieving electrical conduction of carbon fiber, comprising the steps of:

[0050] ① Determine the mathematical model of the metal block a and the metal wire b, and design the positioning and connection tooling d of the conductor c based on the mathematical model;

[0051] ② According to the size requirements of the carbon fiber frame unit window connection hole, design the positioning connection tool d, and use the positioning tool d to ensure the position and size of the metal block a;

[0052] ③ Conduct a continuity test on the conductive body c composed of the metal block a and the metal wire b. The series and parallel relationships of the conductive circuits can be adjusted to meet the requirements of the conductivity value;

[0053] ④ According to the mold e formed by the carbon fiber frame unit, the conductor c is pre-laid, and the metal block a can completely cover the position of the carbon fiber frame connection hole;

[0054] ⑤ On the mold e of the carbon fiber frame unit, the carbon fiber inner skin 2 is laid through layer design, and the vacuum negative pressure process is carried out in stages according to the layer thickness to make it adhere to the mold;

[0055] ⑥ First, the metal wire support layer 3-1 of the metal wire b on the conductive body c is laid on the reverse side, and then the conductive body c is laid on the inner skin 2 and adjusted and positioned on the mold e. Then, the metal wire coating layer 3-3 and the metal block coating layer 3-2 of the metal wire b are laid, and the rest of the entire surface is filled with carbon fiber prepreg. Through a vacuum negative pressure process, it is attached to the carbon fiber frame mold e with the inner skin 2; finally, the outer skin 1 is laid, and the conductive body is completely sandwiched between the inner and outer skins. The carbon fiber prepreg is cured to form a carbon fiber frame unit 4;

[0056] ⑦ Using mold marking or machining, connection holes with conduction requirements are made to complete the manufacture of the entire carbon fiber conduction frame unit 4.

Claims

1. A carbon fiber composite material electrically conductive structure, characterized by: It comprises a conductor (c), an outer skin (1), an inner skin (2), a metal wire support layer (3-1) and a metal wire covering layer (3-3); The conductive body (c) comprises a plurality of metal blocks (a) and metal wires (b), wherein the metal blocks (a) have a groove structure or a hole structure; the metal wires (b) are used to connect adjacent metal blocks (a), and the metal wires (b) are embedded in the groove structure or the hole structure of the metal blocks (a); the conductive body (c) is laid on the inner skin (2) on the surface of the forming mold (e); the metal wire support layer (3-1) is located at the bottom of the metal wires (b) and is used to support the metal wires; the metal wire coating layer (3-3) is located on the top of the metal wires (b), and the upper surface of the metal coating layer and the metal blocks are located in the same plane; the outer skin is provided on the metal wire coating layer (3-3) and the upper surface of the metal blocks (a).

2. The carbon fiber composite material electrical conduction structure according to claim 1, characterized in that: The metal block covering layer (3-2) is used to fill the outer space of the metal block, and the height of the metal block covering layer is consistent with the height of the metal block.

3. A method for manufacturing a carbon fiber composite material electrically conductive structure, for manufacturing a carbon fiber composite material electrically conductive structure as claimed in claim 1 or claim 2, characterized in that: The specific steps include: Step 1: Determine the mathematical model of the metal block (a) and the metal wire (b), and design the positioning and connection tooling (d) of the conductor (c) based on the mathematical model; Step 2: Design a positioning and connecting tool (d) according to the size requirements of the connecting hole of the carbon fiber frame unit window, and use the positioning tool (d) to ensure the position of the metal block (a); Step 3: Conduct a continuity test on the conductive body (c) composed of the metal block (a) and the metal wire (b), and adjust the series and parallel relationships of the conductive circuits to meet the conductivity value requirements; Step 4: Lay the inner skin on the carbon fiber frame unit forming mold and lay a metal wire support layer at the corresponding position of the inner skin; remove the conductive body (c) that has passed the conductivity test from the positioning tool (d) and place the conductive body (c) on the inner skin, wherein the metal wire is opposite to the metal wire support layer and is located on the upper surface of the metal wire support layer; Step 5: When the conductor (c) is laid on the inner skin (2), it is necessary to adjust the positioning on the carbon fiber frame unit forming mold, and then lay the metal wire coating layer (3-3) and the metal block coating layer (3-2) at the corresponding positions, and fill the remaining positions of the entire surface with carbon fiber prepreg; finally, lay the outer skin (1), and completely sandwich the conductor between the inner skin and the outer skin, and the carbon fiber prepreg is cured to form a carbon fiber frame unit (4); Step 6: Use mold marking or machining to make connection holes with conductivity requirements, thereby completing the manufacture of the entire carbon fiber conductive frame unit (4).

4. The method for manufacturing a carbon fiber composite material electrically conductive structure according to claim 3, characterized in that: The positioning tooling includes a base plate, a first positioning assembly and a second positioning assembly; the first positioning assembly and the second positioning assembly are both fixed to the upper surface of the base plate, and the top of the first positioning assembly is provided with a slot for fixing the metal block; the top of the second positioning assembly is provided with a strip groove for constraining the metal wire, and the width of the strip groove is the same as the diameter of the metal wire.

5. The method for manufacturing a carbon fiber composite material electrically conductive structure according to claim 4, characterized in that: Step 1 specifically includes: determining the shape and size of the top slot of the first positioning component according to the shape and size of the metal block (a), and determining the width of the top strip slot of the second positioning component according to the diameter of the metal wire (b).

6. The method for manufacturing a carbon fiber composite material electrically conductive structure according to claim 4, characterized in that: The step 2 is specifically as follows: determining the positions of the first positioning component and the second positioning component on the substrate according to the size requirements of the carbon fiber frame unit window connection hole; and installing the metal block and the metal wire on the top of the corresponding first positioning component and the top of the second positioning component.

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