A method for manufacturing the main load-bearing side plate of an airborne monitoring console

Abstract

This invention discloses a method for manufacturing the main load-bearing side plate of an airborne monitoring console in the field of composite materials, comprising the following steps: Step 1) Machining of foam board: pre-embedded holes are machined on the foam board at the locations where embedded parts need to be installed; Step 2) Outer skin laying: the outer skin prepreg is laid out on the molding die and vacuum pre-pressed; Step 3) Foam board installation: the foam board is placed in the molding die and attached to the outer skin; Step 4) Embedded part installation: the embedded parts are installed into the corresponding pre-embedded holes on the foam board; Step 5) Inner skin laying: the inner skin prepreg is laid on the surface of the foam board and vacuum pre-pressed; Step 6) Curing: the inner skin is sealed with a vacuum bag and then sent to an autoclave for co-curing. This invention solves the problems of large weight and inaccurate positioning of embedded parts in existing main load-bearing side plates of airborne monitoring consoles.

Description

Technical Field

[0001] This invention relates to the field of composite material technology, and in particular to a main load-bearing side plate for an airborne monitoring platform. Background Technology

[0002] Monitoring station (such as) Figure 8 As shown, composite materials serve as carriers for in-flight equipment and are widely used in various military and civilian aircraft. With increasing demands on these devices, the high strength, low specific gravity, and designability of composite materials are playing an increasingly important role in the design of airborne equipment. The number of monitoring consoles made primarily of composite materials in aircraft has increased significantly. A monitoring console typically consists of side panels, partitions, covers, and adapter plates. The side panels play a crucial role in supporting the overall performance of the monitoring console and are its main load-bearing components. The quality of the side panel molding directly affects the stability and strength of the entire monitoring console; optimizing the side panel molding process is beneficial for improving the quality of the monitoring console product.

[0003] Currently, the side panel forming process for monitoring consoles involves directly laying prepreg on top of a mold, adding embedded parts during the layering process, and then curing the entire process together. While this method can meet the performance requirements of the monitoring console, it is difficult to form, involves a complex process, and most importantly, it is difficult to control the installation accuracy of the embedded parts. Furthermore, the resulting side panels are quite heavy, which cannot meet the requirements for lightweighting the overall weight of the aircraft. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a method for manufacturing the main load-bearing side plate of an airborne monitoring console, which solves the problems of large mass of the main load-bearing side plate and inaccurate positioning of embedded parts in existing airborne monitoring consoles.

[0005] The objective of this invention is achieved as follows: A method for manufacturing the main load-bearing side plate of an airborne monitoring console, comprising the following steps:

[0006] Step 1) Machining the foam board: Machining pre-embedded holes at the locations where the pre-embedded parts need to be installed on the foam board;

[0007] Step 2) Outer skin laying: The outer skin prepreg is laid out on the molding die and vacuum pre-pressed.

[0008] Step 3) Foam board installation: Place the foam board into the molding die and attach it to the outer skin;

[0009] Step 4) Install the embedded parts and insert them into the corresponding pre-embedded holes on the foam board;

[0010] Step 5) Inner skin laying: Lay the inner skin prepreg on the surface of the foam board and vacuum pre-press.

[0011] Step 6) Curing: Seal with a vacuum bag and then transfer to an autoclave for co-curing.

[0012] As a preferred technical solution of the method for manufacturing the main load-bearing side plate of an airborne monitoring station according to the present invention, in step 2), when laying the outer skin, the parts on the inner side that do not need to be turned over are separated by absorbent tape between the last N layers of the outer skin. In step 5), when laying the inner skin, first lay a layer of adhesive film on the foam board, then turn the last layer of outer skin that does not need to be turned over inward onto the foam board and remove the absorbent tape. Then lay the first layer of inner skin, and align the inner skin with the turned-over outer skin. The same operation is performed on the remaining turned-over outer skins. Finally, lay all the remaining inner skins and cut off the excess outer skin that does not need to be turned over. After completion, vacuum pre-extraction and compaction are performed.

[0013] As a preferred technical solution of the method for manufacturing the main load-bearing side plate of the airborne monitoring station according to the present invention, in step 3), when installing the foam board, a layer of adhesive film is laid between the foam board and the outer skin, and the edges that do not match are filled with expanding foam, and the expanding foam does not exceed the height of the foam.

[0014] As a preferred technical solution of the method for manufacturing the main load-bearing side plate of the airborne monitoring station of the present invention, step 4) the embedded part is pre-treated before installation. The pre-treatment process is as follows: the selected embedded part has a hollow cavity inside, and foam blocks are filled in the hollow area. When filling, first apply adhesive to the surface of the foam block in contact with the embedded part, then insert the foam block into the embedded part, and finally put it into the oven for curing.

[0015] As a preferred technical solution of the method for manufacturing the main load-bearing side plate of an airborne monitoring station according to the present invention, step 4) requires secondary processing of the embedded parts during installation. The secondary processing is as follows: fiberglass prepreg is laid on the embedded parts at the positions where the outer skin and inner skin are attached. When installing the embedded parts, adhesive is applied around the embedded parts and then installed on the corresponding positions on the foam board. The gap between the embedded parts and the foam board is filled with expanding foam. If the embedded parts are recessed and not flush with the outer surface of the foam board, they are filled with prepreg until the surface of the embedded parts is the same height as the surface of the foam board. After installation, the embedded parts are heated in an oven and vacuum pre-pressed and then removed. Expanding foam is then applied around the foam board again.

[0016] As a preferred technical solution of the method for manufacturing the main load-bearing side plate of an airborne monitoring station according to the present invention, during step 6) curing, a silicone plate of the same shape and size is placed on the surface of the inner skin.

[0017] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0018] (1) The monitoring console side panel manufactured by the present invention adopts an integrated molding method, which has a lighter weight and higher strength than the monitoring console side panel with glue riveting, and significantly reduces the number of parts, eliminating some of the flatness and fit problems caused by the assembly of parts, and reducing the workload to a certain extent.

[0019] (2) Compared with the method of directly laying out the mold and then adding the embedded parts, the present invention uses a machined high-strength structural foam board as the core and lays the skin inside and outside. This method not only reduces the weight of the monitoring station, but also facilitates the installation of the embedded parts. Furthermore, the embedded parts installed by this method are accurately positioned and will not be misaligned when other parts are connected to the side plate.

[0020] (3) The monitoring station side panel manufactured by the present invention has high dimensional accuracy, good surface quality, reliable connection method, and the finished product is lightweight and strong, which can greatly improve the mobility performance of the vehicle. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0022] Figure 1 A flowchart for the creation of this invention.

[0023] Figure 2 The external shape of the main load-bearing side plate of the airborne monitoring station manufactured for this invention is shown in the figure.

[0024] Figure 3 A schematic diagram of the internal foam board structure of the main load-bearing side plate of the airborne monitoring station manufactured for this invention.

[0025] Figure 4 This is a schematic diagram showing the application location of the absorbent cloth in this invention.

[0026] Figure 5 This is a schematic diagram of the embedded part structure in this invention.

[0027] Figure 6 This is a schematic diagram of the curing curve in this invention.

[0028] Figure 7 This is a photograph of the side panel after demolding according to the present invention.

[0029] Figure 8 This is a schematic diagram of the airborne monitoring console.

[0030] Among them, 100 is the side plate, 101 is the foam board, and 102 is the embedded part. Detailed Implementation

[0031] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] like Figure 1 The method shown is for manufacturing a main load-bearing side plate of an airborne monitoring console. The side plate 100 has the following shape: Figure 2 As shown, it includes the following steps:

[0033] Step 1) Machining of foam board 101;

[0034] Foam board 101 has a special shape, such as Figure 3 As shown, it contains multiple holes for embedded parts 102 (the holes in the figure have been filled with embedded parts 102); the ideal foam structure is obtained by machining; the foam board 101 greatly reduces the weight of the monitoring station, the structural strength also meets the requirements, and the position of the embedded parts 102 can be cut out by machining, which provides convenience for the placement of the embedded parts 102.

[0035] Step 2) Mold processing;

[0036] Before using the mold, use a wiping paper or clean cloth to clean the residual resin and other debris from the mold surface. Use a wiping paper dipped in acetone to clean the working surface of the mold. Apply 5 coats of 770NC release agent to the mold surface, ensuring there are no missed areas. Allow at least 15 minutes between each coat. After applying the last coat of release agent, place the mold in an oven and heat at 120°C for 30 minutes.

[0037] Step 3) Laying the outer skin;

[0038] The outer skin prepreg is laid out according to the pre-designed layup method and sequence. To ensure tight adhesion between the fibers and eliminate air gaps, vacuum bags are used to wrap the laid fabric. The bags are then vacuum-sealed at room temperature, using vacuum pressure to compact the fabric. After the outer skin is laid, the vacuum is applied for 15 minutes to further strengthen the bond between the layers. Figure 4 As shown, no flange is required on the inner side between the last three layers of the outer skin (the flange location is as follows). Figure 2 The parts shown on the left and bottom sides (as indicated in the image) are separated by absorbent tape, which is the white area in the image.

[0039] Step 4) Install foam board 101;

[0040] The machined foam board 101 is laid on the outer skin. Since the foam board 101 has a porous structure, in order to prevent the foam from detaching from the outer skin, a layer of adhesive film should be laid between the foam board 101 and the outer skin. Any misalignment at the edges should be filled with expanding foam. The expanding foam should be higher than the foam height.

[0041] Step 5) Install embedded part 102;

[0042] The structural schematic diagram of embedded part 102 is shown below. Figure 5 As shown, various shapes are included. The selected embedded part 102 has a hollow cavity inside. The embedded part 102 is installed into the pre-embedded hole position on the foam board 101. In order to prevent the hollow embedded part 102 from collapsing due to the pressure during curing, foam blocks (not shown in the figure) should be filled into these embedded parts 102 in advance without affecting the weight. Figure 3 (Only the hollow cavity is shown in the middle). First, cut the foam block into a shape and size that matches the inner cavity of the embedded part 102. Then, apply adhesive to the surface of the foam block that contacts the embedded part 102 and insert it into the embedded part 102. Place it in an oven and cure at 70°C for 1 hour.

[0043] Since the embedded part 102 is made of aluminum alloy, direct contact with carbon fiber will cause galvanic corrosion, reducing the service life of the monitoring station. Therefore, before installing the embedded part 102, a layer of glass fiber prepreg needs to be laid on the surface of the embedded part 102 that contacts the inner and outer skin. After applying adhesive around the embedded part 102, it is installed on the corresponding position on the foam board 101. The gap between the embedded part 102 and the foam board 101 is filled with expanding foam. If the embedded part 102 is recessed and not flush with the outer surface of the foam board 101, it is filled with prepreg until the surface of the embedded part 102 is at the same height as the surface of the foam board 101. After installation, it is heated to 80°C in an oven and vacuum pre-pressed for 1 hour. After 1 hour, it is taken out. At this time, the adhesive has cured and the expanding foam has softened and collapsed. To avoid missing adhesive on the side after the side plate 100 has cured, expanding foam needs to be filled around the foam board 101 again.

[0044] Step 5) Laying the inner skin;

[0045] Similar to the outer skin installation, first apply a layer of adhesive film to the foam board 101. Then, fold the last outer skin layer (without any folding) inwards onto the foam board 101 and remove the absorbent tape. The folding width should be 10mm. Then, install the first inner skin layer. Repeat the same process for the second-to-last outer skin layer, folding it inwards 20mm, and then install the second inner skin layer. To prevent the inner side of the side panel 100 from being too thick, the inner skin layer should be joined with the folded outer skin layer. Finally, install all remaining inner skin layers and cut off any excess outer skin layer that does not need to be folded. After completion, vacuum pre-press and compact the outer skin layer (the number of folded outer skin layers can be reasonably arranged according to the actual design and strength requirements).

[0046] Step 6) Curing;

[0047] After the inner and outer skins and foam board 101 are laid, to ensure the smoothness and flatness of the inner side panel 100, a 2mm thick silicone sheet with the same dimensions as the inner skin is pressed onto the laid side panel 100. It is then sealed in a vacuum bag and placed in an autoclave for co-curing. The curing curve is shown below. Figure 6 As shown.

[0048] Step 7) Demolding;

[0049] After the curing process is complete, close the autoclave and wait for the mold temperature to cool to below 60°C before demolding. Remove the baffles around the mold and take the product out of the mold. Figure 7 As shown.

[0050] Step 8) Post-processing;

[0051] For burrs and resin-rich areas on the product edges, use 800# sandpaper to remove them, and then use 1000# wet sandpaper to smooth them. Do not damage the fibers during sanding.

[0052] The above description of the embodiments is only for the purpose of helping to understand the method and core ideas of the present invention. It should be noted that those skilled in the art can make several improvements and modifications to the present invention without departing from the principles of the present invention, and these improvements and modifications also fall within the protection scope of the claims of the present invention.

Claims

1. A method for manufacturing the main load-bearing side plate of an airborne monitoring console, characterized in that, Includes the following steps: Step 1) Machining the foam board: Machining pre-embedded holes in the foam board at the locations where aluminum alloy pre-embedded parts need to be installed; Step 2) Outer skin laying: Lay the outer skin prepreg on the molding mold and vacuum prepress; When laying the outer skin, use absorbent tape to separate the last N layers of the outer skin and the inner parts that do not need to be turned over. Step 3) Foam board installation: Place the foam board into the molding mold and attach it to the outer skin; Step 4) Install aluminum alloy embedded parts: Insert the aluminum alloy embedded parts into the corresponding pre-embedded holes on the foam board. When installing aluminum alloy embedded parts, secondary treatment is required. The secondary treatment is as follows: glass fiber prepreg is laid on the aluminum alloy embedded parts at the positions where the outer and inner skins are attached to avoid galvanic corrosion between the aluminum alloy material and the carbon fiber. When installing the aluminum alloy embedded parts, adhesive is applied around the embedded parts and then they are installed on the corresponding positions on the foam board. The gap between the aluminum alloy embedded parts and the foam board is filled with expanding foam. If the aluminum alloy embedded parts are recessed and not flush with the outer surface of the foam board, they are filled with prepreg until the surface of the aluminum alloy embedded parts is the same height as the surface of the foam board. After installation, the parts are heated in an oven and vacuum pre-pressed and compacted before being removed. Expanding foam is then applied again around the foam board. Step 5) Inner skin laying: Lay the inner skin prepreg on the surface of the foam board and vacuum pre-press; When laying the inner skin, first lay a layer of adhesive film on the foam board, then fold the last outer skin inward to the foam board where it does not need to be folded and remove the absorbent tape, then lay the first inner skin, and align the inner skin with the folded outer skin. Repeat the same operation for the remaining folded outer skins. Finally, lay all the remaining inner skins and cut off the excess outer skin where it does not need to be folded. After completion, vacuum pre-press and compact. Step 6) Curing: Seal with a vacuum bag and then transfer to an autoclave for co-curing.

2. The method for manufacturing the main load-bearing side plate of an airborne monitoring station according to claim 1, characterized in that, Step 3) When installing the foam board, lay a layer of adhesive film between the foam board and the outer skin. Fill any misaligned edges with expanding foam, ensuring that the expanding foam does not exceed the height of the foam.

3. The method for manufacturing the main load-bearing side plate of an airborne monitoring station according to claim 1, characterized in that, Step 4) Before installing the aluminum alloy embedded parts, the aluminum alloy embedded parts should be pre-treated. The pre-treatment process is as follows: The selected aluminum alloy embedded parts have a hollow cavity inside. The hollow area is filled with foam blocks. When filling, first apply adhesive to the surface of the foam block that contacts the aluminum alloy embedded parts, then insert the foam block into the aluminum alloy embedded parts, and finally put it into the oven for curing.

4. The method for manufacturing the main load-bearing side plate of an airborne monitoring station according to claim 1, characterized in that, Step 6) During curing, place a silicone plate of the same shape and size on the surface of the inner skin.

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