Combined air inlet and method of forming same

Abstract

The application provides a combined air inlet channel, which comprises an air inlet channel shell (10), a cross grid (20), a foam sandwich (30), a left fixing block (4), a right fixing block (5), a lower fixing block (6) and an upper fixing block (7); the air inlet channel shell (10) comprises an inner profile shell (11), an outer profile upper shell (12) and an outer profile lower shell (13); the foam sandwich (30) comprises a front foam (31) and a rear foam (32), and the rear foam (32) is combined with the inner profile shell (11) and then cured and formed together. The application adopts a combined design, is formed in sections, simplifies the process, reduces the manufacturing difficulty and manufacturing cost, improves the product qualification rate and shortens the manufacturing cycle. The application also provides a forming method of the combined air inlet channel, which also solves the above technical problems.

Description

Technical Field

[0001] This invention relates to the field of unmanned aerial vehicle (UAV) technology, and more specifically to an air intake for a UAV and its forming method. Background Technology

[0002] Unmanned aerial vehicles (UAVs) possess advantages such as small size, light weight, and wide range of applications, playing an increasingly important role in both national defense and civilian sectors. Consequently, the requirements for materials are also becoming increasingly stringent. Composite materials, with their high specific strength and stiffness, and customizable mechanical properties, are widely used in UAV design. The air intake is a key component of the UAV's aerodynamic system, providing airflow to the engine. During UAV operation, strong airflow enters the air intake, creating significant internal pressure. Therefore, this air intake component must not only meet strength and stiffness requirements but also aerodynamic requirements, demanding smooth inner and outer surfaces and high machining precision for both. Currently, air intake machining typically employs integral molding. Ensuring the precision of both inner and outer surfaces simultaneously complicates the manufacturing process, increases costs, and leads to a high scrap rate after product molding, thus extending the manufacturing cycle. Summary of the Invention

[0003] The technical problem solved by this invention is to provide a combined air intake manifold that features simplified process, low cost, high yield, and short manufacturing cycle. Furthermore, this invention also provides a method for forming the combined air intake manifold, which similarly solves the aforementioned technical problem.

[0004] A combined air intake includes an air intake housing 10, a cross grille 20, a foam core 30, a left-side fixing wooden block 4, a right-side fixing wooden block 5, a lower fixing wooden block 6, and an upper fixing wooden block 7.

[0005] The intake housing 10 includes an inner surface housing 11, an upper outer surface housing 12, and a lower outer surface housing 13. The inner surface housing 11 has a recessed area 8 at its rear flanged portion, the upper outer surface housing 12 has a recessed area 8 at its front, and the lower outer surface housing 13 has recessed areas 8 at its front and on its left and right sides. The upper part of the front flanged portion of the inner surface housing 11 overlaps with the recessed area 8 at the front of the upper outer surface housing 12, and the lower part of the front flanged portion of the inner surface housing 11 overlaps with the recessed area 8 at the front of the lower outer surface housing 13. The upper shell 12 overlaps with the upper recessed area 8 above the rear flange of the inner shell 11, and the lower shell 13 overlaps with the lower recessed area 8 below the rear flange of the inner shell 11. The left and right sides of the upper shell 12 overlap with the left and right recessed areas 8 of the lower shell 13. The inner shell 11 has openings on its lower, upper, left, and right sides, the upper shell 12 has openings on its left and right sides, and the lower shell 13 has an opening on its lower side, so as to realize the installation of the cross grille 20.

[0006] The cross-shaped grid 20 includes a horizontal right-side grid 21, a horizontal left-side grid 22, and a vertical grid 23; wherein the vertical grid 23 has four through holes, the horizontal right-side grid 21 has two blind holes and two connecting shafts, and the horizontal left-side grid 22 has two blind holes and two connecting shafts; the two connecting shafts of the horizontal right-side grid 21 pass through the corresponding two through holes on the vertical grid 23 and are inserted into the corresponding two blind holes on the horizontal left-side grid 22, and the two connecting shafts of the horizontal left-side grid 22 pass through the corresponding two through holes on the vertical grid 23 and are inserted into the corresponding two blind holes on the horizontal right-side grid 21;

[0007] The foam core 30 includes a front foam 31 and a rear foam 32; the front foam 31 has openings on its left, right, lower and upper sides, respectively, to allow the front foam 31 to be installed and fixed with the left fixed wooden block 4, the right fixed wooden block 5, the lower fixed wooden block 6 and the upper fixed wooden block 7; the rear foam 32 is installed in the rear flange of the inner shell 11.

[0008] The left fixed wooden block 4, the right fixed wooden block 5, the lower fixed wooden block 6, and the upper fixed wooden block 7 are all provided with corresponding openings to achieve the installation and fixation of the cross grid.

[0009] Furthermore, the lower front part of the inner shell 11 is a solid laminate structure.

[0010] Furthermore, adhesive films are placed between the intake housing 10 and the foam, between the wood block and the foam, and between the wood block and the intake housing 10. Structural adhesive is placed between the cross grille 20 and the wood block, and structural adhesive is placed between the vertical grille 23 and the horizontal right grille 21 and the horizontal left grille 22 to form the cross grille 20.

[0011] Furthermore, the rear foam 32 is combined with the inner shell 11 and then cured together.

[0012] In addition, the present invention provides a combined intake manifold forming method, the forming process of which is as follows: The front foam 31, rear foam 32, left-side fixed wooden block 4, right-side fixed wooden block 5, lower fixed wooden block 6, upper fixed wooden block 7, right-side grille 21, horizontal left-side grille 22, and vertical grille 23 are processed respectively. Through three forming fixtures, the upper outer shell 12, lower outer shell 13, rear foam 32, and inner shell 11 are combined and formed. The front foam 31 is wrapped with a layer of adhesive film, and the lower outer shell 13 and the upper outer shell 12 are wrapped with adhesive film on all surfaces except the outer surface. Adhesive film; Place the front foam 31, left fixed wooden block 4, right fixed wooden block 5, lower fixed wooden block 6, upper fixed wooden block 7, lower outer shell 13 and upper outer shell 12 on the inner shell 11 in sequence, cover with a vacuum bag and then cure. After curing, demold. Then, make openings in the inner shell 11, upper outer shell 12 and lower outer shell 13 at the corresponding grille installation positions, and install the vertical grille 23, horizontal right grille 21 and horizontal left grille 22 in sequence, and glue them with structural adhesive. After gluing, cure to achieve the final shape of the air intake.

[0013] Furthermore, the inner shell 11 and the rear foam 32 are cured and molded together. The operation steps include: laying prepreg on the inner mold a according to the specified layers, reserving the required length of prepreg for back-wrapping in the area where the flange needs to be turned, and separating each layer of reserved prepreg with a release film to prevent the material layers from sticking together; after laying the prepreg according to the specified layers, placing the rear foam 32 wrapped with a layer of adhesive film at the designated position at the bottom, back-wrapping the reserved prepreg, and then installing the lower outer left mold e and the rear outer right mold f in place; placing the filling left mold b and the filling right mold c in the designated area at the top in sequence, back-wrapping the reserved prepreg, and then installing the upper outer mold d, right positioning block g, rear positioning block h, left positioning block k and front positioning block m in sequence, sealing the vacuum bag and then curing it, and demolding after curing.

[0014] This invention improves the design and forming method of the air intake, adopting a modular design and segmented forming, thus simplifying the process, reducing manufacturing difficulty and cost, improving product qualification rate, and shortening the manufacturing cycle. Attached Figure Description

[0015] Figure 1 An assembly diagram of a combined air intake duct according to a specific embodiment of the present invention is shown;

[0016] Figure 2 An exploded view of a combined air intake duct according to a specific embodiment of the present invention is shown;

[0017] Figure 3 A schematic diagram of the upper shell structure on the outer surface of a specific embodiment of the present invention is shown;

[0018] Figure 4 A schematic diagram of the upper shell structure on the outer surface of a specific embodiment of the present invention is shown;

[0019] Figure 5 A front view of the inner shell according to a specific embodiment of the present invention is shown;

[0020] Figure 6 It shows Figure 5 A sectional view on section AA;

[0021] Figure 7 It shows Figure 6 Detailed view at point A;

[0022] Figure 8 It shows Figure 5 A sectional view on section BB;

[0023] Figure 9 It shows Figure 8 Detailed view at point A;

[0024] Figure 10 A schematic diagram of the structure of the foam sandwich core according to a specific embodiment of the present invention is shown;

[0025] Figure 11 A front view of a combined air intake duct according to a specific embodiment of the present invention is shown;

[0026] Figure 12 It shows Figure 11 A sectional view on section AA;

[0027] Figure 13 It shows Figure 12 Detailed view at point A;

[0028] Figure 14 It shows Figure 12 Detailed view at point B;

[0029] Figure 15 It shows Figure 12 Detailed view at point C;

[0030] Figure 16 It shows Figure 12 Detailed view at point D;

[0031] Figure 17 It shows Figure 12 Detailed view at point E;

[0032] Figure 18 It shows Figure 12 A sectional view on the FF section;

[0033] Figure 19 It shows Figure 18Detailed view at point A;

[0034] Figure 20 It shows Figure 18 Detailed view at point B;

[0035] Figure 21 It shows Figure 18 Detailed view at point C;

[0036] Figure 22 It shows Figure 18 Detailed view at point D;

[0037] Figure 23 The invention illustrates a specific embodiment of the inner shell and rear foam molding assembly tooling.

[0038] The specific labels in the diagram are explained as follows:

[0039] 10—Intake duct housing; 11—Inner surface housing; 12—Upper outer surface housing; 13—Lower outer surface housing; 20—Cross grille; 21—Horizontal right side grille; 22—Horizontal left side grille; 23—Vertical grille; 30—Foam core; 31—Front foam; 32—Rear foam; 4—Left side fixing block; 5—Right side fixing block; 6—Lower fixing block; 7—Upper fixing block; 8—Sunken area; a—Inner surface mold; b—Left filling mold; c—Right filling mold; d—Upper outer surface mold; e—Lower outer surface left mold; f—Rear outer surface right mold; g—Right positioning block; h—Rear positioning block; k—Left positioning block; m—Front positioning block. Detailed Implementation

[0040] The present invention will now be described in further detail with reference to the accompanying drawings.

[0041] This invention proposes a combined air intake, such as Figure 1 , 2 As shown, the combined air intake includes an air intake housing 10, a cross grille 20, a foam core 30, a left-side fixed wooden block 4, a right-side fixed wooden block 5, a lower fixed wooden block 6, and an upper fixed wooden block 7.

[0042] like Figure 2 As shown, the intake housing 10 includes an inner surface housing 11, an upper outer surface housing 12, and a lower outer surface housing 13. Figure 5-9 As shown, the lower front part of the inner shell 11 has a solid laminated plate structure, which improves the rigidity of the air intake. Figure 3-5 As shown, the inner shell 11 has a recessed area 8 at the rear flange, the upper shell 12 has a recessed area 8 at the front, and the lower shell 13 has recessed areas 8 at the front and on the left and right sides. Figure 18-22As shown, the upper part of the front flange of the inner shell 11 overlaps with the recessed area 8 of the front of the upper shell 12 on the outer surface; the lower part of the front flange of the inner shell 11 overlaps with the recessed area 8 of the front of the lower shell 13 on the outer surface; the rear part of the upper shell 12 overlaps with the upper recessed area 8 above the rear flange of the inner shell 11; and the rear part of the lower shell 13 overlaps with the lower recessed area 8 below the rear flange of the inner shell 11. Figure 14 , 15 As shown, the left and right sides of the upper shell 12 overlap with the left and right recessed areas 8 of the lower shell 13. Figure 3-5 and Figure 11-16 As shown, the inner shell 11 has openings on its lower, upper, left, and right sides, the upper outer shell 12 has openings on its left and right sides, and the lower outer shell 13 has an opening on its lower side, so as to realize the installation of the cross grille 20.

[0043] like Figure 2 As shown, the cross-shaped grid 20 includes a horizontal right-side grid 21, a horizontal left-side grid 22, and a vertical grid 23. (As...) Figure 1 , 2 and Figure 17 As shown, the vertical grille 23 has four through holes, the horizontal right grille 21 has two blind holes and two connecting shafts, and the horizontal left grille 22 has two blind holes and two connecting shafts. The two connecting shafts of the horizontal right grille 21 pass through the corresponding two through holes on the vertical grille 23 and are inserted into the corresponding two blind holes on the horizontal left grille 22. The two connecting shafts of the horizontal left grille 22 pass through the corresponding two through holes on the vertical grille 23 and are inserted into the corresponding two blind holes on the horizontal right grille 21.

[0044] like Figure 10 As shown, the foam sandwich core 30 includes a front foam 31 and a rear foam 32. The front foam 31 has openings on its left, right, lower, and upper sides, respectively, to allow for the installation and fixation of the front foam 31 to the left-side fixing block 4, right-side fixing block 5, lower fixing block 6, and upper fixing block 7. The rear foam 32 is installed within the rear flange of the inner shell 11.

[0045] like Figure 2 As shown, the left fixed wooden block 4, the right fixed wooden block 5, the lower fixed wooden block 6, and the upper fixed wooden block 7 are all provided with corresponding openings to realize the installation and fixation of the cross grid.

[0046] Since the inner shell 11 has a recessed area 8 at the rear flange, if the inner shell 11 is cured and then combined with the rear foam 32, the rear foam 32 needs to be further decomposed into more and smaller components, which increases the workload and is not easy to operate. Therefore, a combination tool is made to combine the rear foam 32 and the inner shell 11 and cure them together.

[0047] This invention also proposes a combined air intake molding method, the specific molding process of which is as follows: The front foam 31, rear foam 32, left-side fixed wooden block 4, right-side fixed wooden block 5, lower fixed wooden block 6, upper fixed wooden block 7, right-side grille 21, horizontal left-side grille 22, and vertical grille 23 are processed separately. Using three molding fixtures, the upper outer shell 12, lower outer shell 13, rear foam 32, and inner shell 11 are molded together. The front foam 31 needs to be wrapped with a layer of adhesive film. The lower outer shell 13 and the upper outer shell 12, except for their outer surfaces, are also wrapped with adhesive film. The front foam 31, left-side fixed wooden block 4, right-side fixed wooden block 5, lower fixed wooden block 6, upper fixed wooden block 7, lower outer shell 13, and upper outer shell 12 are placed sequentially on the inner shell 11. A vacuum bag is then formed and cured. After curing, the shell is demolded. Then, openings are made in the inner shell 11, the upper shell 12, and the lower shell 13 at the corresponding grille mounting positions. The vertical grille 23, the horizontal right grille 21, and the horizontal left grille 22 are installed in sequence and bonded with structural adhesive. After the adhesive is bonded and cured, the air intake is finally formed.

[0048] Briefly describe the operation steps of curing the inner shell 11 and the rear foam 32 together. Figure 23 Lay the prepreg layers on the inner mold a as specified, leaving enough prepreg for backfilling in areas requiring flanges. Each layer of prepreg must be separated with a release film to prevent adhesion. After laying the layers as specified, place the rear foam 32, wrapped with one layer of adhesive film, at the designated lower position. Backfill the reserved prepreg, then install the lower outer mold left e and the rear outer mold right f. Place the filling left mold b and filling right mold c as shown in the diagram in the designated upper area, backfill the reserved prepreg, and then install the upper outer mold d, right positioning block g, rear positioning block h, left positioning block k, and front positioning block m in sequence. After sealing with a vacuum bag, allow it to cure. Demold after curing.

[0049] The above-described specific embodiments are limited to explaining and illustrating the technical solutions of the present invention, but do not constitute a limitation on the scope of protection of the claims. Those skilled in the art should understand that any new technical solutions obtained by making simple modifications or substitutions based on the technical solutions of the present invention fall within the scope of protection of the present invention.

Claims

1. A combined air intake, characterized in that, Includes an air intake housing (10), a cross grille (20), a foam core (30), a left-side fixing block (4), a right-side fixing block (5), a lower fixing block (6), and an upper fixing block (7); The intake housing (10) includes an inner surface housing (11), an upper outer surface housing (12), and a lower outer surface housing (13); wherein the rear flange of the inner surface housing (11) has a recessed area, the front of the upper outer surface housing (12) has a recessed area, and the front and left and right sides of the lower outer surface housing (13) have recessed areas; the upper part of the front flange of the inner surface housing (11) overlaps with the recessed area at the front of the upper outer surface housing (12), and the lower part of the front flange of the inner surface housing (11) overlaps with the recessed area at the front of the lower outer surface housing (13); The upper shell (12) overlaps with the upper recessed area above the flange of the inner shell (11), the lower shell (13) overlaps with the lower recessed area below the flange of the inner shell (11), and the left and right sides of the upper shell (12) overlap with the left and right recessed areas of the lower shell (13). The inner shell (11) has openings on its lower, upper, left, and right sides, the upper shell (12) has openings on its left and right sides, and the lower shell (13) has an opening, thus enabling the installation of the cross grille (20). The cross grid (20) includes a horizontal right grid (21), a horizontal left grid (22), and a vertical grid (23); wherein the vertical grid (23) is provided with four through holes, the horizontal right grid (21) is provided with two blind holes and two connecting shafts, and the horizontal left grid (22) is provided with two blind holes and two connecting shafts; the two connecting shafts of the horizontal right grid (21) pass through the corresponding two through holes on the vertical grid (23) and are inserted into the corresponding two blind holes on the horizontal left grid (22), and the two connecting shafts of the horizontal left grid (22) pass through the corresponding two through holes on the vertical grid (23) and are inserted into the corresponding two blind holes on the horizontal right grid (21); The foam core (30) includes a front foam (31) and a rear foam (32); the front foam (31) has openings on the left, right, lower and upper sides, respectively, to realize the installation and fixation of the front foam (31) with the left fixed wooden block (4), the right fixed wooden block (5), the lower fixed wooden block (6) and the upper fixed wooden block (7); the rear foam (32) is installed in the rear flange of the inner shell (11); The left fixed wooden block (4), the right fixed wooden block (5), the lower fixed wooden block (6) and the upper fixed wooden block (7) are all provided with corresponding openings to realize the installation and fixing of the cross grid.

2. The combined air intake duct according to claim 1, characterized in that, The lower front part of the inner shell (11) is a solid laminate structure.

3. A combined air intake duct according to claim 1, characterized in that, Adhesive film is placed between the intake housing (10) and the foam, between the wood block and the foam, and between the wood block and the intake housing (10). Structural adhesive is placed between the cross grille (20) and the wood block, and structural adhesive is placed between the vertical grille (23) and the horizontal right grille (21) and the horizontal left grille (22) to form the cross grille (20).

4. A combined air intake duct according to claim 1, characterized in that, The rear foam (32) is combined with the inner shell (11) and then cured together.

5. The method for forming a combined air intake duct according to claim 1, characterized in that, The molding process is as follows: The front foam (31), rear foam (32), left-side fixed wooden block (4), right-side fixed wooden block (5), lower fixed wooden block (6), upper fixed wooden block (7), right-side grid (21), horizontal left-side grid (22), and vertical grid (23) are processed separately. Using three molding fixtures, the upper shell (12), lower shell (13), rear foam (32), and inner shell (11) are molded together. The front foam (31) is wrapped with a film, and the lower shell (13) and upper shell (12) are wrapped with film on all surfaces except the outer surface. The inner shell... (11) Place the front foam (31), left fixed wooden block (4), right fixed wooden block (5), lower fixed wooden block (6), upper fixed wooden block (7), lower outer shell (13) and upper outer shell (12) in sequence. After the vacuum bag is made, it is cured and demolded after curing. Then, make openings in the inner shell (11), upper outer shell (12) and lower outer shell (13) at the corresponding grille installation positions. Install the vertical grille (23), horizontal right grille (21) and horizontal left grille (22) in sequence and use structural adhesive to bond them. After bonding, cure to achieve the final formation of the air intake.

6. The method for forming a combined air intake duct according to claim 5, characterized in that, The inner shell (11) and the rear foam (32) are cured together. The operation steps include: laying prepreg on the inner mold (a) according to the specified layers, reserving the required length of prepreg for back wrapping in the area where the edge needs to be turned up, and separating each layer of reserved prepreg with a release film to prevent the material layers from sticking together; after laying the prepreg according to the specified layers, placing the rear foam (32) wrapped with a layer of adhesive film at the designated position at the bottom, back wrapping the reserved prepreg, and then installing the lower outer left mold (e) and the rear outer right mold (f) in place; placing the filling left mold (b) and the filling right mold (c) in the designated area at the top in sequence, back wrapping the reserved prepreg, and then installing the upper outer mold (d), right positioning block (g), rear positioning block (h), left positioning block (k) and front positioning block (m) in place in sequence, making a vacuum bag and then curing it, and demolding after curing.

Images