A molding die and molding method for a carbon fiber radial beam

Abstract

This invention belongs to the field of composite material molding technology, specifically relating to a molding die and molding method for carbon fiber radial beams. The molding die of this invention includes a combined core mold, a combined steel mold, multiple metal embedded parts, and a clamping mechanism. The multiple metal embedded parts and the combined core mold are all placed inside the combined steel mold, and the multiple metal embedded parts are distributed at the intersection nodes of the combined core mold. Multiple sets of clamping mechanisms are provided, each set being detachably connected to the top of the combined steel mold. Each clamping mechanism is positioned directly above a metal embedded part, used to apply a downward clamping force to the metal embedded part. This invention utilizes the principle of air-inflated molding. A process gap is designed between the combined core mold and the combined steel mold. When high-pressure air enters the air-inflated bag, the pressure of the air-inflated bag is evenly transmitted to the carbon fiber prepreg, ensuring that the carbon fiber prepreg adheres fully to the combined steel mold. After hot-press curing, the thin-walled structure of the carbon fiber becomes denser, effectively improving the stiffness of the carbon fiber radial beam.

Description

Technical Field

[0001] This invention belongs to the field of composite material molding technology, specifically relating to a molding die and molding method for carbon fiber radial beams. Background Technology

[0002] Carbon fiber radiating beams are load-bearing truss structural components between the antenna reflector and the turntable. They are one of the core structures that support and position large and medium-sized reflectors and transmit external loads.

[0003] Traditional carbon fiber radial beams typically employ two molding methods. One method is as follows: Figure 15 As shown, the carbon fiber straight tube and the metal joint are bonded together using structural adhesive; another method is as follows... Figure 16 As shown, carbon fiber skin is formed separately and then bonded to the honeycomb core sandwich layer with an adhesive film for secondary curing. Both of these forming methods involve secondary forming, which significantly reduces the stiffness of the carbon fiber radial beam and the connection strength between the metal components and the carbon fiber tubes. This invention provides another forming method for carbon fiber radial beams.

[0004] Patent application number 201310525888.6 discloses a carbon fiber antenna radiating beam and its manufacturing method. While its application can reduce the weight of the radiating beam, increase its strength and rigidity, and simplify the process, overcoming many shortcomings of traditional antenna radiating beams, the carbon fiber tubes of the radiating beam require steel joints for connection. If the joints become loose or damaged during use, it will affect the stability of the product.

[0005] Patent application number 202110819466.4 discloses a method and molding die for integral molding of carbon fiber radiating beams for composite material antennas, but it has the following defects: the bonding strength between carbon fiber and metal embedded parts is insufficient. Summary of the Invention

[0006] This invention provides a molding die and molding method for carbon fiber radial beams. One objective is to provide a mold and molding method that can solve the stiffness problem in the molding of carbon fiber radial beams. Another objective is to provide a method that enables carbon fiber and metal embedded parts to be co-cured and molded, thereby improving the bonding strength between the two.

[0007] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0008] A molding die for a carbon fiber radial beam includes at least a plurality of embedded metal parts, and further includes a combined core mold, a combined steel mold, and a clamping mechanism; the plurality of embedded metal parts and the combined core mold are all placed inside the combined steel mold, and the plurality of embedded metal parts are respectively arranged at the intersection nodes of the combined core mold; multiple sets of clamping mechanisms are provided, and the multiple sets of clamping mechanisms are detachably connected to the top of the combined steel mold, and each set of clamping mechanisms is placed directly above a embedded metal part for applying a downward clamping force to the embedded metal part.

[0009] The combined steel mold includes a mold plate, a mold frame, and a top cover plate; the mold frame is connected to the mold plate, and the top cover plate is connected to the top of the mold frame; multiple sets of clamping mechanisms are detachably connected to the top cover plate, and each set of clamping mechanisms is placed directly above different metal embedded parts.

[0010] The mold plate is a rectangular steel plate with one corner cut off; the mold frame includes an outer frame and multiple inner partitions. The outer frame is a steel frame with the same shape as the radial beam. Seven different triangular steel inner partitions are set inside the outer frame, which divide the internal space of the outer frame into multiple spaces that match the combined core mold; the upper cover plate is composed of multiple sub-cover plates of different shapes. The upper part of the space formed between the outer frame and the multiple inner partitions, and between adjacent inner partitions, is covered by multiple sub-cover plates. An opening is opened on the sub-cover plate opposite the metal embedded part for connecting the clamping mechanism to clamp the metal embedded part.

[0011] The combined core mold includes an air-inflating bag and a foam core; the foam core is composed of multiple foam blocks made of EPS; the air-inflating bag is made of nylon ducts with open ends, and an air inlet is connected to one open end of the air-inflating bag. Multiple foam blocks that make up the foam core are placed sequentially inside the air-inflating bag through the other open end of the air-inflating bag, forming a radial beam shape before being sealed; the multiple foam blocks match the shape of the inner cavity space of the combined steel mold.

[0012] The clamping mechanism includes a connecting plate, ejector screws, and a molding plate; the molding plate is placed inside the upper cover plate of the combined steel mold and is positioned directly above the metal embedded part; the connecting plate is located on the top of the combined steel mold and directly above the molding plate, and the connecting plate is detachably connected to the top of the combined steel mold; at least two ejector screws are provided, and the ejector screws are evenly and vertically threadedly connected to the connecting plate for clamping and loosening the molding plate.

[0013] There is a gap between the molding plate and the connecting plate; the outer diameter of the molding plate is smaller than the outer diameter of the metal embedded part.

[0014] It also includes a steel formwork under-formation assembly; the steel formwork under-formation assembly includes an outer frame, two support plates, and a reinforcing rib plate; the outer frame is fixedly connected to the lower surface of the combined steel formwork; the two support plates and the reinforcing rib plate are vertically arranged inside the outer frame, with the two support plates respectively placed at both ends of the central axis of the outer frame, and the reinforcing rib plate placed in the middle of the central axis; the top surfaces of the two support plates and the reinforcing rib plate are fixedly connected to the lower surface of the combined steel formwork, and the bottom surfaces of the two support plates and the reinforcing rib plate are fixedly connected to the inner bottom surface of the outer frame; two lifting lugs are fixedly connected to the outer surfaces of the two support plates respectively.

[0015] The support plate has multiple heat dissipation holes on its side wall.

[0016] A method for molding a carbon fiber radial beam, using a molding die for the carbon fiber radial beam, includes the following steps:

[0017] Step 1: Prepare the combined core mold;

[0018] Connect one opening of the air inflatable bag to the air inlet, then place multiple foam blocks from the composite core mold into the air inflatable bag in sequence; then seal the other opening of the air inflatable bag.

[0019] Step 2: Lay the carbon fiber prepreg fabric into the cavity formed by the mold plate and mold frame in the combined steel mold;

[0020] Step 3: Place multiple metal embedded parts at the intersection of the combined core mold;

[0021] Step 4: Place the multiple foam blocks from the combined core mold on top of the carbon fiber prepreg fabric according to the preset positions, and place each foam block in the space divided by the mold frame accordingly;

[0022] Step 5: Flip the top edge of the carbon fiber prepreg fabric onto the combined mandrel, then cover it with the top cover plate and fix the top cover plate to the mold frame;

[0023] Step Six: Connect multiple sets of clamping mechanisms to the sub-cover plates where the metal embedded parts are located;

[0024] Step 7: Place the assembled carbon fiber radial beam molding mold into the autoclave, connect the air inlet on the combined core mold to the external air compressor, continuously fill the air bag with high-pressure air, and the autoclave starts to heat up. Under the pressure of the high-pressure air, the carbon fiber prepreg is hot-pressed and cured into shape.

[0025] The specific process of step seven, heating and pressurizing, is as follows: The air compressor continuously inflates and pressurizes the air-inflated bag. When the pressure reaches 0.2 MPa, it stops for 5 to 10 minutes; inflation continues until the pressure reaches 0.3 MPa, then stops for 5 to 10 minutes; inflation continues until the pressure reaches 0.4 MPa, then stops for 10 to 15 minutes; inflation continues until the pressure reaches 0.5 MPa and is maintained; the temperature is increased to 120 to 130 degrees Celsius at a heating rate of 0.5 to 2°C / minute, and after holding at that temperature for 90 minutes, cooling begins. When the temperature drops to 60 degrees Celsius, the pressure is released, the autoclave is opened, and the mold is removed.

[0026] Beneficial effects:

[0027] (1) The molding die of the present invention is organically composed of a combined core mold, a combined steel mold, multiple metal embedded parts, and a pressing mechanism. The present invention utilizes the principle of air-inflated molding process. A process gap is designed between the combined core mold and the combined steel mold. When high-pressure air enters the air-inflated bag, the pressure of the air-inflated bag is evenly transmitted to the carbon fiber prepreg, so that the carbon fiber prepreg and the combined steel mold are fully bonded and integrally formed. After hot pressing and curing, the carbon fiber thin-walled structure becomes more dense, which effectively improves the stiffness of the carbon fiber radial beam.

[0028] (2) The present invention improves the bonding strength between the carbon fiber and the metal embedded part by designing a pressing mechanism to achieve co-curing and molding of the carbon fiber and the metal embedded part.

[0029] (3) The present invention is more suitable for molding complex cavity structure parts by designing multiple foam blocks and a mold frame cavity that matches the foam blocks.

[0030] (4) By setting up a steel film under-component, the present invention ensures the rigidity of the mold when it is pressurized and heated, and prevents the mold from deforming.

[0031] The above description is merely an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention and to implement it in accordance with the contents of the specification, the preferred embodiments of the present invention are described in detail below with reference to the accompanying drawings. Attached Figure Description

[0032] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0033] Figure 1 This is a schematic diagram of the combined steel mold in this invention.

[0034] Figure 2 This is a top view of the combined steel mold of the present invention.

[0035] Figure 3 This is the front view of the combined steel mold in this invention.

[0036] Figure 4 This is a diagram showing the arrangement of the foam blocks in the combined core mold of the present invention.

[0037] Figure 5 This is a schematic diagram of the clamping mechanism of the present invention.

[0038] Figure 6 This is a schematic diagram of the structure of the combined core mold of the present invention.

[0039] Figure 7 This is a schematic diagram showing the location of the embedded metal parts in the carbon fiber radial beam of the present invention.

[0040] Figure 8 This is a cross-sectional view of the location of the first metal embedded part of the present invention.

[0041] Figure 9 This is a cross-sectional view of the location of the second metal embedded part of the present invention.

[0042] Figure 10 This is a cross-sectional view of the location of the third metal embedded part of the present invention.

[0043] Figure 11 This is a cross-sectional view of the location of the fourth metal embedded part of the present invention.

[0044] Figure 12 This is a schematic diagram illustrating the principle of the air expansion method of the present invention.

[0045] Figure 13 This is a schematic diagram showing the positioning of the foam block in the composite core mold.

[0046] Figure 14 This is a schematic diagram of the upper cover plate.

[0047] Figure 15 This is a schematic diagram of the bonding and molding of carbon fiber tubes and metal joints in the prior art.

[0048] Figure 16 This is a schematic diagram of the bonding and curing process between the skin and the honeycomb core in the existing technology.

[0049] In the diagram: 1. Mold plate; 2. Mold frame; 3. Top cover plate; 4. First screw; 5. Inflatable bag; 6. Foam core; 7. Air inlet; 8. Combined core mold; 9. Carbon fiber prepreg; 10. Pressing mechanism; 11. Combined steel mold; 12. Metal embedded part; 13. Connecting plate; 14. Ejector screw; 15. Connecting bolt; 16. Molding plate; 17. Steel mold lower assembly; 18. Heat dissipation hole; 19. First pin; 20. Second screw; 21. Second pin; 22. Lifting lug; 23. Reinforcing rib plate; 24. Outer frame; 25. First inner partition frame; 26. Second inner partition frame; 27. Third inner partition frame; 28. Fourth inner partition frame; 29. ​​Fifth inner partition frame; 30. Sixth inner partition frame; 31. Seventh inner partition frame; 32. First foam block; 33. Second foam block; 34. Third foam block; 35. Fourth foam block; 36. Fifth foam block; 37. Sixth foam block; 38. Seventh foam block; 39. Eighth foam block; 40. Ninth foam block; 41. Tenth foam block; 42. Eleventh foam block; 43. Twelfth foam block; 44. Thirteenth foam block. 45. Foam block; 46. Fourteenth foam block; 47. Fifteenth foam block; 48. Outer frame; 49. Support plate; 50. First metal embedded part; 51. Second metal embedded part; 52. Third metal embedded part; 53. Fourth metal embedded part; 54. Fifth metal embedded part; 55. Sixth metal embedded part; 56. Seventh metal embedded part; 57. Eighth metal embedded part; 58. Rounded corner; 59. First sub-cover plate; 60. Second sub-cover plate; 61. Third sub-cover plate; 62. Fourth sub-cover plate; 63. Fifth sub-cover plate 63. Sixth Sub-cover Plate; 64. Seventh Sub-cover Plate; 65. Eighth Sub-cover Plate; 66. Ninth Sub-cover Plate; 67. Tenth Sub-cover Plate; 68. Eleventh Sub-cover Plate; 69. Twelfth Sub-cover Plate; 70. Thirteenth Sub-cover Plate; 71. Fourteenth Sub-cover Plate; 72. Fifteenth Sub-cover Plate; 73. Sixteenth Sub-cover Plate; 74. Seventeenth Sub-cover Plate; 75. Eighteenth Sub-cover Plate; 76. Nineteenth Sub-cover Plate; 77. Twentieth Sub-cover Plate; 78. Twenty-first Sub-cover Plate; 79. Twenty-second Sub-cover Plate; 80. Twenty-third Sub-cover Plate. Detailed Implementation

[0050] 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 a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0051] Example 1:

[0052] according to Figures 1-14The molding die for a carbon fiber radial beam shown includes at least a plurality of metal embedded parts 12, and also includes a combined core mold 8, a combined steel mold 11, and a clamping mechanism 10. The plurality of metal embedded parts 12 and the combined core mold 8 are all placed inside the combined steel mold 11, and the plurality of metal embedded parts 12 are respectively arranged at the intersection nodes of the combined core mold 8. Multiple sets of clamping mechanisms 10 are provided, and the multiple sets of clamping mechanisms 10 are detachably connected to the top of the combined steel mold 11. Each set of clamping mechanism 10 is placed directly above a metal embedded part 12 and is used to apply a downward clamping force to the metal embedded part 12.

[0053] In practical use, the combined core mold 8 is first prepared. After the combined core mold 8 is prepared, the carbon fiber prepreg fabric 9 is laid in the cavity of the combined steel mold 11. Multiple metal embedded parts 12 are placed at the intersection of the combined core mold 8. Then, the combined core mold 8 is placed on top of the carbon fiber prepreg fabric 9 according to the preset position, and the combined core mold 8 is placed in the space of the combined steel mold 11 accordingly. Then, the top of the carbon fiber prepreg fabric 9 is flipped onto the combined core mold 8. Then, the upper cover plate 3 in the combined steel mold 11 is covered and fixed. Then, multiple sets of clamping mechanisms 10 are connected to the upper cover plate 3 at the locations of the metal embedded parts 12. Then, the mold of the installed carbon fiber radial beam is placed into the autoclave. The combined core mold 8 is connected to an external air compressor, and high-pressure air is continuously injected into the combined core mold 8. After reaching the preset pressure, the autoclave starts to heat up. Under the pressure of the high-pressure air, the carbon fiber prepreg is hot-pressed and cured.

[0054] This invention utilizes the principle of air-expansion molding process. When high-pressure air enters the combined core mold 8, the pressure is evenly transmitted to the carbon fiber prepreg 9, so that the carbon fiber prepreg 9 and the combined steel film 11 are fully bonded and integrally formed. After hot pressing and curing, the carbon fiber thin-wall structure becomes more dense, which effectively improves the stiffness of the carbon fiber radial beam.

[0055] The present invention improves the bonding strength between the carbon fiber and the metal embedded part by designing the clamping mechanism 10 to co-cur and form the carbon fiber and the metal embedded part.

[0056] Example 2:

[0057] according to Figures 1-3 , Figure 5 , Figure 13 and Figure 14 The molding die for a carbon fiber radial beam shown differs from that in Embodiment 1 in that: the combined steel mold 11 includes a mold plate 1, a mold frame 2, and an upper cover plate 3; the mold frame 2 is connected to the mold plate 1, and the upper cover plate 3 is connected to the top of the mold frame 2; multiple sets of clamping mechanisms 10 are detachably connected to the upper cover plate 3, and each set of clamping mechanism 10 is placed directly above a different metal embedded part 12.

[0058] Furthermore, the mold plate 1 is a rectangular steel plate with one corner cut off; the mold frame 2 includes an outer frame 24 and multiple inner partitions. The outer frame 24 is a steel frame with the same shape as the radial beam. Seven different triangular steel inner partitions are set inside the outer frame 24. The seven inner partitions divide the internal space of the outer frame 24 into multiple spaces that match the combined core mold 8. The upper cover plate 3 is composed of multiple sub-cover plates of different shapes. The upper part of the space formed between the outer frame 24 and the multiple inner partitions, and between adjacent inner partitions, is covered by multiple sub-cover plates. An opening is opened on the sub-cover plate opposite the metal embedded part 12 for connecting the clamping mechanism 10 to clamp the metal embedded part 12.

[0059] In this embodiment, the seven inner partitions are the first inner partition 25, the second inner partition 26, the third inner partition 27, the fourth inner partition 28, the fifth inner partition 29, the sixth inner partition 30, and the seventh inner partition 31, as follows: Figure 2 As shown. The space formed between the outer frame 24 and the seven inner frames, and between adjacent inner frames, is used to place the metal embedded parts 12 and multiple foam blocks in the combined core mold 8. The upper cover plate 3 includes a first sub-cover plate 58, a second sub-cover plate 59, a third sub-cover plate 60, a fourth sub-cover plate 61, a fifth sub-cover plate 62, a sixth sub-cover plate 63, a seventh sub-cover plate 64, an eighth sub-cover plate 65, a ninth sub-cover plate 66, a tenth sub-cover plate 67, an eleventh sub-cover plate 68, a twelfth sub-cover plate 69, a thirteenth sub-cover plate 70, a fourteenth sub-cover plate 71, a fifteenth sub-cover plate 72, a sixteenth sub-cover plate 73, a seventeenth sub-cover plate 74, an eighteenth sub-cover plate 75, a nineteenth sub-cover plate 76, a twentieth sub-cover plate 77, a twenty-first sub-cover plate 78, a twenty-second sub-cover plate 79, and a twenty-third sub-cover plate 80. The shape of each sub-cover plate should be such that it can cover the space it occupies, facilitates connection with the inner partition frame and the outer frame, and saves materials.

[0060] In practical applications, after the air inflatable bag 5 is assembled, the carbon fiber prepreg fabric 9 is laid on the combined steel mold 11, and then multiple metal embedded parts 12 are placed at the intersections of the combined core mold 8. Subsequently, multiple foam blocks in the combined core mold 8 are placed in the spaces that match the combined core mold 8, which are divided by the seven inner partitions covered with carbon fiber prepreg fabric 9, according to the preset positions. Then, the top edge of the carbon fiber prepreg fabric 9 is flipped onto the combined core mold 8. After that, the first sub-cover plate 58, the second sub-cover plate 59, the third sub-cover plate 60, the fourth sub-cover plate 61, the fifth sub-cover plate 62, the sixth sub-cover plate 63, the seventh sub-cover plate 64, the eighth sub-cover plate 65, the ninth sub-cover plate 66, the tenth sub-cover plate 67, the eleventh sub-cover plate 68, the twelfth sub-cover plate 69, and the tenth sub-cover plate 60 are placed on the upper cover plate 3. The three sub-covers 70, fourteenth sub-cover 71, fifteenth sub-cover 72, seventeenth sub-cover 74, eighteenth sub-cover 75, twentieth sub-cover 77, twenty-first sub-cover 78, and twenty-third sub-cover 80 are placed in a counter-clockwise direction above the space divided between the outer frame 24 and the multiple inner partitions, starting from the upper left corner of the outer frame 24. The twenty-second sub-cover 79 is placed above the space formed between the first inner partition 25 and the second inner partition 26. The nineteenth sub-cover 76 is placed above the space formed between the third inner partition 27 and the fourth inner partition 28. The sixteenth sub-cover 73 is placed above the space formed between the fifth inner partition 29 and the sixth inner partition 30. Each sub-cover is detachably connected to the corresponding outer frame 24 and inner partition. Subsequently, clamping mechanisms 10 are connected to the twenty-first sub-cover plate 78, eighteenth sub-cover plate 75, fifteenth sub-cover plate 72, thirteenth sub-cover plate 70, eleventh sub-cover plate 68, eighth sub-cover plate 65, and fifth sub-cover plate 62 at the locations of the metal embedded parts 12, respectively. Figure 14 As shown. To facilitate the connection of the clamping mechanism 10, in this embodiment, openings for placing the molding plate are provided at the connection points of the clamping mechanism 10 on the 21st sub-cover plate 78, 18th sub-cover plate 75, 15th sub-cover plate 72, 13th sub-cover plate 70, 11th sub-cover plate 68, 8th sub-cover plate 65, and 5th sub-cover plate 62. After the molding die of the carbon fiber radial beam is connected and installed, the whole assembly is placed in the autoclave. The air inlet 7 on the combined core mold 8 is connected to an external air compressor, and high-pressure air is continuously injected into the air inflator 5. The autoclave begins to heat up, and under the pressure of the high-pressure air, the carbon fiber prepreg is hot-pressed and cured into shape.

[0061] In practical applications, to ensure that the foam block in the combined core mold 8 can be stably placed within the space divided on the mold frame 2, the three corners of the triangular inner partition are all rounded. This also ensures that the corresponding positions within the inner cavity of the fabricated carbon fiber radial beam are rounded, resulting in more even stress distribution. Figure 13As shown. The mold plate 1 and the mold frame 2 are positioned by the first pin 19 and connected and fixed by the first screw 4; the mold frame 2 and the upper cover plate 3 are positioned by the second pin 21 and connected and fixed by the second screw 20.

[0062] The present invention, through the design of multiple foam blocks and a mold frame cavity that matches the foam blocks, makes the present invention more suitable for molding complex cavity structure parts.

[0063] Example 3:

[0064] according to Figure 1 , Figure 4 , Figure 6 and Figure 13 The molding die for a carbon fiber radial beam shown differs from that in Embodiment 1 in that: the combined core mold 8 includes an air-inflating bag 5 and a foam core 6; the foam core 6 is composed of multiple foam blocks made of EPS; the air-inflating bag 5 is made of nylon ducts with open ends, and an air inlet 7 is connected to one open end of the air-inflating bag 5. Multiple foam blocks that make up the foam core 6 are sequentially placed inside the air-inflating bag 5 through the other open end of the air-inflating bag 5 to form a radial beam shape and then sealed; the multiple foam blocks match the shape of the inner cavity space of the combined steel mold 11.

[0065] In this embodiment, the inflatable bag 5 is made of a nylon duct with open ends.

[0066] In actual use, connect an air inlet 7 to one opening of the air inflatable bag 5, then place multiple foam blocks from the combined core mold 8 into the air inflatable bag 5 in sequence through the other opening of the air inflatable bag 5, and then seal the other opening of the air inflatable bag 5. The combined core mold 8 is then completed.

[0067] In this embodiment, the foam core 6 is composed of a first foam block 32, a second foam block 33, a third foam block 34, a fourth foam block 35, a fifth foam block 36, a sixth foam block 37, a seventh foam block 38, an eighth foam block 39, a ninth foam block 40, a tenth foam block 41, an eleventh foam block 42, a twelfth foam block 43, a thirteenth foam block 44, a fourteenth foam block 45, and a fifteenth foam block 46. Each foam block matches the shape of the partition space within the mold frame 2. To ensure stable contact between each foam block and the partition space within the mold frame 2, the foam blocks have rounded corners 57 at the three corners where they contact the triangular inner partition within the mold frame 2. Figure 13As shown. The outer dimensions and thickness of each foam block are pre-drilled with a 5-10mm gap between the inner cavity of the mold frame 2. When placing multiple foam blocks into the inflatable bag 5, they can be placed in the following order: first foam block 32, second foam block 33, third foam block 34, fourth foam block 35, fifth foam block 36, sixth foam block 37, seventh foam block 38, eighth foam block 39, ninth foam block 40, tenth foam block 41, eleventh foam block 42, twelfth foam block 43, thirteenth foam block 44, fourteenth foam block 45, and fifteenth foam block 46, and then sealed. This facilitates the placement of different foam blocks on the combined steel mold 11 with the carbon fiber prepreg 9 laid on it when the combined core mold 8 is placed on the combined steel mold 11 with the space divided, shortening the assembly time of the molding mold.

[0068] The function of foam core 6 is to serve as a hollow spacer for the carbon fiber radial beam. Therefore, the shapes of the first foam block 32, the second foam block 33, the third foam block 34, the fourth foam block 35, the fifth foam block 36, the sixth foam block 37, the seventh foam block 38, the eighth foam block 39, the ninth foam block 40, the tenth foam block 41, the eleventh foam block 42, the twelfth foam block 43, the thirteenth foam block 44, the fourteenth foam block 45, and the fifteenth foam block 46 match the shape of the inner cavity of the carbon fiber radial beam at the corresponding positions. Among them, the length of the fifteenth foam block 46 is shorter than the length of the space it occupies, so that the air inflatable bag 5 can provide cushioning. In specific placement, the second foam block 33 is placed within the space enclosed by the first metal embedded part 49, the eighth metal embedded part 56, the first inner partition frame 25, and the outer frame 24; the third foam block 34 is placed within the space enclosed by the first inner partition frame 25, the second inner partition frame 26, and the eighth metal embedded part 56; the first foam block 32 is placed within the space enclosed by the first metal embedded part 49, the first inner partition frame 25, the second inner partition frame 26, and the third foam block 34; and the fourth foam block 35 is placed within the space enclosed by the outer frame 24, the first metal embedded part 49, the second inner partition frame 26, and the second metal embedded part 50. Inside; the fifth foam block 36 is placed within the space enclosed by the second inner partition 26, the third inner partition 27, the second metal embedded part 50, the eighth metal embedded part 56, and the third foam block 34; the sixth foam block 37 is placed within the space enclosed by the outer frame 24, the eighth metal embedded part 56, the third inner partition 27, and the seventh metal embedded part 55; the seventh foam block 38 is placed within the space enclosed by the third inner partition 27, the fourth inner partition 28, the second metal embedded part 50, and the seventh metal embedded part 55; the eighth foam block 39 is placed within the outer frame 24, the fourth inner partition 28, and the second metal embedded part 50. The space enclosed by the third metal embedded part 51 and the seventh foam block 38; the ninth foam block 40 is placed within the space enclosed by the fourth inner frame 28, the fifth inner frame 29, the third metal embedded part 51, and the seventh metal embedded part 55; the tenth foam block 41 is placed within the space enclosed by the outer frame 24, the fifth inner frame 29, the sixth metal embedded part 54, and the seventh metal embedded part 55; the eleventh foam block 42 is placed within the space enclosed by the fifth inner frame 29, the sixth inner frame 30, the third metal embedded part 51, and the sixth metal embedded part 54; the twelfth foam block 43 is placed within the space enclosed by the outer frame 24, the... The space enclosed by the sixth inner partition 30, the third metal embedded part 51, the fourth metal embedded part 52 and the eleventh foam block 42; the thirteenth foam block 44 is placed in the space enclosed by the sixth inner partition 30, the seventh inner partition 31, the fourth metal embedded part 52 and the sixth metal embedded part 54; the fourteenth foam block 45 is placed in the space enclosed by the outer frame 24, the seventh inner partition 31, the fifth metal embedded part 53 and the sixth metal embedded part 54; the fifteenth foam block 46 is placed in the space enclosed by the outer frame 24, the seventh inner partition 31, the fourth metal embedded part 52 and the fifth metal embedded part 53.

[0069] In this embodiment, EPS is an abbreviation for Expanded Polystyrene, which means polystyrene foam in Chinese.

[0070] Example 4:

[0071] according to Figure 5 The molding die for a carbon fiber radial beam shown differs from that in Embodiment 1 in that: the clamping mechanism 10 includes a connecting plate 13, ejector screws 14, and a molding plate 16; the molding plate 16 is placed inside the upper cover plate 3 in the combined steel mold 11 and is positioned directly above the metal embedded part 12; the connecting plate 13 is located on the top of the combined steel mold 11 and directly above the molding plate 16, and the connecting plate 13 is detachably connected to the top of the combined steel mold 11; at least two ejector screws 14 are provided, and the ejector screws 14 are evenly and vertically threadedly connected to the connecting plate 13 for clamping and loosening the molding plate 16.

[0072] In actual use, the molding plate 16 contacts the carbon fiber prepreg 9 placed on the top layer after being flipped over. The edge of the connecting plate 13 is connected and fixed to the upper cover plate 3 by the connecting bolts 15. By adjusting the up and down position of the top screw 14, the degree of compression of the molding plate 16 on the carbon fiber prepreg 9 and the metal embedded part 12 below it can be adjusted.

[0073] The present invention utilizes the action of the pressing mechanism 10. When the carbon fiber prepreg 9 is heated to a certain temperature, the top wire 14 and the molding plate 16 exert pressure on the carbon fiber prepreg 9, so that the carbon fiber prepreg 9 and the metal embedded part 12 are co-cured and molded into one piece by hot pressing, thereby improving the bonding strength between the two.

[0074] In practical applications, the metal embedded parts include a first metal embedded part 49, a second metal embedded part 50, a third metal embedded part 51, a fourth metal embedded part 52, a fifth metal embedded part 53, a sixth metal embedded part 54, a seventh metal embedded part 55, and an eighth metal embedded part 56. The first metal embedded part 49 is placed within the space formed between the outer frame 24 and the first inner partition 25; the second metal embedded part 50 is placed at the intersection of the space enclosed by the second inner partition 26, the outer frame 24, and the third inner partition 27; the third metal embedded part 51 is placed at the intersection of the space enclosed by the fourth inner partition 28, the outer frame 24, and the fifth inner partition 29; the fourth metal embedded part 52 is placed at the intersection of the space enclosed by the sixth inner partition 30, the outer frame 24, and the seventh inner partition 31; and the fifth metal embedded part 53 is placed at... The sixth metal embedded part 54 is placed at the apex of the space enclosed by the outer frame 24 and the seventh inner partition 31; the sixth metal embedded part 54 is placed at the intersection of the space enclosed by the outer frame 24, the fifth inner partition 29, the sixth inner partition 30 and the seventh inner partition 31; the seventh metal embedded part 55 is placed at the intersection of the space enclosed by the outer frame 24, the third inner partition 27, the fourth inner partition 28 and the fifth inner partition 29; the eighth metal embedded part 56 is placed at the intersection of the space enclosed by the outer frame 24, the first inner partition 25, the second inner partition 26 and the third inner partition 27. A clamping mechanism 10 needs to be installed at the positions of the second metal embedded part 50, the third metal embedded part 51, the fourth metal embedded part 52, the fifth metal embedded part 53, the sixth metal embedded part 54, the seventh metal embedded part 55, and the eighth metal embedded part 56. The size and number of the molding plate 16 and the connecting plate 13 can be adjusted according to the actual size and shape of the seven metal embedded parts, so that the clamping mechanism 10 is convenient for both clamping and handling.

[0075] In this embodiment, the pressing mechanism connected to the 21st sub-cover plate 78, 18th sub-cover plate 75, and 15th sub-cover plate 72 consists of 6 molding plates 16 and 3 connecting plates 13. The specific number and size are determined based on the need to meet the pressing requirements. In this embodiment, the second metal embedded part 50, the third metal embedded part 51, and the fourth metal embedded part 52 have the same structure, as do the sixth metal embedded part 54, the seventh metal embedded part 55, and the eighth metal embedded part 56. The molding plates 16 and connecting plates 13 on the metal embedded parts with the same structure can be set in the same way.

[0076] Example 5:

[0077] according to Figure 5 The molding die for a carbon fiber radial beam shown differs from that in Embodiment 1 in that there is a gap between the molding plate 16 and the connecting plate 13; and the outer diameter of the molding plate 16 is smaller than the outer diameter of the metal embedded part 12.

[0078] In actual use, a gap is set between the molding plate 16 and the connecting plate 13 for easy adjustment; the outer diameter of the molding plate 16 is smaller than the outer diameter of the metal embedded part 12, which can make the pressing effect better.

[0079] Example 6:

[0080] according to Figure 1 and Figure 3 The molding die for a carbon fiber radial beam shown differs from that in Embodiment 1 in that it further includes a steel mold lower assembly 17. The steel mold lower assembly 17 includes an outer frame 47, two support plates 48, and a reinforcing rib plate 23. The outer frame 47 is fixedly connected to the lower surface of the combined steel mold 11. The two support plates 48 and the reinforcing rib plate 23 are vertically arranged inside the outer frame 47. The two support plates 48 are respectively placed at both ends of the central axis of the outer frame 47, and the reinforcing rib plate 23 is placed in the middle of the central axis. The top surfaces of the two support plates 48 and the reinforcing rib plate 23 are fixedly connected to the lower surface of the combined steel mold 11, and the bottom surfaces of the two support plates 48 and the reinforcing rib plate 23 are fixedly connected to the inner bottom surface of the outer frame 47. Two lifting lugs 22 are fixedly connected to the outer surfaces of the two support plates 48 respectively.

[0081] In practical use, the steel mold lower component 17 is used to improve the rigidity of the mold plate 1, so that the deformation of the mold plate 1 is no more than 0.3mm during the high temperature and high pressure forming process of the carbon fiber radial beam.

[0082] In actual use, the outer frame 47, the two support plates 48, and the reinforcing rib plate 23 can all be made of I-beams, which are welded together to make the steel mold under-panel assembly 17 and the mold plate 1 a single unit. This not only makes the materials readily available but also reduces the cost.

[0083] In this embodiment, the lifting lug 22 is designed to facilitate the hoisting of the carbon fiber radial beam mold into the autoclave after the mold is assembled.

[0084] Example 7:

[0085] according to Figure 1 and Figure 3 The molding die for a carbon fiber radial beam shown differs from that in Embodiment 7 in that the support plate 48 has multiple heat dissipation holes 18 on its side wall.

[0086] In actual use, the side wall of the support plate 48 is provided with multiple heat dissipation holes 18, which ensures that the mold is heated evenly and improves the molding quality of the carbon fiber radial beam.

[0087] Example 8:

[0088] Reference Figures 1-13 A method for forming a carbon fiber radial beam, using a molding die for the carbon fiber radial beam, includes the following steps:

[0089] Step 1: Prepare the combined core mold 8;

[0090] Connect one opening of the air inflatable bag 5 to the air inlet 7, then place multiple foam blocks from the combined core mold 8 inside the air inflatable bag 5 in sequence; then seal the other opening of the air inflatable bag 5.

[0091] Step 2: Lay the carbon fiber prepreg 9 into the cavity formed by the mold plate 1 and the mold frame 2 in the combined steel mold 11;

[0092] Step 3: Place multiple metal embedded parts 12 at the intersection of the combined core mold 8;

[0093] Step 4: Place multiple foam blocks from the combined core mold 8 on top of the carbon fiber prepreg fabric 9 according to the preset positions, and place each foam block in the space divided by the mold frame 2.

[0094] Step 5: Flip the top edge of the carbon fiber prepreg 9 onto the combined core mold 8, then cover it with the upper cover plate 3 and fix the upper cover plate 3 to the mold frame 2;

[0095] Step 6: Connect the multiple sets of clamping mechanisms 10 to the sub-cover plates where the metal embedded parts 12 are located;

[0096] Step 7: Place the assembled carbon fiber radial beam molding mold into the autoclave, connect the air inlet 7 on the combined core mold 8 to the external air compressor, continuously fill the air bag 5 with high-pressure air, and the autoclave starts to heat up. Under the pressure of the high-pressure air, the carbon fiber prepreg is hot-pressed and cured into shape.

[0097] This invention utilizes the principle of air-inflated molding process. A process gap is designed between the combined core mold 8 and the combined steel mold 11. When high-pressure air enters the air-inflated bag 5, the pressure of the air-inflated bag 5 is evenly transmitted to the carbon fiber prepreg 9, so that the carbon fiber prepreg 9 and the combined steel mold 11 are fully bonded and integrally formed. After hot-press curing, the carbon fiber thin-walled structure becomes more dense, which effectively improves the stiffness of the carbon fiber radial beam.

[0098] Example 9:

[0099] Reference Figure 1As shown, a method for forming a carbon fiber radial beam differs from Embodiment Nine in that the specific process of heating and pressurizing in step seven is as follows: the air compressor continuously inflates and pressurizes the air bag 5. When the pressure reaches 0.2 MPa, it stops for 5 to 10 minutes; inflation continues until the pressure reaches 0.3 MPa, then stops for 5 to 10 minutes; inflation continues until the pressure reaches 0.4 MPa, then stops for 10 to 15 minutes; inflation continues until the pressure reaches 0.5 MPa and is maintained; the temperature is increased to 120 to 130 degrees Celsius at a heating rate of 0.5 to 2 °C / min, and after holding at that temperature for 90 minutes, cooling begins. When the temperature drops to 60 degrees Celsius, the pressure is released, the autoclave is opened, and the mold is removed.

[0100] In practical use, by adopting the above technical solution, not only is the pressure uniform, but the heating is also uniform, which ensures that the carbon fiber prepreg 9 and the combined steel film 11 are fully bonded, thus guaranteeing the forming quality of the carbon fiber radial beam.

[0101] Where there is no conflict, those skilled in the art can combine the relevant technical features in the above examples according to the actual situation to achieve the corresponding technical effects. Specific details of the various combinations will not be elaborated here.

[0102] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present invention are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indication will also change accordingly.

[0103] Furthermore, the use of terms such as "first" and "second" in this invention is for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features.

[0104] The above description is merely a preferred embodiment of the present invention. The present invention is not limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein. Any simple modifications, equivalent variations, and alterations made to the above embodiments based on the technical essence of the present invention shall still fall within the scope of the present invention.

Claims

1. A molding die for a carbon fiber radial beam, comprising at least a plurality of metal embedded parts (12), characterized in that: It also includes a combined core mold (8), a combined steel mold (11), and a clamping mechanism (10); the multiple metal embedded parts (12) and the combined core mold (8) are all placed inside the combined steel mold (11), and the multiple metal embedded parts (12) are respectively arranged at the intersection of the combined core mold (8); multiple sets of clamping mechanisms (10) are provided, and the multiple sets of clamping mechanisms (10) are detachably connected to the top of the combined steel mold (11), and each set of clamping mechanism (10) is placed directly above a metal embedded part (12) for applying a downward clamping force to the metal embedded part (12); The combined steel mold (11) includes a mold plate (1), a mold frame (2) and a top cover plate (3); the mold frame (2) is connected to the mold plate (1), and the top cover plate (3) is connected to the top of the mold frame (2); multiple sets of clamping mechanisms (10) are detachably connected to the top cover plate (3), and each set of clamping mechanism (10) is placed directly above a different metal embedded part (12); The mold plate (1) is a rectangular steel plate with one corner cut off; the mold frame (2) includes an outer frame (24) and multiple inner frames. The outer frame (24) is a steel frame with the same shape as the radial beam. The outer frame (24) is equipped with seven different triangular steel inner frames. The seven inner frames divide the internal space of the outer frame (24) into multiple spaces that match the combined core mold (8); the upper cover plate (3) is composed of multiple sub-cover plates of different shapes. The upper part of the space formed between the outer frame (24) and multiple inner frames, and between adjacent inner frames, is covered by multiple sub-cover plates. An opening is opened on the sub-cover plate opposite the metal embedded part (12) for connecting the clamping mechanism (10) to clamp the metal embedded part (12). The clamping mechanism (10) includes a connecting plate (13), a set screw (14), and a molding plate (16); the molding plate (16) is placed inside the upper cover plate (3) in the combined steel mold (11) and is positioned directly above the metal embedded part (12); the connecting plate (13) is set on the top of the combined steel mold (11) and is positioned directly above the molding plate (16), and the connecting plate (13) is detachably connected to the top of the combined steel mold (11); at least two set screws (14) are provided, and the set screws (14) are evenly and vertically threadedly connected to the connecting plate (13) for clamping and loosening the molding plate (16); It also includes a steel mold lower assembly (17); the steel mold lower assembly (17) includes an outer frame (47), two support plates (48) and a reinforcing rib plate (23); the outer frame (47) is fixedly connected to the lower surface of the combined steel mold (11); the two support plates (48) and the reinforcing rib plate (23) are vertically arranged inside the outer frame (47), the two support plates (48) are respectively placed at both ends of the central axis of the outer frame (47), and the reinforcing rib plate (23) is placed in the middle of the central axis; the top surfaces of the two support plates (48) and the reinforcing rib plate (23) are respectively fixedly connected to the lower surface of the combined steel mold (11), and the bottom surfaces of the two support plates (48) and the reinforcing rib plate (23) are fixedly connected to the inner bottom surface of the outer frame (47); two lifting lugs (22) are respectively fixedly connected to the outer surfaces of the two support plates (48). The outer frame (47), support plate (48) and reinforcing rib plate (23) are all made of I-beams, and the steel film under-mount component (17) is integrated with the mold plate (1).

2. The molding die for a carbon fiber radial beam as described in claim 1, characterized in that: The combined core mold (8) includes an air-inflating bag (5) and a foam core (6); the foam core (6) is composed of multiple foam blocks made of EPS; the air-inflating bag (5) is made of nylon duct with open ends, and an air inlet (7) is connected to one open end of the air-inflating bag (5). Multiple foam blocks that make up the foam core (6) are placed sequentially inside the air-inflating bag (5) through the other open end of the air-inflating bag (5) to form a radial beam shape and then sealed; the multiple foam blocks match the shape of the inner cavity space of the combined steel mold (11).

3. The molding die for a carbon fiber radial beam as described in claim 1, characterized in that: There is a gap between the molding plate (16) and the connecting plate (13); the outer diameter of the molding plate (16) is smaller than the outer diameter of the metal embedded part (12).

4. The molding die for a carbon fiber radial beam as described in claim 1, characterized in that: The support plate (48) has multiple heat dissipation holes (18) on its side wall.

5. A method for forming a carbon fiber radial beam, characterized in that: The molding die for the carbon fiber radial beam as described in any one of claims 1-4 includes the following steps: Step 1: Prepare the combined core mold; Connect one opening of the air inflatable bag (5) to the air inlet (7), then place multiple foam blocks from the combined core mold (8) inside the air inflatable bag (5) in sequence; then seal the other opening of the air inflatable bag (5); Step 2: Lay the carbon fiber prepreg (9) in the cavity formed by the mold plate (1) and the mold frame (2) in the combined steel mold (11); Step 3: Place multiple metal embedded parts (12) at the intersection of the combined core mold (8); Step 4: Place multiple foam blocks from the combined core mold (8) on top of the carbon fiber prepreg fabric (9) according to the preset positions, and place each foam block in the space divided by the mold frame (2); Step 5: Flip the top of the carbon fiber prepreg (9) onto the combined core mold (8), then cover it with the top cover plate (3) and fix the top cover plate (3) on the mold frame (2); Step 6: Connect multiple sets of clamping mechanisms (10) to the sub-cover plates where the metal embedded parts (12) are set; Step 7: Place the mold of the installed carbon fiber radiant beam into the autoclave, connect the air inlet (7) on the combined core mold (8) to the external air compressor, continuously fill the air bag (5) with high pressure air, the autoclave starts to heat up, and under the pressure of high pressure air, the carbon fiber prepreg is hot-pressed and cured.

6. The method for forming a carbon fiber radial beam as described in claim 5, characterized in that: The specific process of heating and pressurizing in step seven is as follows: The air compressor continuously inflates and pressurizes the air-inflated bag (5). When the pressure reaches 0.2 MPa, stop for 5 to 10 minutes; continue inflating until the pressure reaches 0.3 MPa, stop for 5 to 10 minutes; continue inflating until the pressure reaches 0.4 MPa, stop for 10 to 15 minutes; continue inflating until the pressure reaches 0.5 MPa and maintain it; heat up to 120 to 130 degrees Celsius at a heating rate of 0.5 to 2 °C / min, keep warm for 90 minutes, and then start cooling down. When the temperature drops to 60 degrees Celsius, release the pressure, open the autoclave, and take out the mold.

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