Method for manufacturing a composite polyhedral product and composite polyhedron

Abstract

The present application relates to the technical field of composite material processing, and particularly relates to a manufacturing method of a composite material polyhedron and the composite material polyhedron. The manufacturing method of the composite material polyhedron comprises a fiber cloth layering step and a hot-pressing forming step. The fiber cloth layering step comprises: step one, using initial layer fiber cloths to form a complete contour of the composite material polyhedron; at least one initial layer fiber cloth is in a bent state and has two bending sides, and a bending line between the two bending sides corresponds to an edge of the composite material polyhedron; step two, laying at least one secondary layer fiber cloth outside the initial layer fiber cloth, at least one secondary layer fiber cloth is in a bent state, and a bending line between the two bending sides of the at least one secondary layer fiber cloth corresponds to an edge formed by the edge butt joint of the two initial layer fiber cloths. Fiber cloths are covered between the adjacent surfaces of the corresponding edges to ensure the connection between the two adjacent surfaces, to realize one-time forming of a complex polyhedral composite material structure and to reduce subsequent processing.

Description

Technical Field

[0001] This invention relates to the field of composite material processing technology, and more specifically to a layup method for composite material polyhedra. Background Technology

[0002] When designing composite material products, the overall performance is typically influenced by three factors: the strength of the composite fibers themselves, the fiber layup method, and the overall product structure. The fiber layup method mainly includes the fiber layup direction and the layup technique, which also affects the overall product structure. Therefore, the layup method is one of the main factors influencing the performance of composite material products.

[0003] In the processing of composite three-dimensional polyhedral products, it is usually necessary to lay out fiber cloth in layers according to the designed direction, then form simple parts through thermoforming, and finally fabricate the required three-dimensional structure through gluing or local T-shaped reinforcement. A schematic diagram of local T-shaped reinforcement is shown below. Figure 1 As shown, when using horizontal component 16 and vertical component 17 to make a three-dimensional structure that is perpendicular to each other, three layers of L-shaped reinforcing fiber cloth 18 need to be laid at the intersection of horizontal component 16 and vertical component 17, and then another layer of overall fiber cloth 19 covering horizontal component 16 and vertical component 17 is laid on the L-shaped reinforcing fiber cloth 18 to enhance the connection strength between horizontal component 16 and vertical component 17.

[0004] The processing method for three-dimensional polyhedral composite products is similar to the manufacturing method of a carbon fiber reinforced composite corrugated core sandwich structure automotive anti-collision beam disclosed in Chinese patent document CN207758262U. First, a suitable number and size of carbon fiber prepreg fabric are cut. The cut carbon fiber prepreg fabric is then laid on a hot press mold using an alternating 0° / 90° layup pattern. Next, a hot press is used to hot press the mold into shape. Finally, excess scrap material around the formed simple parts is cut off with a cutting machine. The contact areas of the assembled simple parts are sanded, cleaned with acetone solution, and then glued together to create the desired three-dimensional structure.

[0005] However, simple parts formed by thermoforming are typically fiber shells, round or square tubes, etc. Although they are simple to manufacture, these simple parts require post-processing to complete subsequent processing (such as meeting bonding requirements), which increases the number of steps, processing time, and cost. Furthermore, the overall performance of these simple parts is significantly stronger in the fiber reinforcement direction than in other directions, and the isotropy of the composite material is poor, which limits the applicability of the composite material. Summary of the Invention

[0006] The purpose of this invention is to provide a method for manufacturing composite polyhedron products, thereby solving the technical problem that existing processing methods cannot form composite polyhedrons in one step, resulting in numerous processing steps and high costs. Another purpose of this invention is to provide a composite polyhedron, thereby solving the technical problems of long processing time and high cost in existing technologies.

[0007] To achieve the above objectives, the technical solution of the present invention for manufacturing composite material polyhedral products is as follows:

[0008] A method for manufacturing composite polyhedral products includes a fiber cloth layup step and a thermoforming step. The fiber cloth layup step includes the following steps:

[0009] Step 1: Use a primary layer of fiber cloth to form the complete outline of the composite polyhedron; at least one piece of primary layer of fiber cloth is bent and has two bent sides that are at an angle to each other, and the bending line between the two bent sides corresponds to one edge of the composite polyhedron.

[0010] Step 2: Lay at least one layer of fiber cloth on the outside of the primary fiber cloth, and at least one secondary fiber cloth is in a bent state with two bent sides that are at an angle to each other; the bending line between the two bent sides of the at least one secondary fiber cloth corresponds to the edge formed by the joint of the edges of the two primary fiber cloths.

[0011] The beneficial effects are as follows: In the manufacturing method of the composite polyhedron product of the present invention, the initial layer of fiber cloth forms the initial complete outline of the composite polyhedron. The bending lines of the two bent sides of the initial layer of fiber cloth in a bent state correspond to the edges of the composite polyhedron. The edges formed by the edge docking between the two straight initial layer of fiber cloths corresponding to the adjacent surfaces of the composite polyhedron coincide with the edges of the composite polyhedron. The bending lines between the two bent sides of the second layer of fiber cloth correspond to the edges formed by the edge docking between the two initial layer of fiber cloths. That is, the adjacent faces of the corresponding edges of the composite polyhedron are covered with fiber cloth to ensure the connection between the two adjacent faces, thereby ensuring the continuity of the composite material as a whole, realizing the one-time molding of complex polyhedron structures, and reducing subsequent processing.

[0012] Further improvements were made, with the secondary fiber cloths located in the same paving layer forming the complete outline of the composite polyhedron.

[0013] The beneficial effect is that, with this design, each surface of the composite polyhedron is layered, which helps to ensure the structural strength of the composite polyhedron obtained by using the composite polyhedron product manufacturing method.

[0014] Further improvements include ensuring that the bent sides of both the primary and secondary fiber cloths match the corresponding surface shapes of the composite polyhedron, thus covering the entire surface of the composite polyhedron.

[0015] The beneficial effect is that this design allows the fiber cloth to cover all surfaces of the composite polyhedron, which helps to ensure the flatness of each surface of the composite polyhedron.

[0016] In a further improvement, all edges of the composite polyhedron correspond to the bending lines of at least one primary or secondary fiber cloth layer.

[0017] The beneficial effect is that, with this design, all edges of the composite polyhedron can be covered by at least one layer of fiber cloth, further enhancing the overall strength of the composite polyhedron.

[0018] In a further improvement, the fiber reinforcement directions of adjacent primary and secondary fiber fabrics are arranged in an intersecting manner in the primary and secondary fiber fabrics corresponding to each side of the composite polyhedron, and / or the fiber reinforcement directions of adjacent secondary fiber fabrics are arranged in an intersecting manner.

[0019] The beneficial effects are: this design makes it easier to ensure the balanced properties of the composite material in all directions, increases the isotropy of the composite material, and improves the overall strength of the composite material.

[0020] Further improvements include ensuring that the fiber reinforcement direction of the primary and secondary fiber fabrics is perpendicular to the bending line.

[0021] The beneficial effects are: this design improves the reinforcement effect of the fiber reinforcement direction, and the fiber reinforcement directions of different fiber cloths are perpendicular to each other, further enhancing the isotropy of the composite material and improving the strength uniformity of the polyhedral structure of the composite material.

[0022] In a further improvement, the fiber cloth includes a reinforcing fiber cloth, wherein the fiber reinforcement direction of the reinforcing fiber cloth is oblique relative to the edge of the corresponding side of the composite polyhedron.

[0023] The beneficial effect is that this design allows the reinforcing fiber cloth to increase the properties of the composite material in different directions, thereby enhancing the overall strength of the composite polyhedron.

[0024] Further improvements were made, ensuring that the number of sides on both bent sides of each sublayer of fiber cloth is the same.

[0025] The beneficial effects are: this design facilitates the joining of the bent sides of adjacent sub-layer fiber cloths in the same paving layer to form a complete composite polyhedron profile, which helps to ensure the structural strength of the composite polyhedron.

[0026] Further improvements are made to composite polyhedrons with rectangular bottom surfaces and triangular side surfaces. The bent side surface corresponding to the rectangular bottom surface on the secondary fiber cloth of the same number of paving layers is triangular, and the triangular bent side surfaces of the secondary fiber cloth corresponding to the rectangular bottom surface in the same number of paving layers are spliced ​​together to form the rectangular bottom surface.

[0027] The beneficial effect is that this design reduces the area difference of the bent sides on the secondary fiber cloth, and avoids the connection strength of one of the bent sides being too large, which would affect the overall strength.

[0028] In a further improvement, for a composite polyhedron with a rectangular bottom surface and triangular side surfaces, the initial fiber cloth includes a rectangular planar fiber cloth corresponding to the rectangular bottom surface, and also includes a triangular bent fiber cloth with two triangular bent sides for forming two adjacent triangular side surfaces.

[0029] The beneficial effect is that, compared to the method of splicing the bent sides of adjacent primary fiber cloths into rectangular planar fiber cloths to form new edges, this design results in fewer edges on the polyhedral outline of the composite material formed by the primary fiber cloths, avoiding the secondary fiber cloths from covering the new edges and improving the overall strength of the composite polyhedron.

[0030] To achieve the above objectives, the technical solution of the composite material polyhedron of the present invention is as follows:

[0031] A composite polyhedron includes a layup of fiber cloth, the fiber cloth including a primary fiber cloth, all the primary fiber cloths forming an initial complete outline of the composite polyhedron, at least one primary fiber cloth being bent and having two bent sides at an angle to each other; the bending line between the two bent sides corresponds to an edge of the composite polyhedron; at least one layer of fiber cloth is laid outside the primary fiber cloth; at least one secondary fiber cloth is bent and has two bent sides at an angle to each other; the bending line between the two bent sides of at least one secondary fiber cloth corresponds to an edge formed by the abutment of the edges of two primary fiber cloths.

[0032] The beneficial effects are as follows: In the composite polyhedron of the present invention, the initial layer of fiber cloth forms the initial complete outline of the composite polyhedron. The bending lines of the two bent sides of the initial layer of fiber cloth in a bent state correspond to the edges of the composite polyhedron. The edges formed by the edge docking between the two straight initial layer of fiber cloths corresponding to the adjacent surfaces of the composite polyhedron coincide with the edges of the composite polyhedron. The bending lines between the two bent sides of the secondary layer of fiber cloth correspond to the edges formed by the edge docking between the two initial layer of fiber cloths. That is, the initial layer of fiber cloth and the secondary layer of fiber cloth can cover the adjacent faces of the corresponding edges on the composite polyhedron to ensure the connection between the two adjacent faces, thereby ensuring the continuity of the composite material as a whole, realizing the one-time molding of complex polyhedron structures, reducing subsequent processing processes, and lowering costs.

[0033] Further improvements were made, with the secondary fiber cloths located in the same paving layer forming the complete outline of the composite polyhedron.

[0034] The beneficial effect is that, with this design, each surface of the composite polyhedron is layered, which helps to ensure the structural strength of the composite polyhedron obtained by using the composite polyhedron product manufacturing method.

[0035] Further improvements include ensuring that the bent sides of both the primary and secondary fiber cloths match the corresponding surface shapes of the composite polyhedron, thus covering the entire surface of the composite polyhedron.

[0036] The beneficial effect is that this design allows the fiber cloth to cover all surfaces of the composite polyhedron, which helps to ensure the flatness of each surface of the composite polyhedron.

[0037] In a further improvement, all edges of the composite polyhedron correspond to the bending lines of at least one primary or secondary fiber cloth layer.

[0038] The beneficial effect is that, with this design, all edges of the composite polyhedron can be covered by at least one layer of fiber cloth, further enhancing the overall strength of the composite polyhedron.

[0039] In a further improvement, the fiber reinforcement directions of adjacent primary and secondary fiber fabrics are arranged in an intersecting manner in the primary and secondary fiber fabrics corresponding to each side of the composite polyhedron, and / or the fiber reinforcement directions of adjacent secondary fiber fabrics are arranged in an intersecting manner.

[0040] The beneficial effects are: this design makes it easier to ensure the balanced properties of the composite material in all directions, increases the isotropy of the composite material, and improves the overall strength of the composite material.

[0041] Further improvements include ensuring that the fiber reinforcement direction of the primary and secondary fiber fabrics is perpendicular to the bending line.

[0042] The beneficial effects are: this design improves the reinforcement effect of the fiber reinforcement direction, and the fiber reinforcement directions of different fiber cloths are perpendicular to each other, further enhancing the isotropy of the composite material and improving the strength uniformity of the polyhedral structure of the composite material.

[0043] In a further improvement, the fiber cloth includes a reinforcing fiber cloth, wherein the fiber reinforcement direction of the reinforcing fiber cloth is oblique relative to the edge of the corresponding side of the composite polyhedron.

[0044] The beneficial effect is that this design allows the reinforcing fiber cloth to increase the properties of the composite material in different directions, thereby enhancing the overall strength of the composite polyhedron.

[0045] Further improvements were made, ensuring that the number of sides on both bent sides of each sublayer of fiber cloth is the same.

[0046] The beneficial effects are: this design facilitates the joining of the bent sides of adjacent sub-layer fiber cloths in the same paving layer to form a complete composite polyhedron profile, which helps to ensure the structural strength of the composite polyhedron.

[0047] Further improvements include a composite polyhedron with a rectangular bottom surface and triangular side surfaces. The bent side surface corresponding to the rectangular bottom surface on the secondary fiber cloth of the same number of paving layers is triangular. The triangular bent side surfaces of the secondary fiber cloth corresponding to the rectangular bottom surface in the same number of paving layers are spliced ​​together to form the rectangular bottom surface.

[0048] The beneficial effect is that this design reduces the area difference of the bent sides on the secondary fiber cloth, and avoids the connection strength of one of the bent sides being too large, which would affect the overall strength.

[0049] In a further improvement, the composite polyhedron has a rectangular bottom surface and triangular side surfaces. The initial fiber cloth includes a rectangular planar fiber cloth corresponding to the rectangular bottom surface, and also includes a triangular bent fiber cloth with two triangular bent sides for forming two adjacent triangular side surfaces.

[0050] The beneficial effect is that, compared to the method of splicing the bent sides of adjacent primary fiber cloths into rectangular planar fiber cloths to form new edges, this design results in fewer edges on the polyhedral outline of the composite material formed by the primary fiber cloths, avoiding the secondary fiber cloths from covering the new edges and improving the overall strength of the composite polyhedron. Attached Figure Description

[0051] Figure 1 This is a schematic diagram of local T-shaped reinforcement in the prior art;

[0052] Figure 2 This is a schematic diagram of Example 1 of the method for manufacturing composite polyhedral products in this invention;

[0053] Figure 3 for Figure 2 A schematic diagram of the state of a hexahedron formed by a layering method;

[0054] Figure 4 This is a schematic diagram of Example 2 of the method for manufacturing composite polyhedral products in this invention;

[0055] Figure 5 for Figure 4 A schematic diagram of the state of a square pyramid formed by layering.

[0056] In the diagram: 11. Primary fiber cloth; 12. Secondary fiber cloth; 13. Bending side; 14. Rectangular flat fiber cloth; 15. Triangular bent fiber cloth; 16. Horizontal component; 17. Vertical component; 18. L-shaped reinforcing fiber cloth; 19. Overall fiber cloth. Detailed Implementation

[0057] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only for explaining the invention and are not intended to limit the invention; that is, the described embodiments are merely some embodiments of the invention, not all embodiments. The components of the embodiments of the invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0058] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0059] It should be noted that relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any actual relationship or order between these entities or operations. Furthermore, terms such as "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the process or method that includes said element.

[0060] In the description of this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linkage" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium, or they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0061] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the term "provided with" should be interpreted broadly. For example, the object "provided with" can be a part of the main body, or it can be separately arranged from the main body and connected to the main body. This connection can be a detachable connection or a non-detachable connection. Those skilled in the art can understand the specific meaning of the above terms in this invention through specific circumstances.

[0062] The present invention will be further described in detail below with reference to the embodiments.

[0063] Example 1 of the method for manufacturing composite polyhedral products of the present invention:

[0064] In this embodiment, it is used for molding as follows: Figure 3 The regular hexahedron shown is formed by the following steps in the manufacturing method of composite material polyhedron products of the present invention.

[0065] Step (1), as follows Figure 2 As shown, three pieces of primary fiber cloth 11 are laid on the inner mold surface of the hot press mold. All primary fiber cloth 11 are in a bent state, and each primary fiber cloth 11 has two mutually perpendicular bent sides 13. The bending line between the two bent sides 13 of the same primary fiber cloth 11 corresponds to one edge of a regular hexahedron. The bent sides 13 of the three primary fiber cloths 11 correspond to different surfaces of the regular hexahedron and match their shapes. The bent sides 13 of the primary fiber cloth 11 are all square to cover the entire surface of the regular hexahedron. Specifically, the two bent sides 13 of the first primary fiber cloth 11 correspond to the A and B faces of the regular hexahedron, the two bent sides 13 of the second primary fiber cloth 11 correspond to the C and D faces of the regular hexahedron, and the two bent sides 13 of the third primary fiber cloth 11 correspond to the E and F faces of the regular hexahedron. Furthermore, the folded side 13 of each initial layer of fiber cloth 11 matches the corresponding surface shape of the regular hexahedron, and is a regular quadrilateral, thus covering the entire surface of the regular hexahedron. The fiber reinforcement direction of each initial layer of fiber cloth 11 is perpendicular to the folding line of the two folded side 13. Figure 2 The dashed line indicates that the fiber cloth connected by the same dashed line belongs to the same number of laying layers.

[0066] Step (II): Three layers of fiber cloth 12 are laid on the outside of the primary fiber cloth 11. Each layer contains three secondary fiber cloth 12 pieces. The secondary fiber cloth 12 pieces of the same layer can form the outer surface outline of a regular hexahedron. All secondary fiber cloth 12 pieces are bent, and each secondary fiber cloth 12 piece has two mutually perpendicular bent sides 13. The bending line between the two bent sides 13 corresponds to one edge of the regular hexahedron. The bent sides 13 of the three secondary fiber cloth pieces of the same layer correspond to different surfaces of the regular hexahedron and match their shapes. The bent sides 13 of each secondary fiber cloth 12 piece are square to cover the entire surface of the regular hexahedron. In the first layer of the paving layer, the two bent sides 13 of the first secondary fiber cloth 12 correspond to the B and E faces of a regular hexahedron, respectively; the two bent sides 13 of the second secondary fiber cloth 12 correspond to the A and C faces of a regular hexahedron, respectively; and the two bent sides 13 of the third secondary fiber cloth 12 correspond to the F and D faces of a regular hexahedron, respectively. This is to ensure that each secondary fiber cloth 12 covers the edge formed by the joint of the bent sides of any two adjacent primary fiber cloths 11. The secondary fiber cloths 12 in other paving layers are arranged in a similar manner. However, the combination of the two bent sides 13 of the secondary fiber cloth 12 in each paving layer is different, so that the secondary fiber cloth 12 of the next paving layer can cover the edge formed by the joint of the bent sides 13 of any two adjacent secondary fiber cloths 12 in the previous paving layer. This edge refers to the edge of a regular hexahedron. Furthermore, the fiber reinforcement directions of the primary fiber cloth 11 and the secondary fiber cloth 12 are perpendicular to the corresponding bending lines to ensure fiber continuity at the bends. Simultaneously, the fiber reinforcement directions of adjacent layers are perpendicular to each other to enhance the isotropy of the composite material and improve the structural strength of the hexahedron. Thus, a complete cycle is achieved through four layers, ensuring that all twelve edges of the hexahedron are covered by fiber cloth. This cycle is repeated until the desired composite material thickness is reached, at which point the next step, hot pressing, can proceed. Hot pressing completes the fabrication of the hexahedral structure of the composite material without the need for subsequent bonding.

[0067] In the manufacturing method of the composite polyhedron product of the present invention, the bent sides of the primary fiber cloth and the secondary fiber cloth both match the corresponding surface shape of the composite polyhedron. Both the primary and secondary fiber cloths can form the overall outline of the composite polyhedron, and the bending lines of the two bent sides of each fiber cloth correspond to the edges of the composite polyhedron. Furthermore, the combination of the bent sides of the fiber cloth in each layer is different, so that the fiber cloth of the next layer covers the edge formed by the edge-to-edge connection of any two bent sides of the fiber cloth in the previous layer. This edge is the edge of the composite polyhedron, thus ensuring that all edges of the composite polyhedron are covered by fiber cloth, enhancing the overall continuity of the composite material. Moreover, because the combination of the bent sides of each fiber cloth is different, the fiber layup direction automatically forms an even distribution of 0° and 90°, preserving the original designability of the composite fiber layup direction. The intersection of fiber directions ensures the strength of the polyhedron structure and improves the applicability of the composite material. Composite materials of the designed thickness can be hot-pressed to create composite polyhedrons without subsequent bonding, enabling one-time molding of complex polyhedral structures and reducing subsequent processing steps. Furthermore, continuous fibers along each edge of the composite polyhedron ensure edge strength, improving the structural strength uniformity of the composite polyhedron.

[0068] Example 2 of the method for manufacturing composite polyhedral products of the present invention:

[0069] The difference between this embodiment and Embodiment 1 is that in Embodiment 1, the composite material polyhedral product manufacturing method is used to lay out a regular hexahedron, all the fiber cloths are in a bent state, and the bent side 13 of each fiber cloth is a square with the same shape as each surface of the regular hexahedron. In this embodiment, as... Figure 5 As shown, the composite material polyhedral product manufacturing method is used to lay out a square pyramid, which has a rectangular base surface and triangular side surfaces.

[0070] Step (1), as follows Figure 4 As shown, three pieces of initial fiber cloth 11 are used to form the outer surface outline of a square pyramid. The three initial fiber cloths 11 include a rectangular planar fiber cloth 14 whose shape matches the rectangular base surface of the square pyramid. This rectangular base surface is... Figure 4 The O-face also includes two triangular bent fiber cloths 15. The bending lines of the two bent sides 13 of the triangular bent fiber cloth 15 correspond to one edge of a square pyramid. The two bent sides 13 of the triangular bent fiber cloth 15 are triangles that match the shape of the two adjacent side surfaces of the triangular side surface. The two bent sides 13 of the first triangular bent fiber cloth 15 correspond to the S-face and P-face of the square pyramid, respectively, and the two bent sides 13 of the second bent fiber cloth correspond to the R-face and Q-face of the square pyramid, respectively. Figure 4The dashed lines in the diagram indicate that three pieces of fiber cloth connected by the same dashed line belong to the same paving layer.

[0071] Step (II): Two layers of fiber cloth 12 are laid outside the primary fiber cloth 11. Each layer includes three secondary fiber cloths 12, which together form the complete outer surface outline of a square pyramid. Each secondary fiber cloth 12 is bent, and includes two bent sides 13 that form an angle with each other. The bending lines of the two bent sides 13 correspond to one edge of the square pyramid. All bent sides 13 of the secondary fiber cloth 12 are triangular, wherein the bent sides are triangular with respect to the rectangular base surface (i.e., Figure 4 The two triangular bent sides 13 of the second-layer fiber cloth 12 corresponding to the O-face of the pyramid are assembled to form a complete rectangular bottom surface. All other bent sides 13 correspond to and match the triangular side surfaces of the pyramid. Specifically, the two bent sides 13 of the first piece of the second-layer fiber cloth 12 in the first paving layer correspond to the S-face and R-face of the pyramid, respectively; the two bent sides 13 of the second piece of the second-layer fiber cloth 12 correspond to the T-face and Q-face of the pyramid, respectively; and the two bent sides 13 of the third piece of the second-layer fiber cloth 12 correspond to the U-face and P-face of the pyramid, respectively, to form the complete outer surface outline of the pyramid. Each second-layer fiber cloth 13 can cover the edge formed by the edge joint of any two adjacent first-layer fiber cloth 11 bent sides. The second-layer fiber cloths 12 in other paving layers are arranged in a similar manner, but the combination of the bent sides 13 of each second-layer fiber cloth 12 is different, so that all the fiber cloths cover the edges of the pyramid.

[0072] Example 3 of the method for manufacturing composite polyhedral products of the present invention:

[0073] The difference between this embodiment and Embodiment 1 is that in Embodiment 1, the secondary fiber cloth 12 located in the same pavement layer all form the initial complete outline of the composite material polyhedron. In this embodiment, the secondary fiber cloth in the same pavement layer can only cover part of the outline of the composite material polyhedron. For example, in Figure 2 Another layer of fiber cloth is laid on the outside. This layer consists of two pieces of fiber cloth, both of which are bent. The two bent sides of one piece of fiber cloth correspond to the A and B faces of the regular hexahedron, respectively, and the two bent sides of the other piece of fiber cloth correspond to the C and D faces of the regular hexahedron.

[0074] Example 4 of the method for manufacturing composite polyhedral products of the present invention:

[0075] The difference between this embodiment and Embodiment 1 is that in Embodiment 2, the composite material polyhedral product manufacturing method is used to form a square pyramid. The three initial layer fiber cloths 11 include a rectangular planar fiber cloth 14 that matches the shape of the rectangular bottom surface of the square pyramid. This rectangular bottom surface is... Figure 4The O-face also includes two triangular bent fiber cloths 15. The two bent sides 13 of each triangular fiber cloth are triangles that match the shapes of adjacent side surfaces of the triangular side surfaces. In this embodiment, three primary fiber cloths are included, and the bent sides of all primary fiber cloths corresponding to the surfaces of the pyramid are triangular. For example, the two bent sides of the first primary fiber cloth correspond to the S and R faces of the pyramid, respectively; the two bent sides of the second primary fiber cloth correspond to the T and Q faces of the pyramid, respectively; and the two bent sides of the third primary fiber cloth correspond to the U and P faces of the pyramid, respectively. The bent sides corresponding to the U and T faces are assembled to form a complete O-face, thus forming the complete outer surface contour of the pyramid. Three layers of fiber cloth are laid outside the primary fiber cloth. The first layer includes three secondary fiber cloths, and one primary fiber cloth is... Figure 4 The first layer consists of a flat fiber cloth corresponding to the O face of the square pyramid. Two bent sides of one secondary fiber cloth correspond to the S and P faces respectively, and two bent sides of another secondary fiber cloth correspond to the R and Q faces respectively. The second layer includes three secondary fiber cloths. The two bent sides of the first secondary fiber cloth correspond to the P and Q faces of the square pyramid, the two bent sides of the second secondary fiber cloth correspond to the S and U faces respectively, and the two bent sides of the third secondary fiber cloth correspond to the R and T faces respectively. The third layer includes four secondary fiber cloths, each containing one piece that corresponds to the rectangular bottom surface (i.e.,...). Figure 4 The rectangular bent side surface corresponding to the O surface of the pyramid and a triangular bent side surface corresponding to the S, R, Q, and P surfaces of the pyramid respectively.

[0076] Example 5 of the method for manufacturing composite polyhedral products of the present invention:

[0077] The difference between this embodiment and Embodiment 1 is that in Embodiment 2, the number of sides 13 of the three secondary fiber cloths 12 used to form the surfaces of the four-sided pyramid in the same number of layers is the same, and each of the bent sides 13 is triangular. In this embodiment, the number of sides of the bent sides of the same secondary fiber cloth is different. For example, a three-layer paving layer is laid outside the primary paving layer. The first paving layer includes four secondary fiber cloths, all of which are bent, and each of the four secondary fiber cloths includes a piece with a rectangular bottom surface (i.e., Figure 4 The first layer consists of a rectangular bent side corresponding to the O-face of a pyramid and a triangular bent side corresponding to the S-face, R-face, Q-face, and P-face of the pyramid. The second layer consists of two sub-layer fiber fabrics, one with bent sides corresponding to the S-face and P-face of the pyramid, and the other with bent sides corresponding to the R-face and Q-face of the pyramid. The third layer consists of two sub-layer fiber fabrics, one with bent sides corresponding to the S-face and R-face of the pyramid, and the other with bent sides corresponding to the P-face and Q-face of the pyramid.

[0078] Example 6 of the method for manufacturing composite polyhedral products of the present invention:

[0079] The difference between this embodiment and Embodiment 1 is that in Embodiment 1, the fiber reinforcement direction of both the primary fiber cloth 11 and the secondary fiber cloth 12 is perpendicular to the bending line. In this embodiment, the fiber reinforcement direction of the secondary fiber cloth is inclined to the bending line. For example, when reinforcing fiber cloth is laid on the outside of existing fiber cloth, the fiber reinforcement direction of the reinforcing fiber cloth forms a 45° angle with respect to the corresponding edge of the regular hexahedron.

[0080] Example 1 of the composite material polyhedron of the present invention:

[0081] like Figure 2 and Figure 3 As shown, in this embodiment, the composite material polyhedron is a regular hexahedron. The composite material polyhedron includes a layup formed by fiber cloth, which includes three initial fiber cloths 11. The three initial fiber cloths 11 form the complete outline of the regular hexahedron. All initial fiber cloths 11 are in a bent state, and each initial fiber cloth 11 has two mutually perpendicular bent side faces 13. The bending line between the two bent side faces 13 of the same initial fiber cloth 11 corresponds to one edge of the regular hexahedron. The bent side faces 13 of the three initial fiber cloths 11 correspond to different surfaces of the regular hexahedron and match their shapes. The bent side faces 13 of the initial fiber cloths 11 are all square to cover the entire surface of the regular hexahedron. Specifically, the two bent side faces 13 of the first initial fiber cloth 11 correspond to the A and B faces of the regular hexahedron, the two bent side faces 13 of the second initial fiber cloth 11 correspond to the C and D faces of the regular hexahedron, and the two bent side faces 13 of the third initial fiber cloth 11 correspond to the E and F faces of the regular hexahedron. Furthermore, the folded side 13 of each initial layer of fiber cloth 11 matches the corresponding surface shape of the regular hexahedron, and is a regular quadrilateral, thus covering the entire surface of the regular hexahedron. The fiber reinforcement direction of each initial layer of fiber cloth 11 is perpendicular to the folding line of the two folded side 13. Figure 2 The dashed line indicates that the fiber cloth connected by the same dashed line belongs to the same number of laying layers.

[0082] The primary fiber cloth 11 is covered with three layers of secondary fiber cloth 12. Each layer includes three secondary fiber cloths 12. The secondary fiber cloths 12 of the same layer can form the outer surface outline of a regular hexahedron. All secondary fiber cloths 12 are in a bent state, and each secondary fiber cloth 12 has two mutually perpendicular bent sides 13. The bending line between the two bent sides 13 corresponds to one edge of the regular hexahedron. The bent sides 13 of the three secondary fiber cloths 12 in the same layer correspond to different surfaces of the regular hexahedron and match their shapes. The bent sides 13 of each secondary fiber cloth 12 are square to cover the entire surface of the regular hexahedron. In the first paving layer, the two bent sides 13 of the first secondary fiber cloth 12 correspond to the B and E faces of a regular hexahedron, respectively; the two bent sides 13 of the second secondary fiber cloth 12 correspond to the A and C faces of a regular hexahedron, respectively; and the two bent sides 13 of the third secondary fiber cloth 12 correspond to the F and D faces of a regular hexahedron, respectively. This is to ensure that each secondary fiber cloth 12 covers the edge formed by the joint of the bent sides 13 of any two adjacent primary fiber cloths 11. The secondary fiber cloths 12 in other paving layers have similar structures, but the combination of the two bent sides 13 of the secondary fiber cloth 12 in each paving layer is different, so that the secondary fiber cloth 12 of the next paving layer can cover the edge formed by the joint of the bent sides 13 of any two adjacent secondary fiber cloths 12 in the previous paving layer. This edge refers to the edge of a regular hexahedron. Furthermore, the fiber reinforcement directions of the primary fiber cloth 11 and the secondary fiber cloth 12 are perpendicular to the corresponding bending lines to ensure fiber continuity at bends. Simultaneously, the fiber reinforcement directions of adjacent layers are perpendicular to each other to enhance the isotropy of the composite material and improve the structural strength of the hexahedron. Thus, four layers of fiber cloth form a complete cycle, ensuring that all twelve edges of the hexahedron are covered by fiber cloth. In actual processing, this cycle can be repeated according to thickness requirements.

[0083] In the composite polyhedron of this invention, the bent sides of the primary and secondary fiber cloths conform to the corresponding surface shapes of the composite polyhedron. The bending lines of the two bent sides of each fiber cloth correspond to the edges of the composite polyhedron. That is, adjacent faces of corresponding edges are covered with fiber cloth to ensure the connection between the two adjacent faces, thereby ensuring the overall continuity of the composite material and realizing a one-time molding of a complex polyhedral composite material structure, reducing subsequent processing. Furthermore, the combination of the bent sides of the fiber cloth in each layer is different. The fiber cloth of the next layer covers the edge formed by the edge-to-edge connection of any two bent sides of the fiber cloth in the previous layer. This edge is the edge of the composite polyhedron, thus ensuring that all edges of the composite polyhedron are covered by fiber cloth, enhancing the overall continuity of the composite material. Moreover, the fiber layup direction automatically forms an even distribution of 0° and 90°, preserving the original designability of the composite fiber layup direction. The intersection of fiber directions ensures the strength of the polyhedron structure and improves the isotropy of the composite polyhedron.

[0084] Example 2 of the composite material polyhedron of the present invention:

[0085] The difference between this embodiment and Embodiment 1 is that in Embodiment 1, the composite material polyhedron is a regular hexahedron, all the fiber cloths are in a bent state, and the bent side of each fiber cloth is a square with the same shape as each surface of the regular hexahedron. In this embodiment, as shown... Figure 5 As shown, the composite material polyhedron is a square pyramid with a rectangular base and triangular lateral surfaces. The composite material polyhedron comprises three initial fiber fabrics that form the complete outline of a regular hexahedron. The three initial fiber fabrics 11 include a rectangular planar fiber fabric 14 whose shape matches the rectangular base surface of the square pyramid. This rectangular base surface is... Figure 4 The O-face also includes two triangular bent fiber cloths 15. The bending lines of the two bent sides 13 of the triangular bent fiber cloth 15 correspond to one edge of a square pyramid. The two bent sides 13 of the triangular bent fiber cloth 15 are triangles that match the shape of the two adjacent side surfaces of the triangular side surface. The two bent sides 13 of the first triangular bent fiber cloth 15 correspond to the S-face and P-face of the square pyramid, respectively, and the two bent sides 13 of the second bent fiber cloth correspond to the R-face and Q-face of the square pyramid, respectively.

[0086] The primary fiber cloth 11 is covered with two layers of secondary fiber cloth 12. Each layer includes three secondary fiber cloths 12, which together form the complete outer surface outline of a square pyramid. Each secondary fiber cloth 12 is bent, and each secondary fiber cloth 12 includes two bent sides 13 that form an angle with each other. The bending lines of the two bent sides 13 correspond to one edge of the square pyramid. All the bent sides 13 of the secondary fiber cloth 12 are triangular, wherein the base surface (i.e., the rectangular base surface) is... Figure 4 The two triangular bent sides 13 of the second-layer fiber cloth 12 corresponding to the O-face of the pyramid are assembled to form a complete rectangular bottom surface. All other bent sides 13 correspond to and match the triangular side surfaces of the pyramid. Specifically, the two bent sides 13 of the first secondary fiber cloth 12 in the first paving layer correspond to the S-face and R-face of the pyramid, respectively; the two bent sides 13 of the second secondary fiber cloth 12 correspond to the T-face and Q-face of the pyramid, respectively; and the two bent sides 13 of the third secondary fiber cloth 12 correspond to the U-face and P-face of the pyramid, respectively, to form the complete outer surface outline of the pyramid. Each secondary fiber cloth 13 can cover the edge formed by the edge joint of any two adjacent primary fiber cloth 11 bent sides. The secondary fiber cloths 12 in other paving layers have similar structures, but the combination of the bent sides 13 of each secondary fiber cloth 12 is different, so that all the fiber cloths cover the edges of the pyramid.

[0087] Example 3 of the composite material polyhedron of the present invention:

[0088] The difference between this embodiment and Embodiment 1 is that in Embodiment 1, the secondary fiber cloths 12 located in the same number of paving layers all form the initial complete outline of the composite material polyhedron. In this embodiment, the secondary fiber cloths in the same number of paving layers only match the partial outline shape of the composite material polyhedron. For example, in Embodiment 1, another layer of fiber cloth is provided on the outside. This secondary fiber cloth consists of only two pieces of secondary fiber cloth that are both bent. The two bent sides of one secondary fiber cloth match the shapes of the A and B faces of the regular hexahedron, respectively, and the two bent sides of the other secondary fiber cloth match the shapes of the C and D faces of the regular hexahedron.

[0089] Example 4 of the composite material polyhedron of the present invention:

[0090] The difference between this embodiment and Embodiment 1 is that in Embodiment 1, the composite material polyhedron is a square pyramid, and the three initial layer fiber cloths 11 include a rectangular planar fiber cloth 14 whose shape matches the rectangular base surface of the square pyramid. This rectangular base surface is... Figure 4The O-face also includes two triangular bent fiber cloths 15. The two bent sides 13 of each triangular fiber cloth are triangles that match the shapes of adjacent side surfaces of the triangular side surfaces. In this embodiment, three primary fiber cloths are included, and the bent sides of all primary fiber cloths corresponding to the surfaces of the pyramid are triangular. For example, the two bent sides of the first primary fiber cloth match the shapes of the S and R surfaces of the pyramid, respectively; the two bent sides of the second primary fiber cloth match the shapes of the T and Q surfaces of the pyramid, respectively; and the two bent sides of the third primary fiber cloth match the shapes of the U and P surfaces of the pyramid, respectively. The bent sides corresponding to the U and T surfaces are assembled to form a complete O-face, thus forming the complete outer surface outline of the pyramid. Three layers of fiber cloth are provided outside the primary fiber cloth. The first layer includes three secondary fiber cloths, and one primary fiber cloth is... Figure 4 The first layer consists of a planar fiber cloth whose shape matches the O-face of a square pyramid. Two bent sides of one secondary fiber cloth match the S-face and P-face respectively, and two bent sides of another secondary fiber cloth match the R-face and Q-face respectively. The second layer comprises three secondary fiber cloths: the first secondary fiber cloth's two bent sides match the P-face and Q-face of the pyramid; the second secondary fiber cloth's two bent sides match the S-face and U-face of the pyramid; and the third secondary fiber cloth's two bent sides match the R-face and T-face of the pyramid. The third layer comprises four secondary fiber cloths, each including one that matches the rectangular bottom surface (i.e.,...). Figure 4 The rectangular bent side surface that matches the shape of the O-face in the diagram, and a triangular bent side surface that matches the shapes of the S-face, R-face, Q-face, and P-face of the square pyramid respectively.

[0091] Example 5 of the composite material polyhedron of the present invention:

[0092] The difference between this embodiment and Embodiment 1 is that in Embodiment 2, the number of sides 13 of the three secondary fiber cloths 12 used to form the surfaces of the four-sided pyramid in the same number of layers is the same, and each of the bent sides 13 is triangular. In this embodiment, the number of sides of the bent sides of the same secondary fiber cloth is different. For example, a three-layer paving layer is provided outside the primary paving layer. The first paving layer includes four secondary fiber cloths, all of which are bent, and each of the four secondary fiber cloths includes a piece with a rectangular bottom surface (i.e., Figure 4The first layer consists of a rectangular bent side that matches the shape of the O-face of a pyramid, and a triangular bent side that matches the shapes of the S-face, R-face, Q-face, and P-face of a pyramid. The second layer includes two sub-layer fiber fabrics; one sub-layer fiber fabric has bent sides that match the shapes of the S-face and P-face of a pyramid, and the other sub-layer fiber fabric has bent sides that match the shapes of the R-face and Q-face of a pyramid. The third layer includes two sub-layer fiber fabrics; one sub-layer fiber fabric has bent sides that match the shapes of the S-face and R-face of a pyramid, and the other sub-layer fiber fabric has bent sides that match the shapes of the P-face and Q-face of a pyramid.

[0093] Example 6 of the composite material polyhedron of the present invention:

[0094] The difference between this embodiment and Embodiment 1 is that in Embodiment 1, the fiber reinforcement directions of both the primary fiber cloth 11 and the secondary fiber cloth 12 are perpendicular to the bending line. In this embodiment, the fiber reinforcement direction of the secondary fiber cloth is inclined to the bending line. For example, a reinforcing fiber cloth is added to the outside of the existing fiber cloth, and the fiber reinforcement direction of the reinforcing fiber cloth forms a 45° angle with respect to the corresponding edge of the regular hexahedron.

[0095] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still make modifications to the technical solutions described in the foregoing embodiments without creative effort, or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method of manufacturing a composite polyhedral product comprising a step of laying up a fibrous cloth and a step of hot press forming, characterized in that, The laying step of the fiber cloth comprises the following steps: Step one, using the initial layer of fiber cloth to enclose the complete contour of the composite polyhedron; each initial layer of fiber cloth is in a bent state, having two bent sides at an included angle, and the bent line between the two bent sides corresponds to an edge of the composite polyhedron; Step two, laying at least one secondary layer of fiber cloth outside the initial layer of fiber cloth; each secondary layer of fiber cloth is in a bent state, having two bent sides at an included angle and a bent line between the two bent sides corresponding to the edge formed by the abutting edges of the two initial layers of fiber cloth; each edge of the composite polyhedron can be covered by the fiber cloth in a bent state; the secondary layers of fiber cloth in the same laying layer enclose the complete contour of the composite polyhedron, and the bent sides of each initial layer of fiber cloth and secondary layer of fiber cloth are consistent with the corresponding surface shape of the composite polyhedron, for covering the entire surface of the composite polyhedron.

2. The method of claim 1, wherein All edges of the composite polyhedron correspond to the bent lines of at least one initial layer of fiber cloth or secondary layer of fiber cloth.

3. The composite polyhedral product manufacturing method according to claim 1 or 2, characterized by, Among the initial layers of fiber cloth and secondary layers of fiber cloth corresponding to each side of the composite polyhedron, the fiber reinforcement directions of adjacent initial layers of fiber cloth and secondary layers of fiber cloth are arranged in a cross form, and / or the fiber reinforcement directions of adjacent secondary layers of fiber cloth are arranged in a cross form.

4. The method of claim 3, wherein The fiber reinforcement directions of the initial layers of fiber cloth and secondary layers of fiber cloth are perpendicular to the bent lines.

5. The composite polyhedral product manufacturing method according to claim 1 or 2, characterized by, The fiber cloth comprises a reinforcing fiber cloth, and the fiber reinforcement direction of the reinforcing fiber cloth is oblique with respect to the edge of the corresponding side surface of the composite polyhedron.

6. The method according to claim 1 or 2, wherein The number of edges of the two bent sides of each secondary layer of fiber cloth is the same.

7. The method of claim 6, wherein For a composite polyhedron having a rectangular bottom surface and triangular side surfaces, the bent side corresponding to the rectangular bottom surface on the secondary layer of fiber cloth in the same laying layer is triangular, and the bent sides of the triangular corresponding to the rectangular bottom surface on the secondary layers of fiber cloth in the same laying layer are spliced into the rectangular bottom surface.

8. The method according to claim 1 or 2, wherein For a composite polyhedron having a rectangular bottom surface and triangular side surfaces, the initial layer of fiber cloth comprises a rectangular planar fiber cloth corresponding to the rectangular bottom surface, and two triangular bent fiber cloths having triangular bent sides for forming two adjacent triangular side surfaces.

9. A composite polyhedron comprising a layup formed from a fibre cloth, characterised in that, The fiber cloth includes primary layer fiber cloths, all of which surround the initial complete contour of the composite polyhedron; each primary layer fiber cloth is in a bent state and has two bent sides at an included angle, and the bent line between the two bent sides corresponds to an edge of the composite polyhedron; at least one secondary layer fiber cloth is laid on the outer part of the primary layer fiber cloth, each secondary layer fiber cloth is in a bent state and has two bent sides at an included angle and a bent line corresponding to the edge of the polyhedron, and the bent line between the two bent sides of at least one secondary layer fiber cloth corresponds to the edge formed by the abutting edges of the two primary layer fiber cloths; each edge of the composite polyhedron can be covered by the fiber cloth in the bent state; the secondary layer fiber cloths in the same laying layer all surround the complete contour of the composite polyhedron, and the bent sides of each primary layer fiber cloth and secondary layer fiber cloth all conform to the corresponding surface shape of the composite polyhedron and cover the entire surface of the composite polyhedron.

10. The composite polyhedron of claim 9, wherein, All edges of the composite polyhedron correspond to the bent lines of at least one primary layer fiber cloth or secondary layer fiber cloth.

11. The composite polyhedron of claim 9 or 10, wherein, In the primary layer fiber cloths and secondary layer fiber cloths corresponding to each side of the composite polyhedron, the fiber reinforcement directions of adjacent primary layer fiber cloths and secondary layer fiber cloths are arranged in a cross form, and / or the fiber reinforcement directions of adjacent secondary layer fiber cloths are arranged in a cross form.

12. The composite polyhedron of claim 11, wherein, The fiber reinforcement directions of the primary layer fiber cloths and secondary layer fiber cloths are perpendicular to the bent lines.

13. The composite polyhedron of claim 9 or 10, wherein, The fiber reinforcement directions of the primary layer fiber cloths and secondary layer fiber cloths are perpendicular to the bent lines.

14. The composite polyhedron of claim 9 or 10, wherein, The fiber cloth includes a reinforcing fiber cloth, and the fiber reinforcement direction of the reinforcing fiber cloth is oblique with respect to the edge of the corresponding side surface of the composite polyhedron.

15. The composite polyhedron of claim 14, wherein, The number of edges of the two bent sides of each secondary layer fiber cloth is the same.

16. The composite polyhedron of claim 9 or 10, wherein, The composite polyhedron has a rectangular bottom surface and triangular side surfaces, the bent sides corresponding to the rectangular bottom surface in the secondary layer fiber cloths in the same laying layer are triangular, and the bent sides of the triangular corresponding to the rectangular bottom surface in the secondary layer fiber cloths in the same laying layer are spliced to form the rectangular bottom surface. The composite polyhedron has a rectangular bottom surface and triangular side surfaces, the primary layer fiber cloth includes a rectangular planar fiber cloth corresponding to the rectangular bottom surface, and further includes two triangular bent fiber cloths with triangular bent sides, which are used to form two adjacent triangular side surfaces.

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