One-step forming die and one-step forming method for composite material pcm perforated product

Abstract

The application discloses a one-time forming die and a one-time forming method for a composite PCM product with holes, wherein the upper end of a lower die is provided with a core boss, the upper end of the core boss is provided with a forming groove, the forming groove is configured to be adapted to the profile of the product, and the bottom of the forming groove is distributed with avoiding holes; the lower end of an upper die is provided with a cavity matched with the core boss, the upper part of the upper die is provided with an assembly channel, and the assembly channel and the cavity are distributed with sliding holes, each of the sliding holes is one-to-one matched with each of the avoiding holes; a push plate is slidably arranged in the assembly channel, a return spring is arranged on the upper side of the push plate, a top rod is slidably connected in the sliding hole on the lower side of the push plate, and the top rod is configured to be adapted to the hole position on the product. The one-time forming die and the one-time forming method can ensure that the PCM product is formed in the die once, overcome the technical defects of the traditional process, such as complex process, low product manufacturing efficiency, many input devices and unsuitable for large-scale production and manufacturing.

Description

Technical Field

[0001] This invention relates to PCM molds, and more specifically to a one-time molding mold for PCM composite material products with holes. Background Technology

[0002] PCM products refer to products made by uniformly spraying a resin matrix onto woven continuous fiberglass cloth, allowing both materials to fully impregnate the cloth, and obtaining a preform at a certain temperature. The preform is then placed into a preheated mold, and pressure is applied to obtain the final product. PCM is a material with special properties; it can absorb or release a large amount of heat within a certain temperature range, and therefore is widely used in construction, automotive, and electronics industries.

[0003] PCM plate-like parts, for example, have been widely used as battery casing components for new energy vehicles due to their advantages of good mechanical properties, low density, and high strength. To meet the assembly requirements of batteries, when PCM plates are used as battery casings or covers, the plates generally have a number of holes to accommodate studs or corresponding protrusions on the outside of the battery product.

[0004] For perforated PCM boards, the traditional manufacturing process involves placing prepreg (a mixture of PCM material and substrate) into a mold and hot-pressing it into a PCM board. The PCM board is then removed and further processed using mechanical cutting, drilling, and other methods to ensure the product outline and corresponding hole dimensions. The problems with this process are: complex procedures, low production efficiency, and the need for more equipment, making it unsuitable for large-scale production. Summary of the Invention

[0005] In view of this, the present invention provides a one-time molding die for PCM composite material products with holes, which aims to solve the technical problems mentioned in the background art.

[0006] To achieve the above objectives, the technical solution of the present invention is as follows:

[0007] A one-time molding die for PCM perforated composite products includes an upper die and a lower die. The key features are: a core boss is provided at the upper end of the lower die, a molding groove is provided at the upper end of the core boss, the molding groove is configured to conform to the contour of the product, and clearance holes are distributed at the bottom of the molding groove.

[0008] The upper mold has a cavity at its lower end that matches the core boss. The upper part of the upper mold has an assembly channel. Sliding holes are distributed between the assembly channel and the cavity. Each sliding hole is directly opposite to each clearance hole. A push plate is slidably installed in the assembly channel. A return spring is installed on the upper side of the push plate, and a push rod is slidably connected in the sliding hole on the lower side. The push rod is configured to adapt to the hole position on the product.

[0009] The upper and lower molds are each equipped with a heating oil circuit system to heat the molds.

[0010] The upper mold is equipped with a negative pressure system. After the mold is closed, the negative pressure system is used to create a vacuum between the cavity and the core boss.

[0011] Preferably, the heating oil circuit system includes an oil inlet channel, an oil outlet channel, and a number of transition channels arranged in the lower mold. The oil inlet channel and the oil outlet channel are arranged parallel to each other along the length of the lower mold, and each of the transition channels is distributed between the oil inlet channel and the oil outlet channel.

[0012] Preferably, each of the transition channels extends through the width direction of the lower mold, and sealing bolts are provided at both ends of the transition channel, with the inner end of the sealing bolts extending to the position of the oil inlet channel or the oil outlet channel.

[0013] Preferably, the upper mold includes a cavity seat, two sets of pads disposed on the upper side of the cavity seat, and a cover plate fixed to the upper end of the two sets of pads. The assembly channel is formed by the cavity seat, the cover plate, and the two sets of pads. Four guide posts are provided between the cavity seat and the cover plate. The push plate is slidably mounted on the four guide posts. There are a total of four sets of return springs, which are correspondingly mounted on the four guide posts.

[0014] Preferably, the negative pressure system includes a first air passage disposed within the pad and a second air passage disposed at both ends of the cavity seat. The first air passage extends through the length of the pad, and both ends of the first air passage are connected to the outer end of the second air passage via air pipes. The inner end of the second air passage is connected to the cavity. An air nozzle connected to the first air passage is installed at the front end of the pad.

[0015] Preferably, the top of the cavity is provided with a rectangular groove that communicates with the second air passage, and a rectangular plate is installed at the lower end of the rectangular groove, with air holes distributed in an array on the rectangular plate.

[0016] Preferably, the core boss is circumferentially fitted with a sealing ring.

[0017] Preferably, four sets of positioning components are provided between the lower end of the upper mold and the upper end of the lower mold. The four sets of positioning components are used to ensure the mold closing accuracy of the upper mold and the lower mold in the width and length directions.

[0018] The upper end of the lower mold is provided with limiting shims to ensure the mold closing accuracy of the upper and lower molds in the height direction.

[0019] The present invention also provides a method for one-time forming of PCM sheet metal based on the above-mentioned forming mold, comprising the following steps:

[0020] S1: Prepreg required for preparing PCM sheets;

[0021] S2: According to the dimensions of the PCM sheet drawing, the prepreg is contour-cut on the cutting equipment and the prepreg is hole-processed on the drilling equipment;

[0022] S3: Connect the temperature controller to the heating oil circuit system of the upper and lower molds to bring the mold to the working temperature;

[0023] S4: Place the prepreg obtained in step S2 into the forming groove of the lower mold;

[0024] S5: The upper mold closes downwards. During the mold closing process, the ejector rod passes downwards through the prepreg hole and abuts against the bottom of the clearance hole. The mold closing force pushes the push plate upwards, and the elastic resistance of the return spring keeps the ejector rod stably in the clearance hole.

[0025] S6: After the mold is closed, the negative pressure system is turned on to create a vacuum environment between the cavity and the core boss;

[0026] S7: After the prepreg has cured in the mold, open the upper mold and then take out the PCM sheet product.

[0027] Preferably, the prepreg has a metal insert. In step S2, a plug is fitted onto the metal insert. The plug material should be a high-temperature resistant, wear-resistant, and tough plastic with a Rockwell hardness between 80 and 140. Using this plug material to cover the metal insert prevents damage caused by temperature, pressure, or other factors during mold closing, such as friction or compression between the metal insert and the mold cavity surface. Therefore, the plug provides protection for the metal insert. The top of the mold cavity is provided with a clearance groove adapted to the plug.

[0028] Compared with the prior art, the beneficial effects of the present invention are:

[0029] 1. Using the composite material PCM perforated product one-time molding die provided by this invention, before hot pressing the PCM product, the prepreg is first cut to the same outline size as the PCM product, and the holes on the PCM product are reserved in advance. Then, the prepreg is placed into the molding groove, and the upper mold closes downwards. During this process, the ejector pin passes downwards through the holes in the prepreg and abuts against the bottom of the clearance hole. The mold closing force pushes the ejector plate upwards, and the elastic resistance of the return spring keeps the ejector pin stably in the clearance hole. After the mold is closed, the heating oil circuit system and the negative pressure system provide the necessary temperature and negative pressure environment for hot pressing. After a period of time, the prepreg can be hot pressed into a PCM finished product in the mold. Therefore, through the synergistic action of the molding groove and the ejector pin in the upper mold, it is possible to ensure that the PCM product is formed in one step in the mold without subsequent secondary processing. This overcomes the technical defects of traditional processes, such as complex procedures, low product manufacturing efficiency, large equipment investment, and inapplicability to large-scale production.

[0030] 2. Directly molding PCM products in a mold in one step can also improve the dimensional accuracy of the product outline and its corresponding holes. Attached Figure Description

[0031] Figure 1 This is an exploded structural diagram of the molding die of the present invention;

[0032] Figure 2 This is a sectional view of the lower mold 2;

[0033] Figure 3 This is a schematic diagram of the upper mold 1;

[0034] Figure 4 This is a schematic diagram of the push plate 3.

[0035] Figure 5 This is the left view of the upper model 1;

[0036] Figure 6 For along Figure 5 Sectional view of BB;

[0037] Figure 7 For along Figure 5 Sectional view of CC;

[0038] Figure 8 This is a structural diagram of a PCM product. Detailed Implementation

[0039] The present invention will be further described below with reference to the embodiments and accompanying drawings.

[0040] Example 1

[0041] like Figure 1 As shown, a molding die includes an upper die 1 and a lower die 2. The lower die 2 has an upwardly protruding core boss 2a on its upper part. The upper end of the core boss 2a is provided with a downwardly recessed molding groove 2b. The molding groove 2b is configured to conform to the contour of a PCM sheet 8. Clearance holes 2c are distributed at the bottom of the molding groove 2b, and the positions of the clearance holes 2c correspond to the positions of holes on the PCM sheet 8. (See attached diagram.) Figure 3 It can be seen that the lower end of the upper mold 1 is provided with a cavity 1a that matches the core boss 2a, and the upper part of the upper mold 1 is provided with an assembly channel 1b. A push plate 3 is slidably arranged in the assembly channel 1b, and a return spring 4 is installed on the upper side of the push plate 3. Figure 4 It can be seen that downwardly extending push rods 3b are distributed on the lower side of the push plate 3. Combined with the attached... Figure 7It can be seen that there are sliding holes 1c distributed between the assembly channel 1b and the cavity 1a. The sliding holes 1c are adapted to the push rod 3b, and the push rod 3b is slidably connected to the sliding holes 1c. Each sliding hole 1c is directly opposite to each clearance hole 2c. The push rod 3b is also configured to adapt to the hole positions on the PCM sheet 8.

[0042] Each of the upper mold 1 and the lower mold 2 is equipped with a heating oil circuit system, which is used to heat the upper and lower molds respectively. The upper mold 1 is equipped with a negative pressure system, which is used to create a vacuum between the cavity 1a and the core boss 2a after the mold is closed.

[0043] Based on the above structural arrangement of the molding die, before hot-pressing the PCM sheet 8, the prepreg is first cut to the same outline size as the PCM sheet 8, and holes are pre-reserved on the PCM sheet 8. Then, the prepreg is placed into the molding groove 2b, and the upper mold 1 closes downwards. During this process, the ejector pin 3b passes downwards through the holes in the prepreg and abuts against the bottom of the clearance hole 2c. The mold closing force pushes the push plate 3 upwards, and the elastic resistance of the return spring 4 keeps the ejector pin 3b stably within the clearance hole 2c. After the mold is closed, the heating oil circuit system and the negative pressure system provide the necessary temperature and negative pressure environment for hot pressing. After a period of time, the prepreg can be hot-pressed into a PCM finished product in the mold. Therefore, through the synergistic action of the lower mold 2 molding groove 2b and the upper mold 1 ejector pin 3b, PCM products can be formed in the mold in one step without subsequent secondary processing. This overcomes the technical defects of traditional processes, such as complex procedures, low product manufacturing efficiency, large equipment investment, and inapplicability to large-scale production. At the same time, molding in one step in the mold can also improve the dimensional accuracy of the product outline and its corresponding holes.

[0044] like Figure 2 As shown, in this embodiment, the arrangement structure of the heating oil circuit system inside the lower mold 2 is as follows:

[0045] The heating oil circuit system includes an oil inlet channel a, an oil outlet channel b, and a number of transition channels c arranged within the lower mold 2. The oil inlet channel a and the oil outlet channel b are arranged parallel to each other along the length of the lower mold 2. The transition channels c are arrayed between the oil inlet channel a and the oil outlet channel b, with their left and right ends connected to the oil inlet channel a and the oil outlet channel b, respectively. After connecting the oil temperature controller's inlet and outlet ports to the ends of the oil inlet channel a and the oil outlet channel b, respectively, the operation of the oil temperature controller allows the hot oil to circulate through the oil inlet channel a, the various transition channels c, and the oil outlet channel b, thereby achieving the heating task of the lower mold 2. The oil inlet channel a, the various transition channels c, and the oil outlet channel b also have the advantage of a reasonable structural distribution, ensuring the heating rate and uniformity. Furthermore, each transition channel c extends through the width direction of the lower mold 2, and sealing bolts d are provided at both ends of the transition channel c. The inner end of the sealing bolt d extends to the position of the oil inlet channel a or the oil outlet channel b. With this design, the transition channel c can be processed by drilling through holes first and then sealing both ends, which solves the technical obstacle of forming the transition channel c in the middle alone.

[0046] In specific implementation, the heating oil circuit system in the upper mold 1 is arranged in the same way as the heating oil circuit system in the lower mold 2, which will not be repeated here.

[0047] like Figure 1 As shown, the core boss 2a is circumferentially fitted with a sealing ring 5. After the cavity 1a is fitted onto the core boss 2a, it can ensure better sealing between the two.

[0048] For example Figure 1 , 3 As shown, four sets of positioning components are provided between the lower end of the upper mold 1 and the upper end of the lower mold 2. In this embodiment, the positioning components include a first positioning block 6a installed at the lower edge of the upper mold 1 and a second positioning block 6b installed at the upper edge of the lower mold 2. The second positioning block 6b has a protrusion 6b1, and the first positioning block 6a has a slot 6a1 that matches the protrusion 6b1. Of the four sets of positioning components, two sets are installed at both ends of the mold length direction, and the other two sets are installed at both ends of the mold width direction. After the upper and lower molds are engaged, the four sets of protrusions 6b1 are engaged in the four sets of slots 6a1, which can ensure the mold closing accuracy of the upper mold 1 and the lower mold 2 in the width and length directions. Limiting shims 7 are distributed at the upper end of the lower mold 2. The limiting shims 7 can ensure the mold closing accuracy of the upper mold 1 and the lower mold 2 in the height direction, thereby better ensuring the thickness dimension of the PCM product.

[0049] like Figure 5As shown, to facilitate the assembly of the push plate 3 and the return spring 4, the upper mold 1 includes a cavity seat 11, two sets of pads 12 disposed on the upper side of the cavity seat 11, and a cover plate 13 fixed to the upper end of the two sets of pads 12. The cavity seat 11, the cover plate 13, and the two sets of pads 12 can form a rectangular cavity, which is the aforementioned assembly channel 1b. Four guide posts 1d are provided between the cavity seat 11 and the cover plate 13. The push plate 3 is slidably mounted on the four guide posts 1d. There are a total of four sets of return springs 4, which are mounted one-to-one on the four guide posts 1d.

[0050] Based on the structure of the upper mold 1 and above, the implementation structure of the negative pressure system is as follows:

[0051] Please refer to the attached document. Figure 6 As shown, the negative pressure system includes a first air passage e disposed within the pad 12 and second air passages f disposed at both ends of the cavity seat 11. The first air passage e extends through the length of the pad 12, and the second air passage f is horizontally arranged, with its outer end located outside the cavity seat 11 and its inner end connected to the cavity 1a. Both ends of the first air passage e are connected to the outer ends of the second air passage f via air pipes g. An air nozzle e1 connected to the first air passage e is installed at the front end of the pad 12. Based on this, after the upper and lower molds are engaged, air can be drawn out through the air nozzle e1 to create a negative pressure state between the cavity 1a and the core boss 2a. Furthermore, in conjunction with the attached... Figure 3 , 6 As can be seen, the top of cavity 1a is provided with a rectangular groove i that communicates with the second air passage f. A rectangular plate h is installed at the opening of the rectangular groove i, and air holes h1 are distributed in an array on the rectangular plate h. This design helps the airflow to be drawn away from cavity 1a evenly.

[0052] Example 2

[0053] A one-time forming method for PCM sheet metal based on the molding die of Embodiment 1, where PCM sheet metal 8 is attached. Figure 8 As shown, the molding method includes the following steps:

[0054] S1: Prepreg required for preparing PCM sheets;

[0055] S2: According to the dimensions of the PCM sheet drawing, the prepreg is outlined on the cutting equipment and the prepreg is drilled with 8c holes on the drilling equipment.

[0056] S3: Connect the temperature controller to the heating oil circuit system of the upper mold 1 and the lower mold 2 to heat the mold to the working temperature;

[0057] S4: Place the prepreg obtained in step S2 into the forming groove 2b of the lower mold 2;

[0058] S5: The upper mold 1 closes downwards. During the mold closing process, the ejector rod 3b passes downwards through the prepreg hole and abuts against the bottom of the clearance hole 2c. The mold closing force pushes the push plate 3 upwards. The elastic resistance of the reset spring 4 keeps the ejector rod 3b stably in the clearance hole 2c.

[0059] S6: After the mold is closed, connect the vacuum equipment to the air nozzle e1 and use the negative pressure system to draw air from the cavity 1a and the molding groove 2b to create a vacuum environment between the cavity 1a and the core boss 2a.

[0060] S7: After the prepreg has cured in the mold for a certain period of time, it can be directly formed into a PCM product. Then, open the upper mold 1 and take out the PCM sheet product.

[0061] Using the above method, PCM sheets can be formed in one mold, including the sheet outline and hole dimensions, without the need for subsequent secondary processing. This overcomes the technical defects of traditional processes, such as complex procedures, low product manufacturing efficiency, large equipment investment, and inapplicability to large-scale production.

[0062] Furthermore, if there is a metal insert 8a on the PCM sheet 8, in step S2 above, a plug should also be fitted onto the metal insert 8a to cover it, preventing it from being affected by temperature, air pressure, etc., in the mold and causing a decrease in the quality of the metal insert. Correspondingly, the top of the upper mold cavity 1a is provided with a first clearance groove 1e adapted to the plug. In this embodiment, the plug material needs to be a plastic with good high temperature resistance, wear resistance, and toughness, with a Rockwell hardness between 80 and 140. Using a plug made of this material to cover the metal insert prevents damage to the metal insert in the mold due to temperature, pressure, etc., and factors such as contact friction or extrusion with the cavity surface during mold closing. Therefore, adding a plug protects the metal insert.

[0063] Furthermore, if there is a large notch 8d on the PCM sheet 8, a protruding core 2e should be provided at the corresponding position of the forming groove 2b. Correspondingly, the top of the upper mold cavity 1a is provided with a second clearance groove 1f that is adapted to the protruding core 2e.

[0064] Finally, it should be noted that the above description is merely a preferred embodiment of the present invention. Those skilled in the art, under the guidance of the present invention, can make various similar representations without departing from the spirit and claims of the present invention, and such modifications all fall within the protection scope of the present invention.

Claims

1. A one-step forming method of a composite PCM hole type product, comprising a forming mold, the forming mold comprising an upper mold (1) and a lower mold (2), the lower mold (2) being provided with a core boss (2a) at the upper end, the core boss (2a) being provided with a forming groove (2b) at the upper end, the forming groove (2b) being configured to adapt to the product profile, the bottom of the forming groove (2b) being provided with an escape hole (2c); the lower end of the upper mold (1) being provided with a cavity (1a) matched with the core boss (2a), the upper mold (1) comprising a cavity seat (11), two groups of pads (12) arranged on the upper side of the cavity seat (11), and a cover plate (13) fixed on the upper end of the two groups of pads (12), a fitting channel (1b) being formed between the cavity seat (11), the cover plate (13) and the two groups of pads (12), a sliding hole (1c) being distributed between the fitting channel (1b) and the cavity (1a), each sliding hole (1c) being in one-to-one correspondence with each escape hole (2c); a push plate (3) being slidably arranged in the fitting channel (1b), a return spring (4) being installed on the upper side of the push plate (3), a top rod (3b) being slidably connected in the sliding hole (1c) on the lower side of the push plate (3), the top rod (3b) being configured to adapt to the hole position on the product; four guide columns (1d) being arranged between the cavity seat (11) and the cover plate (13), the push plate (3) being slidably sleeved on the four guide columns (1d), the return spring (4) being arranged in one-to-one correspondence on the four guide columns (1d); the cavity (1a) being provided with an escape groove (1e) at the top, the escape groove (1e) being adapted to the plug; a set of heating oil circuit systems being arranged in the upper mold (1) and the lower mold (2) respectively, for heating the mold; the heating oil circuit system comprising an oil inlet channel (a), an oil outlet channel (b) and a plurality of transition channels (c) arranged in the lower mold (2), the oil inlet channel (a) and the oil outlet channel (b) being arranged in parallel along the length direction of the lower mold (2), each transition channel (c) being arrayed between the oil inlet channel (a) and the oil outlet channel (b); a negative pressure system being arranged in the upper mold (1), the negative pressure system being used to form a vacuum state between the cavity (1a) and the core boss (2a) after the mold is closed, the negative pressure system comprising a first air duct (e) arranged in the pad (12), and a second air duct (f) arranged at both ends of the cavity seat (11), the first air duct (e) penetrating through the length direction of the pad (12), both ends of the first air duct (e) being communicated with the outer end of the second air duct (f) through an air pipe (g), the inner end of the second air duct (f) being communicated into the cavity (1a); an air nozzle (e1) being installed on the front end of the pad (12) and communicated with the first air duct (e), a rectangular groove (i) being arranged on the top of the cavity (1a) and communicated with the second air duct (f), a rectangular plate (h) being installed on the lower end of the rectangular groove (i), a plurality of air holes (h1) being arrayed on the rectangular plate (h); characterized in that comprising the following forming steps: S1: preparing a prepreg required for the PCM sheet material; S2: According to the drawing size of the PCM plate material, the pre-impregnated material is profiled and cut on the cutting equipment, and the pre-impregnated material is hole processed on the drilling equipment; the pre-impregnated material has a metal insert, and a plug is sleeved on the metal insert, the plug is made of plastic with good high-temperature resistance, wear resistance and toughness, and the Rockwell hardness is 80-140HR; S3: Connect the temperature control machine with the heating oil circuit system of the upper mold (1) and the lower mold (2) to make the mold reach the working temperature; S4: Put the pre-impregnated material obtained in step S2 into the forming groove (2b) of the lower mold (2); S5: The upper mold (1) is closed downward, during the closing process, each said ejector rod (3b) penetrates through the corresponding pre-impregnated material hole and abuts against the bottom of the avoiding hole (2c), then the closing force pushes the said push plate (3) upward, the elastic resistance of the four sets of reset springs (4) makes the ejector rod (3b) stably remain in the avoiding hole (2c); S6: After the mold is closed, open the negative pressure system to form a vacuum environment between the cavity (1a) and the core boss (2a); S7: After the pre-impregnated material is cured in the mold, open the upper mold (1), then take out the PCM plate material product.

2. The one-step forming process for composite PCM perforated products of claim 1, wherein: Each said transition channel (c) extends through the width direction of the lower mold (2), and sealing bolts (d) are arranged at both ends of the transition channel (c), and the inner ends of the sealing bolts (d) extend to the positions of the oil inlet channel (a) or the oil outlet channel (b).

3. The one-step forming process for composite PCM perforated products of claim 1, wherein: The core boss (2a) is circumferentially sleeved with a sealing ring (5).

4. The one-step forming process for composite PCM perforated products of claim 1, wherein: Four sets of positioning assemblies are arranged between the lower end of the upper mold (1) and the upper end of the lower mold (2), and the four sets of positioning assemblies are used to ensure the closing precision of the upper mold (1) and the lower mold (2) in the width and length directions. Limiting washers (7) are arranged on the upper end of the lower mold (2) to ensure the closing precision of the upper mold (1) and the lower mold (2) in the height direction.

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