A multi-channel integrated form composite special operations box and a manufacturing method thereof

Abstract

The application discloses a kind of multi-channel integral forming composite special operation box, including several combined arrangement box, the four faces of box are provided with lug, trapezoidal lower base is attached to the side of box setting.Method for making includes the following steps: first layer of woven fiber cloth is laid on the inner surface of mould and is compacted into shape→polyurethane foam raw material is filled in the recess of mould→second layer of fiber yarn is wound on the first layer of composite material and polyurethane foam respectively→two-layer two-column multi-channel combined structure is obtained using tooling combination and vacuumizing, compacting and curing→moulding is removed to obtain composite special operation box.The special operation box has the characteristics of light weight, high strength, excellent wave transmission performance, excellent heat preservation and heat insulation performance, etc., and the manufacturing method is simple for manufacturing multi-channel, small-diameter, large-length-diameter ratio and thin-walled composite special operation box, and the interlayer bonding effect of the box composite material is strong, and the air tightness is good.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of composite materials, and particularly relates to a multi-channel integrally formed composite material special operation box and a manufacturing method thereof. BACKGROUND

[0002] The main functions of the special operation box are: 1. as a storage box, the inside of the box is arranged with inflation and detection equipment, and is filled with dry air or nitrogen, and after being sealed, the service life of the special equipment in the box can be prolonged; 2. as a transport box, the special equipment is assembled on the support or hanging guide rail in the box, and the locking limiting device is used to prevent the special equipment from being damaged due to external factors such as impact and vibration during transportation; 3. as a special operation box, the operation guide rail, locking limiting device and cable shedding mechanism are arranged in the box, and are connected with the operation equipment through the cable, and have the functions of pre-operation inspection and special operation. The traditional special operation box is mostly made of metal materials such as steel and aluminum alloy, and has the disadvantages of heavy weight and low strength.

[0003] The Chinese invention patent with the publication number CN116231163A discloses a light-weight thermal insulation battery box body, which comprises a glass fiber inner panel and a glass fiber outer panel arranged on the side of the glass fiber inner panel, and a sandwich panel is arranged between the glass fiber inner panel and the glass fiber outer panel. It also includes a preparation process and a prefabrication system for the light-weight thermal insulation battery box body. The invention improves the thermal insulation and impact resistance of the box body, and uses a preforming process for the sandwich foam material, so that the foaming material has a simple structure, which not only reduces the waste of foaming material, but also simplifies the precision during cutting of the foaming material, has better product consistency, and through the double-line movement of the pre-mold and the conveying device, the laying of the fiber composite material is realized through a simple rotating movement. The box body is made of composite materials, but this process is not suitable for the special operation box with complex structure. SUMMARY

[0004] In order to solve the above problems, the present application aims to provide a multi-channel integrally formed composite material special operation box and a manufacturing method thereof.

[0005] In order to achieve the above-mentioned purpose, the following technical scheme is adopted: a multi-channel integrally formed composite material special operation box, comprising a plurality of combined and arranged box bodies, and a plurality of protrusions arranged on the four sides of the box body, wherein the protrusions are irregular trapezoidal shapes, and the lower base of the trapezoidal shape is arranged in close contact with the side of the box body.

[0006] Preferably, the four protrusions of the box body form a channel in the box body, and a plurality of box bodies are combined to form a multi-channel operation box.

[0007] A manufacturing method of a multi-channel integrally formed composite material special operation box, characterized by comprising the following steps:

[0008] Step 1: Lay the first layer of woven fiber cloth on the inner surface of the mold, use a molding tool to press the first layer of woven fiber cloth, and then vacuum-assisted molding to obtain the first layer of composite material;

[0009] Step 2: Fill the mold groove with polyurethane foam raw material. The polyurethane foam is located on the first layer of the composite material and foams it. After molding, remove the excess protrusions and only keep the polyurethane foam in the groove.

[0010] Step 3: Wrap the second layer of fiber yarn around the first layer of composite material and the polyurethane foam respectively to obtain the second layer of composite material;

[0011] Step 4: Use tooling to assemble the four boxes into a two-layer, two-column multi-channel combination structure, so that the contact surfaces between the channels are in contact. After wrapping the third layer of fiber yarn on the second layer of composite material, put on a vacuum bag and vacuum-press it. Then, the second layer of composite material and the third layer of fiber yarn are cured together to obtain the third layer of composite material.

[0012] Step 5: Separate the third layer of the composite material from the mold to obtain the composite material special operation box.

[0013] Preferably, in step 1, the molding tool pre-compacts the first layer of woven fiber cloth with the mold, repeats the operation at least three times, and then performs vacuum compaction and curing.

[0014] Preferably, the polyurethane foam foaming temperature in step 2 is 20–40°C.

[0015] Preferably, in steps 3 and 4, the second and third layers of fiber yarn are coated with epoxy resin material before winding, and the second layer of fiber yarn is wound in a circumferential direction, while the third layer of fiber yarn is wound alternately around the channel.

[0016] Preferably, the tooling in step 4 is adjusted according to the combined box dimensions.

[0017] Preferably, during the channel assembly process in step 4, the gap at the top corner is filled with resin material, which is a medium-temperature curing epoxy resin.

[0018] Preferably, the multi-channel combination formed by the four boxes in step 4 includes, but is not limited to, four channels formed by four boxes, six channels formed by six boxes, and eight channels formed by eight boxes.

[0019] Preferably, the curing process in steps 1 and 4 is as follows: curing at 70℃~150℃ for 3~8 hours.

[0020] Compared with the prior art, the present invention has the following advantages:

[0021] 1. Special operation boxes made of composite materials are lightweight, high-strength, have excellent wave transmission performance, and excellent thermal insulation performance. In addition, when special equipment is in operation, the high-temperature gas generated by the engine will cause high-temperature erosion of the inner wall of the box. Therefore, the high-temperature resistant fiber cloth in the inner layer can protect the box.

[0022] 2. This manufacturing method is simple for producing multi-channel, small-diameter, high aspect ratio, and thin-walled composite special operation boxes, and the produced box body has strong interlayer bonding effect of composite material and good airtightness. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the specific embodiments of the present invention, the drawings used in the description of 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.

[0024] Figure 1 This is a diagram showing the arrangement of special operation channels during composite material molding in this invention.

[0025] Figure 2 for Figure 1 A magnified view of part A;

[0026] In the diagram, 1-First special operation passage; 2-Second special operation passage; 3-Third special operation passage; 4-Fourth special operation passage; 5-Polyurethane foam; 6-First layer of woven fiber cloth; 7-Second layer of fiber yarn; 8-Third layer of fiber yarn; 9-Resin material. Detailed Implementation

[0027] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. However, it should not be construed that the scope of the subject matter of the present invention is limited to the following embodiments. All modifications, substitutions and alterations made based on ordinary technical knowledge and common practices in the art without departing from the above-described technical concept of the present invention are included within the scope of the present invention.

[0028] Example: Pre-treatment of molds: Apply release wax evenly to each molding mold with a thickness not exceeding 0.01mm;

[0029] Step 1: Forming the first layer of woven fiber cloth 6, including: laying the first layer of woven fiber cloth 6 on the mold surface; using a molding tool to compact the fiber cloth, repeating three times with an interval of 15-30 minutes each time, to ensure it adheres firmly to the mold; placing it in a vacuum bag for vacuum compaction at a pressure of 0.1 MPa, and curing at 135℃ for 4 hours. Laying the first layer of woven fiber cloth 6 on the mold surface first is to reduce costs and improve the bonding strength between the filler material and the composite material. The tightness of the fit between the first layer of woven fiber cloth 6 and the mold directly determines the guide rail forming accuracy. Therefore, after laying the first layer of woven fiber cloth 6, it undergoes three pre-compaction molding processes followed by vacuum curing to ensure accuracy.

[0030] Step 2: Polyurethane foam 5 molding, including: filling the first layer of composite material in the mold groove with polyurethane foam 5 raw material, controlling its foaming temperature to 24℃; after foam molding, removing excess protrusions with a blade, leaving only the polyurethane foam 5 in the groove. Directly filling and foaming the first layer of composite material in the mold groove with polyurethane foam 5 significantly reduces demolding difficulty, improves molding accuracy, and simplifies operation for thin-walled composite special operation boxes; however, the foaming temperature of polyurethane foam 5 should be strictly controlled. Excessive temperature will reduce foam strength, causing depressions during subsequent vacuum curing, affecting the appearance quality of the special operation box; while insufficient temperature will increase the density of polyurethane foam 5, thus affecting the weight of the special operation box.

[0031] Step 3: Forming the second layer of fiber yarn 7: Wrap the second layer of fiber yarn 7 around the first layer of composite material and polyurethane foam 5 respectively. When winding, the second layer of fiber yarn 7 is coated with epoxy resin material to ensure that the winding angle is 90° circumferential with the axis of the special operation guide rail. The width of the second layer of fiber yarn 7 is 10mm and the overlap width is 1mm; thus, the second layer of composite material is obtained.

[0032] Step 4: Forming the third layer of fiber yarn 8, including: assembling the four boxes into a two-layer, two-row structure using tooling; adjusting the tooling assembly dimensions to ensure the contact surfaces between the boxes fit together; filling the gaps at the top corners with resin material 9, ensuring no gaps exist; winding the third layer of fiber yarn 8 onto the assembled composite material second layer; coating the third layer of fiber yarn 8 with epoxy resin during winding; ensuring the winding angle alternates between +56° and -56° with the axis of the special operation guide rail; the third layer of fiber yarn 8 is 10mm wide; placing a vacuum bag on top and vacuuming it to a pressure of 0.1MPa; then curing the second layer of fiber yarn 7 and the third layer of fiber yarn 8 together at 120℃ for 3 hours to obtain the desired result. Figure 1 The first special operations channel 1, the second special operations channel 2, the third special operations channel 3, and the fourth special operations channel 4 are shown.

[0033] The combined tooling has an adjustment function to adapt to the dimensional changes of the composite material after molding, avoiding excessive tightness or gaps. The second layer of fiber yarn 7 and the third layer of fiber yarn 8 are co-cured to ensure a tight connection between the interfaces of the second layer of fiber yarn 7 at the bonding surface between the channels, and at the same time, to ensure a tight connection between the interfaces of the second layer of fiber yarn 7 and the third layer of fiber yarn 8, avoiding delamination and making the special operation box have excellent airtight performance.

[0034] Step 5: Product demolding: Use a hydraulic tensile testing machine to apply pressure to the product and mold in the demolding direction opposite to the special operation direction, so that the product and mold separate along the guide rail axis and are slowly pulled out to obtain the composite material special operation box.

[0035] The foregoing has provided a detailed description of a multi-channel integrally molded composite material special operation box and its manufacturing method provided by the present invention. Specific examples have been used to illustrate the structure and working principle of the present invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of the present invention. It should be noted that those skilled in the art can make several improvements and modifications to the present invention without departing from the principles of the present invention, and these improvements and modifications also fall within the scope of protection of the claims of the present invention.

Claims

1. A method for manufacturing a multi-channel integrally molded composite material special operation box, characterized in that: Includes the following steps: Step 1: Lay the first layer of woven fiber cloth (6) on the inner surface of the mold, use a molding tool to press the first layer of woven fiber cloth (6) firmly, and then vacuum-assisted molding to obtain the first layer of composite material; Step 2: Fill the mold groove with polyurethane foam (5) material. The polyurethane foam (5) is located on the first layer of the composite material and foams it. After molding, remove the excess protrusions and only keep the polyurethane foam (5) in the groove. Step 3: Wrap the second layer of fiber yarn (7) around the first layer of composite material and the polyurethane foam (5) respectively to obtain the second layer of composite material; Step 4: Use tooling to assemble the four boxes into a two-layer, two-column multi-channel combination structure so that the contact surfaces between the channels fit together. After wrapping the third layer of fiber yarn (8) on the second layer of composite material, put on a vacuum bag and vacuum and compact it. Then, the second layer of composite material and the third layer of fiber yarn (8) are cured together to obtain the third layer of composite material. Step 5: Separate the third layer of the composite material from the mold to obtain the composite material special operation box.

2. The method for manufacturing the multi-channel integrally molded composite material special operation box according to claim 1, characterized in that: In step 1, the molding tool pre-compacts the first layer of woven fiber cloth (6) with the mold, repeats the operation no less than three times, and then performs vacuum compaction and curing.

3. The method for manufacturing the multi-channel integrally molded composite material special operation box according to claim 1, characterized in that: The polyurethane foam (5) in step 2 has a foaming temperature of 20-40℃.

4. The method for manufacturing the multi-channel integrally molded composite material special operation box according to claim 1, characterized in that: Before winding the second layer of fiber yarn (7) and the third layer of fiber yarn (8) in steps 3 and 4, epoxy resin material must be applied. The second layer of fiber yarn (7) is wound in a circumferential direction, and the third layer of fiber yarn (8) is wound alternately around the channel.

5. The method for manufacturing a multi-channel integrally molded composite material special operation box according to claim 1, characterized in that: The tooling in step 4 is adjusted according to the combined box dimensions.

6. The method for manufacturing a multi-channel integrally molded composite material special operation box according to claim 1, characterized in that: During the channel assembly process in step 4, resin material (9) is filled into the gap at the top corner where the materials are joined. The resin material (9) is a medium-temperature curing epoxy resin.

7. The method for manufacturing a multi-channel integrally molded composite material special operation box according to claim 1, characterized in that: The multi-channel combination formed by the box assembly in step 4 can be four channels composed of four boxes, six channels composed of six boxes, or eight channels composed of eight boxes.

8. The method for manufacturing a multi-channel integrally molded composite material special operation box according to claim 1, characterized in that: The curing process in steps 1 and 4 is as follows: curing at 70℃~150℃ for 3~8 hours.

9. A multi-channel integrally molded composite material special operation box prepared by any one of claims 1-8, characterized in that: It includes several boxes arranged in combination. Each box has a protrusion on its four sides. The protrusion is an irregular trapezoidal shape, and the bottom edge of the trapezoid is set to fit against the side of the box.

10. The multi-channel integrally molded composite material special operation box according to claim 9, characterized in that: The four protrusions of the box form a channel inside the box, and several boxes can be combined to form a multi-channel operation box.

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