Structural member and method of processing the same, and head-mounted display device

Abstract

The application discloses a structural member and a processing method thereof and a head-mounted display device, relates to the technical field of intelligent head-mounted display devices, and the method comprises the following steps: acquiring at least one non-metallic fiber prepreg; placing each non-metallic fiber prepreg into a first whole mold core, step-by-step closing the mold core with at least one split mold core and the first whole mold core, and performing first mold pressing preforming on each non-metallic fiber prepreg; separating each split mold core from each non-metallic fiber prepreg, closing the mold core with a second whole mold core and the first whole mold core, and performing second mold pressing preforming on each non-metallic fiber prepreg to obtain a preform; and transferring the first whole mold core and the second whole mold core to a forming mold frame, performing curing forming on the preform, and obtaining the structural member. The application provides a structural member net size forming method which is low in cost, high in yield and efficiency, and can obtain a structural member with high surface quality and high size precision.

Description

Technical Field

[0001] This application relates to the field of intelligent head-mounted display technology, and more particularly to a structural component, its processing method, and a head-mounted display device. Background Technology

[0002] With the development of hardware such as optical display units, computing units, and sensing units, as well as the continuous enrichment of the software ecosystem, AR (Augmented Reality) / VR (Virtual Reality) technologies have greatly improved the interactivity and immersion for users, showing broad application prospects in fields such as industry, medicine, education, security, and leisure and entertainment. Comfort during prolonged wear is one of the important factors in improving the acceptance of AR / VR devices. Whether positioned as consumer-grade AR / VR devices or those used in industry-grade applications, the discomfort caused by weight is an unavoidable issue. AR / VR devices integrate key functional components such as cameras, sensors, optical modules, lenses, and batteries, resulting in a relatively complex structural design. The overall weight can easily exceed 100g, causing fatigue during prolonged wear and requiring high load-bearing capacity. Carbon fiber composite materials are widely used in aerospace, sporting goods, wind power, and automotive fields. They have advantages such as high specific strength, high specific modulus, designable mechanical properties, fatigue resistance, and aging resistance, making them an ideal lightweight material.

[0003] Currently, the processing of composite curved carbon fiber composite materials is mainly carried out using dedicated 4-axis or even 5-axis or 6-axis CNC (Computer Numerical Control) machine tools. However, due to the complex curved surfaces of structural components in AR / VR devices and the high requirements for precision and appearance, there are more restrictions on CNC machining parameters and tool selection. Accumulated tolerances can easily lead to product defects, and micro-damage and imperfections caused by cutting require surface repair, resulting in high processing costs, low yield, and low efficiency. Summary of the Invention

[0004] The main objective of this application is to provide a structural component and its processing method, as well as a head-mounted display device, in order to solve the technical problems of high cost, low yield and low efficiency in processing structural components for AR / VR devices using carbon fiber as raw material in related technologies.

[0005] To achieve the above objectives, this application provides a method for processing a structural component, which is applied to a head-mounted display device. The method for processing the structural component includes the following steps: Obtain at least one non-metallic fiber prepreg; Each of the non-metallic fiber prepregs is placed into the first whole mold core, and at least one segmented mold core is joined with the first whole mold core in stages to perform the first molding preformation of each of the non-metallic fiber prepregs. Separate each of the segmented mold cores from each of the non-metallic fiber prepregs, and then combine the second whole mold core with the first whole mold core to perform a second molding preform on each of the non-metallic fiber prepregs to obtain a preform. The first and second integral mold cores are transferred to the molding mold frame, and the preform is cured and molded to obtain a structural component.

[0006] Optionally, before the step of separating each of the segmented mold cores from each of the non-metallic fiber prepregs, the method further includes: Cool down each of the segmented mold cores.

[0007] Optionally, the surface of the segmented mold core that is in contact with each of the non-metallic fiber prepregs is provided with a ventilation structure; The step of separating each of the segmented mold cores from each of the non-metallic fiber prepregs includes: Compressed gas is introduced into the ventilation structure to separate each of the segmented mold cores from each of the non-metallic fiber prepregs.

[0008] Optionally, the step of placing each of the non-metallic fiber prepregs into the first integral mold core, and then sequentially joining at least one segmented mold core with the first integral mold core to perform a first compression molding preformation of each of the non-metallic fiber prepregs includes: Each of the aforementioned non-metallic fiber prepregs is laid up and cut according to a preset cutting drawing to obtain a prepreg stack; The prepreg laminate is placed into the first integral mold core, and at least one segmented mold core is joined with the first integral mold core in stages to perform the first molding preforming of the prepreg laminate.

[0009] Optionally, the step of joining the second integral mold core with the first integral mold core to perform a second molding preforming on each of the non-metallic fiber prepregs to obtain a preform includes: Separate each of the segmented mold cores from the prepreg laminate, and then combine the second whole mold core with the first whole mold core to obtain a test block; The test block is tested for integrity defects, wherein the integrity defects include at least one of excess material defects and insufficient material defects; If it is determined that the test block does not have any integrity defects, the test block is identified as a preform. If it is determined that the test block has integrity defects, the preset cutting drawing is optimized, and the process returns to the step of obtaining at least one non-metallic fiber prepreg.

[0010] Optionally, the core of at least one of the first monolithic mold core, each of the segmented mold cores, and the second monolithic mold core matches the net dimension end face boundary of the structural component.

[0011] Optionally, the non-metallic fiber prepreg includes non-metallic fibers and a resin matrix; The non-metallic fibers include at least one of carbon fiber, glass fiber, ceramic fiber, aramid fiber, and polyimide fiber. The resin in the resin matrix includes at least one of epoxy resin, epoxy vinyl resin, phenolic resin, and polyurethane resin.

[0012] Optionally, the mold temperature for the first molding preforming is 25-100℃; the pressure for the first molding preforming is 0.05-0.1MPa.

[0013] Optionally, the mold temperature for the second molding preforming is 25-100℃; the pressure for the second molding preforming is 0.1-0.5MPa.

[0014] Optionally, the curing temperature is 100-200℃; the curing pressure is 1-15MPa; and the curing cycle is 3-10min.

[0015] Optionally, the wall thickness of the segmented mold core is 5-20mm.

[0016] This application also provides a structural component, which is applied to a head-mounted display device and is manufactured using the structural component manufacturing method described above.

[0017] This application also provides a head-mounted display device, which includes the structural components described above.

[0018] This application provides a structural component, its processing method, and a head-mounted display device. The structural component is applied to the head-mounted display device. By obtaining at least one non-metallic fiber prepreg, placing each of the non-metallic fiber prepregs into a first integral mold core, and then performing a step-by-step molding process with at least one segmented mold core and the first integral mold core, the non-metallic fiber prepregs are subjected to a first compression molding pre-forming. This achieves step-by-step compression molding of the non-metallic fiber prepregs. For processing structural components with complex structures or large deformations, the defect rate of one-time molding is high, easily leading to breakage, and the stability and reliability of the processed structure are low. By using step-by-step compression molding, the pressure applied to the non-metallic fiber prepregs can be gradually increased, avoiding… In cases where excessive pressure is applied at once, structural damage occurs. To address this, the segmented mold cores are separated from the non-metallic fiber prepregs. The second integral mold core is then joined with the first integral mold core, and the non-metallic fiber prepregs undergo a second molding process to preform them, resulting in a preform. This second molding process allows the non-metallic fiber prepregs to adhere to the inner wall of the mold cavity within the mold core, achieving a superior appearance. Furthermore, by transferring the first and second integral mold cores to a molding mold frame, the preform is cured to obtain a structural component. This process solidifies the molded metal fiber prepreg, resulting in a structural component with an excellent appearance. This method enables the net-size forming of structural components with complex curved surfaces or structures, resulting in structural components with high surface quality and high dimensional accuracy. It eliminates the need for two high-cost processes: CNC machining and surface repair. The processing technology is simpler, lower in cost, and more efficient. This solves the technical problems of high cost, low yield, and low efficiency in processing structural components for AR / VR devices using carbon fiber as raw material in related technologies, and provides a low-cost, high-yield, and high-efficiency method for net-size forming of structural components. Attached Figure Description

[0019] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0020] To more clearly illustrate the technical solutions in the embodiments of this application or related technologies, the accompanying drawings used in the description of the embodiments or related technologies will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a schematic flowchart illustrating an embodiment of the processing method for the structural component of this application. Figure 2This is a schematic diagram of one possible implementation of the processing method of the structural component in this application involving the first integral mold core; Figure 3 This is a schematic diagram of one possible implementation of the segmented mold core involved in the processing method of the structural component in this application; Figure 4 This is a schematic diagram of one possible implementation of the processing method of the structural component in this application involving the second integral mold core.

[0022] Explanation of icon numbers:

[0023] The purpose, features, and advantages of this application will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0024] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0025] This application provides a method for processing a structural component. In one embodiment of the method for processing a structural component, reference is made to... Figure 1 The processing method of the structural component includes: Step S10: Obtain at least one non-metallic fiber prepreg; In this embodiment, it should be noted that the non-metallic fiber prepreg refers to a composition of a resin matrix and a reinforcement made by impregnating continuous non-metallic fibers with resin under strictly controlled conditions. The preparation method of the non-metallic fiber prepreg is similar to the prior art and will not be described in detail again. The resin is a thermosetting resin, including at least one of epoxy resin, phenolic resin, and bismaleimide resin. Under certain conditions, the resin can be in a liquid state. The liquid resin has a certain fluidity and can fill the space between the non-metallic fibers to form a prepreg. After curing the resin in the prepreg, the non-metallic fibers and the resin can be bonded together into a whole, thereby transferring and distributing the stress to each fiber. This allows the non-metallic fibers and the resin matrix in the structural component to jointly resist deformation and load, resulting in higher strength and toughness. The non-metallic fiber refers to fibers made from inorganic or organic non-metallic materials. Non-metallic fibers have a low density, which is beneficial for meeting the lightweight requirements of products. Non-metallic fibers include at least one of carbon fiber, glass fiber, ceramic fiber, aramid fiber, and polyimide fiber. Non-metallic fibers have the advantages of high modulus, high strength, and low density. The content of resin and non-metallic fibers in the non-metallic fiber prepreg, as well as the distribution pattern of the non-metallic fibers, can be determined according to actual processing needs and the actual requirements of the structural components. This embodiment does not impose any restrictions on these aspects.

[0026] In one feasible embodiment, the resin content in the non-metallic fiber prepreg is 35%-45% by mass, for example, 35%, 40%, 45%, etc.

[0027] In one feasible embodiment, the non-metallic fibers in the non-metallic fiber prepreg are woven in at least one of unidirectional weave, plain weave, twill weave, and satin weave.

[0028] Optionally, the non-metallic fiber prepreg includes non-metallic fibers and a resin matrix; The non-metallic fibers include at least one of carbon fiber, glass fiber, ceramic fiber, aramid fiber, and polyimide fiber. The resin in the resin matrix includes at least one of epoxy resin, epoxy vinyl resin, phenolic resin, and polyurethane resin.

[0029] For example, step S10 includes: obtaining one or more pre-prepared non-metallic fiber prepregs. When using multiple non-metallic fiber prepregs for structural component processing, the non-metallic fiber prepregs can be arranged, stacked, shaped, etc., before subsequent molding preforming and curing operations.

[0030] Step S20: Place each of the non-metallic fiber prepregs into the first integral mold core, and perform step-by-step molding of at least one segmented mold core with the first integral mold core to perform the first molding preformation of each of the non-metallic fiber prepregs. In this embodiment, it should be noted that, compared to composite material structural components in other industries, the structural components of small electronic devices, such as AR glasses, are characterized by their small size, thinness, complex curvature, high precision requirements, and aesthetic appeal. More importantly, their annual production demand is in the hundreds of thousands or even hundreds of millions, requiring manufacturing technology to be rapid, stable, and low-cost. For AR glasses components such as frames and temples with complex curvature and stringent appearance requirements, the manufacturing technology of carbon fiber composite materials poses a significant challenge. In conventional technology, the first molding pre-forming is usually heated to above the curing temperature, completing the shaping and curing process in one go. However, structural components processed in this way are prone to appearance defects such as fiber accumulation and wrinkles at curved parts. These appearance defects are particularly noticeable on small electronic devices, thus requiring additional surface repair processes, which in turn increases processing costs and reduces efficiency.

[0031] Compression molding refers to a process in which the temperature is controlled below the curing temperature of the resin in the non-metallic fiber prepreg, causing the non-metallic fiber prepreg to soften and then being molded. The compression molding process includes a first compression molding and a second compression molding. The first compression molding involves controlling the temperature below the curing temperature of the resin in the non-metallic fiber prepreg, and then pressing different areas of the non-metallic fiber prepreg step-by-step using segmented mold cores in a specific pressing sequence. The structural design, pressing sequence, pressing pressure, and other parameters of each segmented module in the first compression molding can be determined based on actual needs and test results; this embodiment does not impose any limitations on these parameters. The second compression molding preforming refers to controlling the temperature below the curing temperature of the resin in the non-metallic fiber prepreg, allowing the non-metallic fiber prepreg to soften and then be molded within the cavity between the first and second integral mold cores. The structural design of the mold cavity, pressing pressure, mold temperature, and other parameters in the second compression molding preforming can be determined based on actual needs and test results; this embodiment does not impose any limitations on these parameters. At lower temperatures, the viscosity of the resin in the non-metallic fiber prepreg decreases with increasing temperature, resulting in a lower curing reaction rate. Therefore, the softened non-metallic fiber prepreg can deform well according to the shape and pressure of the mold core and fully adhere to the cavity wall during the second compression molding preforming process, avoiding wrinkles and accumulation. Thus, the preform obtained after two compression molding preforming processes will not have defects such as fiber accumulation and wrinkles. Further curing of the preform yields a structural component with excellent appearance.

[0032] For example, step S20 includes: based on the pre-determined layup design of the structural component, laying each of the non-metallic fiber prepregs and placing them in the mold cavity of the first integral mold core, or directly laying each of the non-metallic fiber prepregs in the mold cavity of the first integral mold core. The specific laying method can be determined according to actual conditions, and this embodiment does not impose any limitations on this. Then, each of the segmented mold cores is sequentially molded with the first integral mold core in a certain order. Mold temperature and pressure are controlled on each of the segmented mold cores and / or the first integral mold core, so that under heating and pressurization conditions, each of the non-metallic fiber prepregs gradually deforms under the molding pressure of each of the segmented mold cores, achieving the first molding pre-forming. When each segmented mold core is molded, previously molded segmented mold cores can remain in the molded state or be removed, depending on actual needs. This embodiment does not impose any limitations on this. The mold temperature and pressure should soften the non-metallic fiber prepreg without completely curing it. The specific temperature and pressure can be determined based on the actual situation or experimental test results. This embodiment does not impose any restrictions on this.

[0033] In one feasible embodiment, each of the segmented mold cores is formed by cutting the second integral mold core. That is, after each of the segmented mold cores is molded with the first integral mold core, a complete mold cavity matching the appearance shape of the structural component can be formed between the first integral mold core and each of the segmented mold cores. The step of sequentially molding at least one segmented mold core with the first integral mold core includes sequentially molding each of the segmented mold cores onto the first integral mold core. In this way, after each segmented mold core is molded, each of the non-metallic fiber prepregs can be molded within the mold cavity formed between the first integral mold core and each of the segmented mold cores.

[0034] Optionally, the mold temperature for the first molding preforming is 25-100℃; the pressure for the first molding preforming is 0.05-0.1MPa.

[0035] In this embodiment, if the mold temperature for the first molding preform is too low, the non-metallic fiber prepreg will be difficult to soften and will not have sufficient fluidity. If the mold temperature for the first molding preform is too high, the non-metallic fiber prepreg will easily solidify. Therefore, the mold temperature for the first molding preform is determined to be 25-100℃, such as 25℃, 40℃, 50℃, 60℃, 70℃, 80℃, 90℃, 100℃, etc. If the pressure for the first molding preform is too low, the non-metallic fiber prepreg will not have sufficient fluidity and will not be able to fully fill the mold cavity. If the pressure for the first molding preform is too high, the preform will easily deform and have defects. Therefore, the pressure for the first molding preform is determined to be 0.05-0.1MPa, such as 0.05MPa, 0.07MPa, 0.1MPa, etc.

[0036] Optionally, the wall thickness of the segmented mold core is 5-20mm.

[0037] In this embodiment, after the temperature of the segmented mold core decreases, the segmented mold core is easier to separate from each of the non-metallic fiber prepregs. The smaller the wall thickness of the segmented mold core, the faster the heat conduction and the faster the cooling, resulting in higher separation efficiency and better effect from the non-metallic fiber prepregs. However, it is still necessary to ensure that the segmented mold core has sufficient strength. Therefore, the wall thickness of the segmented mold core is determined to be 5-20mm, such as 5mm, 10mm, 15mm, 20mm, etc.

[0038] Optionally, the step of placing each of the non-metallic fiber prepregs into the first integral mold core, and then sequentially joining at least one segmented mold core with the first integral mold core to perform a first compression molding preformation of each of the non-metallic fiber prepregs includes: Step S21: Lay up each of the non-metallic fiber prepregs and cut them according to the preset cutting drawings to obtain prepreg stacks; Step S22: Place the prepreg laminate into the first whole mold core, and perform step-by-step molding of at least one segmented mold core with the first whole mold core to perform the first molding preforming of the prepreg laminate.

[0039] For example, steps S21 to S22 include: acquiring multiple pre-prepared non-metallic fiber prepregs, laying each of the non-metallic fiber prepregs into layers based on a preset number of layers and a preset layup angle, importing a preset cutting drawing into a cutting machine, and cutting each of the laid-up non-metallic fiber prepregs into a prepreg stack based on the preset cutting drawing to obtain a prepreg stack. Then, the prepreg stack is placed in the mold cavity of a first integral mold core, and each of the segmented mold cores is sequentially molded with the first integral mold core in a certain order. The mold temperature and pressure of each of the segmented mold cores and / or the first integral mold core are controlled, so that the prepreg stack gradually deforms under the molding pressure of each of the segmented mold cores under heating and pressurization conditions, achieving the first molding preforming. The number of layers, layup angle, and cutting drawing can all be designed and determined according to actual conditions and the actual needs of the structural components; this embodiment does not impose any limitations on these.

[0040] In one feasible approach, the thickness of the prepreg laminate should be slightly greater than the target thickness of the structural member. The thickness of the prepreg laminate can be 0.15-1.2 mm, for example, 0.15 mm, 0.3 mm, 0.5 mm, 0.8 mm, 1.0 mm, 1.2 mm, etc.

[0041] In one feasible approach, a rough 2D outline pattern of the structural component can be obtained by unfolding the 3D (3-dimension) drawing of the structural component into 2D (2-dimension) shape. Then, the structural component is processed and tested based on the 2D outline pattern. The 2D outline pattern is iteratively optimized based on the processing and test results until a 2D outline pattern that meets the requirements is obtained, which serves as the cutting drawing for the structural component.

[0042] Optionally, the step of separating each of the segmented mold cores from each of the non-metallic fiber prepregs and then joining the second integral mold core with the first integral mold core includes: Step A10: Separate each of the segmented mold cores from the prepreg laminate block, and then mold the second whole mold core with the first whole mold core to obtain the test block; Step A20: Detect whether the test block has integrity defects, wherein the integrity defects include at least one of excess material defects and insufficient material defects; Step A30: If it is determined that the test block does not have any integrity defects, the step of transferring the first and second integral mold cores to the molding mold frame and curing the preform to obtain the structural component is performed. Step A40: If it is determined that the test block has integrity defects, optimize the preset cutting drawing and return to the step of obtaining at least one non-metallic fiber prepreg.

[0043] In this embodiment, it should be noted that before the formal processing of the structural component, the cutting drawings used in the processing can be determined through processing tests. The cutting drawings initially used in the processing test stage can be obtained by 2D unfolding based on the 3D drawings of the structural component.

[0044] For example, steps A10 to A40 include: in the processing and testing stage, after the first molding preforming, the segmented mold cores and the prepreg laminates can be separated by applying tension, blowing air, etc., and then the second whole mold core and the first whole mold core are molded together. The mold temperature and pressure of the mold core are controlled so that the prepreg laminates in the mold cavity soften under a certain mold temperature and pressure and fully adhere to the cavity wall, forming a test block within the mold cavity. The appearance structure of the test block is then checked for integrity defects. If the test block is determined to have no integrity defects, it is identified as a preform and can be used for subsequent curing and molding operations. If the test block is determined to have integrity defects, the preset cutting drawing is optimized to obtain a new optimized cutting drawing, and the step of obtaining at least one non-metallic fiber prepreg is returned to be executed, and the processing and testing are repeated until a test block without integrity defects is obtained. The integrity defects include at least one of excess material defects and insufficient material defects.

[0045] Optionally, the core of at least one of the first monolithic mold core, each of the segmented mold cores, and the second monolithic mold core matches the net dimension end face boundary of the structural component.

[0046] In this embodiment, the core of at least one of the first integral mold core, each of the segmented mold cores, and the second integral mold core matches the net dimension end face boundary of the structural component. Thus, after processing the test block, it is possible to visually and quickly determine whether the test block has integrity defects. If at least part of the edge area of ​​the test block exceeds the core boundary, it indicates that there is a material over-material defect. If at least part of the edge area of ​​the test block does not reach the core boundary, it indicates that there is a material under-material defect.

[0047] In one feasible approach, during the compression molding preforming stage, due to factors such as irregular shapes of structural components, requirements for the front and back of structural components, and incomplete alignment between the non-metallic fiber prepreg and the mold cavity in the mold core, the position of the prepreg laminate may be inaccurate or prone to movement when placed in the mold core. To address this, during the cutting process, the prepreg laminate can be machined with at least two positioning holes, and corresponding positioning pins are also provided in the mold core. Therefore, when placing the prepreg laminate in the mold core, the positioning holes should match the positioning pins to achieve positioning of the prepreg laminate. After positioning, the positioning pins can be retracted before heating and pressurizing the prepreg laminate for compression molding preforming. This prevents the positioning pins from pulling the material block during compression molding preforming, which could lead to appearance or structural defects in the product. Furthermore, after compression molding preforming, at least two edges of the process material used for positioning can be removed.

[0048] In one feasible approach, the first monolithic mold core is as follows: Figure 2 As shown, the segmented mold core is as follows Figure 3 As shown, the second integral mold core is as follows Figure 3As shown, the first integral mold core 10 is provided with a protrusion 11, and the second integral mold core 30 is provided with a second recess 31 that matches the protrusion on the first integral mold core 10. The protrusion 11 on the first integral mold core 10 can cooperate with the second recess 31 on the second integral mold core 30 to form a mold cavity. In this embodiment, the segmented mold core includes a first segmented mold core 21 and a second segmented mold core 22. The first segmented mold core 21 is provided with a first recess 211 that matches the protrusion on the first integral mold core 10, and a mating hole 213 that matches the second segmented mold core 22. The second segmented mold core 22 can be separated from or movably connected to the first segmented mold core 21. The protrusion 11 on the first integral mold core 10 can cooperate with the first recess 211 on the first segmented mold core 21 and the second segmented mold core 22 to form a mold cavity. The step of placing each of the non-metallic fiber prepregs into the first integral mold core, and then separately closing at least one segmented mold core with the first integral mold core to perform the first compression molding preformation of each of the non-metallic fiber prepregs includes: placing each of the non-metallic fiber prepregs onto the protrusion 11 of the first integral mold core 10; firstly closing the first segmented mold core 21 with the first integral mold core 10; then pressing the second segmented mold core 22 into the non-metallic fiber prepreg in the mold cavity through the mating hole 213 on the second segmented mold core 22, thereby achieving the first compression molding preformation of the non-metallic fiber prepregs in two steps. Then, removing the first segmented mold core 21 and the second segmented mold core 22, and closing the second integral mold core 30 with the first integral mold core 10, thereby performing the second compression molding preformation of each of the non-metallic fiber prepregs. The first integral mold core may also be provided with two positioning pins 12 for positioning the non-metallic fiber prepreg placed thereon. The first segmented mold core 21 may also be provided with cutting holes 212 corresponding to the positioning pins 12 on the first integral mold core for cutting off the process material edge used for positioning on the non-metallic fiber prepreg.

[0049] Step S30: Separate each of the segmented mold cores from each of the non-metallic fiber prepregs, and join the second whole mold core with the first whole mold core to perform a second molding preform on each of the non-metallic fiber prepregs to obtain a preform. In this embodiment, it should be noted that after the first molding preforming, the non-metallic fiber prepregs can be pressed into the desired appearance and shape of the structural component. However, gaps inevitably exist between the segmented mold cores, which will inevitably affect the appearance of the material blocks and reduce the surface flatness during the first molding preforming process. Therefore, after curing, a second molding preforming can be used to modify the surface and obtain a preform with excellent appearance.

[0050] For example, step S30 includes: after the first molding preforming, the segmented mold cores and the non-metallic fiber prepregs can be separated by applying tension, blowing air, etc., and then the second whole mold core and the first whole mold core are molded together. The mold temperature and pressure of the mold core are controlled so that the non-metallic fiber prepreg in the mold cavity softens under a certain mold temperature and pressure and fully adheres to the cavity wall, forming a preform with excellent appearance within the mold cavity. The mold temperature and pressure should soften the non-metallic fiber prepreg without completely curing it. The specific temperature and pressure can be determined based on actual conditions or experimental test results, and this embodiment does not impose any limitations on this.

[0051] Optionally, the mold temperature for the second molding preforming is 25-100℃; the pressure for the second molding preforming is 0.1-0.5MPa.

[0052] In this embodiment, if the mold temperature for the second molding preforming is too low, the non-metallic fiber prepreg will be difficult to soften and will lack fluidity. If the mold temperature for the second molding preforming is too high, the non-metallic fiber prepreg will cure too quickly, easily leading to defects such as fiber accumulation and wrinkles. Therefore, the mold temperature for the second molding preforming is determined to be 25-100℃, for example, 25℃, 40℃, 50℃, 60℃, 70℃, 80℃, 90℃, 100℃, etc. The pressure of the second molding preforming is slightly higher than that of the first molding preforming. This helps to expel gas from the non-metallic fiber prepreg and corrects appearance defects caused by the first molding preforming. However, if the pressure is too high, the preform is prone to deformation and defects. Therefore, the pressure of the second molding preforming is determined to be 0.1-0.5MPa, for example, 0.1MPa, 0.3MPa, 0.5MPa, etc.

[0053] In one feasible approach, the mold core can be a quick-change mold core, which is a mold core that can be separated from the mold frame and thus quickly replaced. The quick-change mold core can move between different mold frames, thereby enabling compression molding and curing molding to be performed separately on different mold frames.

[0054] In one feasible approach, after placing each of the non-metallic fiber prepregs into the mold cavity of the mold core, the mold core containing the non-metallic fiber prepregs is moved to a preforming mold frame. The mold core is heated and pressurized by the preforming mold frame, causing the non-metallic fiber prepregs within the mold cavity to soften under heat and pressure, fully adhering to the cavity wall and forming a preform with excellent appearance within the mold cavity. Then, the mold core and the preform with excellent appearance formed therein are transferred together from the preforming mold frame to the forming mold frame, where the preform is cured to obtain the structural component. In this way, the preforming mold frame and the forming mold frame can maintain a constant temperature, and the compression molding and curing processes can be quickly achieved simply by transferring the mold core. Compared to performing compression molding and curing on the same mold frame, this effectively saves the temperature adjustment time required for each step from the compression molding temperature to the curing temperature and from the curing temperature to the preforming temperature, resulting in higher production efficiency and facilitating mass production.

[0055] Optionally, before the step of separating each of the segmented mold cores from each of the non-metallic fiber prepregs, the method further includes: Cool down each of the segmented mold cores.

[0056] In this embodiment, after the first molding preforming, each of the segmented mold cores is cooled down. As the temperature of the segmented mold cores decreases, the adhesion between the segmented mold cores and the non-metallic fiber prepreg decreases, making it easier to separate them from each of the non-metallic fiber prepregs.

[0057] Optionally, the surface of the segmented mold core that is in contact with each of the non-metallic fiber prepregs is provided with a ventilation structure; The step of separating each of the segmented mold cores from each of the non-metallic fiber prepregs includes: Step S31: Compressed gas is introduced into the ventilation structure to separate each of the segmented mold cores from each of the non-metallic fiber prepregs.

[0058] In this embodiment, it should be noted that the surface of the segmented mold core that is in contact with each of the non-metallic fiber prepregs is provided with a ventilation structure. The ventilation structure refers to a structure that allows gas to be introduced between each of the non-metallic fiber prepregs and the cavity wall of the segmented mold core, including air holes, ventilation grooves, etc.

[0059] For example, step S31 includes: after the first molding preforming, introducing compressed gas into the ventilation structure, applying pressure to each of the non-metallic fiber prepregs through the compressed gas, thereby causing each of the segmented mold cores to separate from each of the non-metallic fiber prepregs.

[0060] Step S40: Transfer the first and second integral mold cores to the molding mold frame, and solidify the preform to obtain a structural component.

[0061] In this embodiment, it should be noted that the curing molding refers to a process in which the temperature is controlled above the curing temperature of the resin in the preform, so that the preform is cured in the mold cavity.

[0062] For example, step S30 includes: transferring the first integral mold core, the second integral mold core, and the preform in the mold cavity together into a molding mold frame; controlling the curing temperature and curing pressure of the mold core, so that the preform in the mold cavity is cured under a certain curing temperature and curing pressure, achieving the excellent appearance obtained after the second molding pre-forming; and after curing, cooling and demolding to obtain a structural component with an excellent appearance. The curing temperature and curing pressure should ensure the preform is cured, and can be determined based on actual conditions or experimental test results; this embodiment does not impose any limitations on this.

[0063] In one feasible approach, the cured material can be cooled to below 60°C for demolding.

[0064] Optionally, the curing temperature is 100-200℃; the curing pressure is 1-20MPa; and the curing cycle is 3-10min.

[0065] In this embodiment, the curing temperature for curing is 100-200℃, such as 100℃, 120℃, 150℃, 170℃, 200℃, etc.; the curing pressure for curing is 1-20MPa, such as 1MPa, 3MPa, 5MPa, 10MPa, 15MPa, 20MPa, etc.; and the curing cycle for curing is 3-10min, such as 3min, 5min, 8min, 10min, etc.

[0066] In one feasible approach, after the steps of transferring the mold core to the molding mold frame and curing the preform to obtain the structural component, the structural component can be further polished to remove burrs. Due to the mold gap, a small amount of resin may overflow from the end face of the structural component; these burrs can be removed by manual or automatic polishing after demolding.

[0067] In this embodiment, by obtaining at least one non-metallic fiber prepreg, placing each of the non-metallic fiber prepregs into a first monolithic mold core, and then performing a step-by-step molding process with at least one segmented mold core to preform each of the non-metallic fiber prepregs using compression molding, the step-by-step compression molding of the non-metallic fiber prepregs is achieved. For the processing of structural components with complex structures or large deformations, the defect rate of one-time molding is high, which can easily lead to breakage, and the stability and reliability of the processed structure are low. By using the step-by-step compression molding method, the pressure applied to the non-metallic fiber prepregs can be gradually increased, avoiding structural damage caused by applying excessive pressure at once. In this case, by separating each of the segmented mold cores from each of the non-metallic fiber prepregs, and then joining the second integral mold core with the first integral mold core, the non-metallic fiber prepregs are subjected to a second molding preforming to obtain a preform. This achieves a second covering of the non-metallic fiber prepregs, which allows the non-metallic fiber prepregs to adhere to the inner wall of the mold cavity in the mold core, resulting in a better appearance. Furthermore, by transferring the first and second integral mold cores to the molding mold frame, the preform is cured and molded to obtain a structural component. This achieves the curing of the covered metal fiber prepregs, resulting in a structural component with an excellent appearance. This method enables the net-size forming of structural components with complex curved surfaces or structures, resulting in structural components with high surface quality and high dimensional accuracy. It eliminates the need for two high-cost processes: CNC machining and surface repair. The processing technology is simpler, lower in cost, and more efficient. This solves the technical problems of high cost, low yield, and low efficiency in processing structural components for AR / VR devices using carbon fiber as raw material in related technologies, and provides a low-cost, high-yield, and high-efficiency method for net-size forming of structural components.

[0068] Furthermore, this application embodiment also provides a structural component, which is applied to a head-mounted display device and is manufactured using the structural component manufacturing method described above.

[0069] The structural component provided in this application solves the technical problems of high cost, low yield, and low efficiency in processing structural components for AR / VR devices using carbon fiber as raw material in related technologies. Compared with related technologies, the beneficial effects of the structural component provided in this embodiment are the same as the beneficial effects of the processing method of the structural component in the above embodiments, and will not be repeated here.

[0070] Furthermore, the present invention also provides a head-mounted display device, the head-mounted display device including the structural components described above.

[0071] In one feasible approach, the head-mounted display device can be a head-mounted display device, a smart wearable device, such as VR / AR glasses, VR / AR helmets, etc.

[0072] The head-mounted display device provided in this application solves the technical problems of high cost, low yield, and low efficiency in processing structural components of AR / VR devices using carbon fiber as raw material in related technologies. Compared with related technologies, the beneficial effects of the head-mounted display device provided in this embodiment are the same as the beneficial effects of the structural components in the above embodiments, and will not be repeated here.

[0073] The above are merely preferred embodiments of this application and do not limit the patent scope of this application. Any equivalent structural or procedural transformations made using the content of this application's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent scope of this application.

Claims

1. A method for processing a structural component, characterized in that, The structural component is used in a head-mounted display device, and the processing method of the structural component includes the following steps: Obtain at least one non-metallic fiber prepreg; Each of the non-metallic fiber prepregs is placed into the first integral mold core, and at least one segmented mold core is joined with the first integral mold core in stages to perform the first molding preformation on each of the non-metallic fiber prepregs, wherein the pressure of the first molding preformation is 0.05-0.1MPa; Separate each of the segmented mold cores from each of the non-metallic fiber prepregs, and then mold the second integral mold core with the first integral mold core. Perform a second molding preforming on each of the non-metallic fiber prepregs to obtain a preform, wherein the pressure of the second molding preforming is 0.1-0.5 MPa. The first and second integral mold cores are transferred to the molding mold frame, and the preform is cured and molded to obtain a structural component.

2. The processing method for the structural component as described in claim 1, characterized in that, Before the step of separating each of the segmented mold cores from each of the non-metallic fiber prepregs, the method further includes: Cool down each of the segmented mold cores.

3. The processing method for the structural component as described in claim 1, characterized in that, The surface of the segmented mold core that is in contact with each of the non-metallic fiber prepregs is provided with a ventilation structure; The step of separating each of the segmented mold cores from each of the non-metallic fiber prepregs includes: Compressed gas is introduced into the ventilation structure to separate each of the segmented mold cores from each of the non-metallic fiber prepregs.

4. The processing method for the structural component as described in claim 1, characterized in that, The steps of placing each of the non-metallic fiber prepregs into the first integral mold core, and sequentially joining at least one segmented mold core with the first integral mold core to perform the first compression molding preforming of each of the non-metallic fiber prepregs include: Each of the aforementioned non-metallic fiber prepregs is laid up and cut according to a preset cutting drawing to obtain a prepreg stack; The prepreg laminate is placed into the first integral mold core, and at least one segmented mold core is joined with the first integral mold core in stages to perform the first molding preforming of the prepreg laminate.

5. The processing method for the structural component as described in claim 4, characterized in that, The step of joining the second integral mold core with the first integral mold core to perform a second molding preforming on each of the non-metallic fiber prepregs to obtain the preform includes: Separate each of the segmented mold cores from the prepreg laminate, and then combine the second whole mold core with the first whole mold core to obtain a test block; The test block is tested for integrity defects, wherein the integrity defects include at least one of excess material defects and insufficient material defects; If it is determined that the test block does not have any integrity defects, the test block is identified as a preform. If it is determined that the test block has integrity defects, the preset cutting drawing is optimized, and the process returns to the step of obtaining at least one non-metallic fiber prepreg.

6. The processing method for the structural component as described in claim 4, characterized in that, The core of at least one of the first monolithic mold core, each of the segmented mold cores, and the second monolithic mold core matches the net dimension end face boundary of the structural component.

7. The processing method for the structural component as described in claim 1, characterized in that, The non-metallic fiber prepreg comprises non-metallic fibers and a resin matrix; The non-metallic fibers include at least one of carbon fiber, glass fiber, ceramic fiber, aramid fiber, and polyimide fiber. The resin in the resin matrix includes at least one of epoxy resin, epoxy vinyl resin, phenolic resin, and polyurethane resin.

8. The processing method for the structural component as described in claim 1, characterized in that, The temperature of the mold for the first molding preforming is 25-100℃.

9. The processing method for the structural component as described in claim 1, characterized in that, The mold temperature for the second molding preforming is 25-100℃.

10. The processing method of the structural component as described in claim 1, characterized in that, The curing temperature for the curing process is 100-200℃; the curing pressure is 1-15MPa; and the curing cycle is 3-10min.

11. The processing method of the structural component as described in claim 1, characterized in that, The wall thickness of the segmented mold core is 5-20mm.

12. A structural component, characterized in that, The structural component is used in a head-mounted display device, and the structural component is manufactured using the processing method of any one of claims 1-11.

13. A head-mounted display device, characterized in that, The head-mounted display device includes the structural component as described in claim 12.

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