A method for manufacturing composite door panels with embedded handles

Abstract

This invention discloses a method for manufacturing a composite door panel with an embedded handle in the field of composite product technology, including the following steps: 1) Prepreg cutting; 2) Mold preparation, cleaning the mold, and applying a release agent before use; 3) Foam pad preparation, making foam pads and wrapping them with release cloth; 4) Laying prepreg, laying the prepreg evenly on the mold, removing the prepreg in the handle slot area, marking the mold lines corresponding to the handle slot area, placing the foam pad in the designated area after laying, and then continuing to lay prepreg on the mold and covering the foam pad; 5) Curing, curing in an autoclave according to the curing curve after laying, cooling to room temperature after curing, and demolding after a preset time; 6) Demolding, removing the middle foam after demolding to obtain a composite door panel with an embedded handle. This invention reduces the weight of the door panel, and the handle on the door panel is directly formed on the door panel without subsequent assembly, ensuring the integrity, sealing and reliability of the door panel.

Description

Technical Field

[0001] This invention relates to the field of composite material products technology, and in particular to a method for manufacturing composite material door panels. Background Technology

[0002] With the development of technology, the demand for weight reduction in ships is increasing. Composite materials used in ship structures can reduce weight by 20-30%. Carbon fiber reinforced materials are a landmark product in the field of composite materials, possessing advantages such as anisotropy (designable), high specific strength, high specific modulus, corrosion resistance, and fatigue resistance. This gives them good design flexibility, enabling them to reduce structural weight while meeting stiffness, strength, and fatigue performance requirements. Currently, ship doors are mostly made of metal, which is too heavy to meet today's weight reduction requirements. While the material of the door panels can be changed, such as using composite materials, the door handles are still metal and are generally installed on the door panels mechanically with fasteners. This method can affect the sealing and strength of the door panels. Summary of the Invention

[0003] To address the shortcomings of existing technologies, this invention provides a method for manufacturing composite material door panels with embedded handles, solving the problem that existing door panels cannot simultaneously meet the requirements of weight reduction and facilitate handle installation.

[0004] The objective of this invention is achieved as follows: a method for manufacturing a composite material door panel with an embedded handle, comprising the following steps:

[0005] Step 1) Prepreg cutting: Cut the prepreg into pieces using an automatic cutting machine according to the preset dimensions;

[0006] Step 2) Mold preparation: Clean the mold, confirm that the mold surface is undamaged, finally confirm the engraving lines, and apply release agent before use;

[0007] Step 3) Prepare the foam pads, make the foam pads, and wrap them with release fabric;

[0008] Step 4) Lay the prepreg. Lay the prepreg on the mold. Remove the prepreg in the handle slot area along the mold lines. The mold lines are pre-cut in the mold and correspond to the handle slot area. After laying the prepreg, place the foam pad in the designated area, then continue to lay the prepreg on the mold and cover it with the foam pad.

[0009] Step 5) Curing: After the paving is completed, the paving is placed in an autoclave for curing according to the curing curve. After curing, the paving is cooled to room temperature and left for a preset time before demolding.

[0010] Step 6) Demolding: After the product is demolded, remove the middle foam to obtain a composite material door panel with an embedded handle.

[0011] As a preferred technical solution of the method for manufacturing a composite door panel with an embedded handle according to the present invention, in step 2), the mold is a concave mold, and the concave mold includes a first plane and a second plane, and the embedded handle is formed between the first plane and the second plane.

[0012] As a preferred technical solution of the method for manufacturing a composite door panel with an embedded handle according to the present invention, the foam pad includes an outer arc surface and an inner arc surface. The outer arc surface and the inner arc surface are connected by four planes. The four planes include an upper plane that mates with a first plane, a lower plane that mates with a second plane, and two side planes. The shape of the foam pad is the shape of the handle groove hole.

[0013] As a preferred technical solution of the method for manufacturing a composite material door panel with an embedded handle according to the present invention, step 4) specifically includes:

[0014] Step 4-1) Lay a layer of prepreg on the mold, and remove the prepreg in the handle slot area along the mold markings;

[0015] Step 4-2) Then, prepreg is laid on the inner arc surface of the foam pad so that when the foam pad is placed in the mold, the prepreg laid on the inner arc surface of the foam pad is in close contact with the prepreg at the joint of the first plane and the second plane.

[0016] Step 4-3) After the prepreg is laid, place the foam pad with prepreg in the handle groove area, then continue to lay the prepreg on the mold and cover the foam pad.

[0017] As a preferred technical solution of the method for manufacturing composite door panels with embedded handles according to the present invention, in step 4-3), each layer of prepreg overlaps by 10±1mm, and the overlap areas of different layers of prepreg are staggered by 100±5mm. The thickness of the flange is thicker than the four sides of the composite door, and the excess thickness is supplemented in the middle of the laying in a reinforcing manner. Each layer of laying covers the allowance line.

[0018] Compared with the prior art, the beneficial effects of the present invention are as follows: the present invention is made of composite materials, which reduces the weight of the door panel. At the same time, the handle on the door panel is directly formed on the door panel and does not require subsequent assembly, thus ensuring the integrity, sealing and reliability of the door panel. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0020] Figure 1 This is a flowchart of the present invention.

[0021] Figure 2 This is a schematic diagram of the composite material door panel structure obtained by the present invention.

[0022] Figure 3 This is a schematic diagram of the mold structure used in this invention.

[0023] Figure 4 This is a schematic diagram of the foam pad structure used in this invention.

[0024] Figure 5 Schematic diagram of the prepreg application of the present invention Figure 1 .

[0025] Figure 6 Schematic diagram of the prepreg application of the present invention Figure 2 .

[0026] Figure 7 Schematic diagram of the prepreg application of the present invention Figure 3 .

[0027] Figure 8 Schematic diagram of the prepreg application of the present invention Figure 4 .

[0028] Among them, 100 is a composite material door panel, 101 is a door flange, 102 is a door panel, 103 is a handle, 200 is a mold, 201 is a first plane, 202 is a second plane, 203 is a third plane, 204 is a side, 300 is a foam pad, 301 is an outer arc surface, 302 is an inner arc surface, 303 is an upper plane, 304 is a lower plane, 305 is a side plane, and 400 is a prepreg. Detailed Implementation

[0029] 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.

[0030] like Figure 1 The method shown is for manufacturing a composite door panel with an embedded handle, such as Figure 2 As shown, the composite material door panel 100 structure includes a door flange 101, a door panel 102, and an embedded handle 103. The embedded handle 103 is integrated with the door panel 102. The manufacturing method includes the following steps:

[0031] Step 1) Cut the prepreg 400 into pieces. Cut the pieces into pieces using an automatic cutting machine according to the preset size. Create the cutting diagram for each unit using the CPD module of the Catia software and cut the pieces into pieces using an automatic cutting machine.

[0032] Step 2) Prepare mold 200, clean mold 200, and confirm that the mold surface of mold 200 is undamaged. Finally, confirm the scribe lines (it should be noted that the scribe lines are pre-machined on the mold and are not shown in the figure. The purpose of the scribe lines is to facilitate cutting. The scribe lines are clearly visible in single-layer prepreg). Apply release agent before use; Figure 3 As shown, mold 200 is a concave mold, which includes a first plane 201 and a second plane 202. An embedded handle 103 is formed between the first plane 201 and the second plane 202. Specifically, the concave mold also includes a third plane 203 and two side surfaces 204. The first plane 201 and the third plane 203 are connected via the second plane 202. The first plane 201 and the third plane 203 are connected to the door flange 101. The two side surfaces 204 of the concave mold, together with the first plane 201, the second plane 202, and the third plane 203, form the mounting groove of the concave mold. It should also be noted that when a new mold 200 arrives at the factory, the oil seal of the mold 200 needs to be removed (after cleaning the tooling with gasoline, it should be cleaned three times with acetone). A release agent needs to be applied before each use. A new mold 200 needs to be wiped 8-10 times, with an interval of 15 minutes between each wipe. A used mold 200 only needs to be wiped 3 times.

[0033] Step 3) Prepare foam pad 300: Make foam pad 300 and wrap it with release fabric; as shown Figure 4 As shown, the foam pad 300 includes an outer arc surface 301 and an inner arc surface 302. The outer arc surface 301 and the inner arc surface 302 are connected by four planes. The four planes include an upper plane 303 that mates with the first plane 201, a lower plane 304 that mates with the second plane 202, and two side planes 305. The shape of the foam pad 300 is the shape of the groove of the handle 103.

[0034] Step 4) Laying the prepreg 400, including:

[0035] Step 4-1) as Figure 5-6 As shown, a layer of prepreg 400 is laid on the mold 200, and the prepreg 400 in the slot area of ​​the handle 103 is removed along the scribe line of the mold 200.

[0036] Step 4-2) Figure 7 As shown, prepreg is then laid on the inner arc surface 302 of the foam pad 300, so that when the foam pad 300 is placed in the mold 200, the prepreg laid on the inner arc surface 302 of the foam pad 300 is closely bonded to the prepreg at the joint of the first plane 201 and the second plane 202.

[0037] Step 4-3) as Figure 8 As shown, after the prepreg 400 is laid, the foam pad 300 with prepreg 400 is placed in the slot area of ​​the handle 103. Then, the prepreg 400 is laid on the mold 200, and the foam pad 300 is covered. Each layer of prepreg 400 overlaps by 10±1mm, and the overlap areas of different layers of prepreg 400 are staggered by 100±5mm. The flange thickness is thicker than the four sides of the composite door. The excess thickness is supplemented in the middle of the laying in a reinforcement manner. Each layer covers the allowance line. It should be noted that, for ease of description, an appendix is ​​attached. Figure 5-8 The image only shows the paving of a portion of the area. In actual operation, the prepreg 400 is laid entirely within the mold 200.

[0038] Step 5) Curing: After the paving is completed, the paving is placed in an autoclave for curing according to the curing curve. After curing, the paving is cooled to room temperature and left for a preset time before demolding.

[0039] Step 6) Demolding: After the product is demolded, the middle foam is removed to obtain the composite material door panel 100 with embedded handle 103.

[0040] The above method can ultimately produce the following: Figure 2 The composite material door panel 100 shown; the composite door manufactured by the present invention reduces the installation of the door handle 103, saves steps, and saves labor costs; the composite door with embedded handle 103 manufactured by the present invention saves the space outward of the handle 103, which is advantageous in space-limited designs; the composite door with embedded handle 103 manufactured by the present invention can keep the handle 103 without disassembling it while meeting the shape requirements, thus improving efficiency.

[0041] The above description of the embodiments is 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 protection scope of the claims of the present invention.

Claims

1. A method for manufacturing a composite material door panel with an embedded handle, characterized in that, Includes the following steps: Step 1) Prepreg cutting: Cut the prepreg into pieces using an automatic cutting machine according to the preset dimensions; Step 2) Mold (200) preparation, cleaning the mold (200), confirming that the mold (200) surface is undamaged, finally confirming the engraving lines, and applying release agent before use; the mold (200) is a concave mold, the concave mold includes a first plane (201) and a second plane (202), and the embedded handle (103) is formed between the first plane (201) and the second plane (202); Step 3) Prepare foam pads, make foam pads and wrap them with release cloth; the foam pads include an outer arc surface (301) and an inner arc surface (302), the outer arc surface (301) and the inner arc surface (302) are connected by four planes, the four planes include the upper plane (303) that matches the first plane (201), the lower plane (304) that matches the second plane (202) and the two side planes (305), the shape of the foam pads is the shape of the handle groove hole; Step 4) Laying the prepreg: Lay the prepreg evenly on the mold (200), and remove the prepreg from the handle slot area along the engraving line of the mold (200). The engraving line of the mold (200) is pre-engraved in the mold (200) and corresponds to the handle slot area. After laying, place the foam pad in the designated area, and then continue to lay the prepreg on the mold (200) and cover it with the foam pad; specifically: Step 4-1) Lay a layer of prepreg on the mold (200) and remove the prepreg in the handle slot area along the engraving line of the mold (200); Step 4-2) Then, prepreg is laid on the inner arc surface (302) of the foam pad so that when the foam pad is placed in the mold (200), the prepreg laid on the inner arc surface (302) of the foam pad is closely attached to the prepreg at the joint of the first plane (201) and the second plane (202); Step 4-3) After the prepreg is laid, place the foam pad with prepreg in the handle groove area, then continue to lay the prepreg on the mold (200) and cover the foam pad; Step 5) Curing: After the paving is completed, the paving is placed in an autoclave for curing according to the curing curve. After curing, the paving is cooled to room temperature and left for a preset time before demolding. Step 6) Demolding: After the product is demolded, the middle foam pad is removed to obtain the composite material door panel (100) with the embedded handle (103).

2. The method for manufacturing a composite material door panel with an embedded handle according to claim 1, characterized in that, In step 4-3), each layer of prepreg overlaps by 10±1mm, and the overlap areas of different layers of prepreg are staggered by 100±5mm.

Images