A complex special-shaped carbon fiber shell forming die and a forming method thereof

Abstract

The application discloses a complex special-shaped carbon fiber shell forming die and a forming method thereof, and relates to the technical field of shell forming dies.The complex special-shaped carbon fiber shell forming die comprises a carbon fiber shell and a die body for forming the carbon fiber shell, and the die body comprises an upper die and a lower die, a forming cavity is formed between the lower die and the upper die, the lower die comprises a base, a first side plate, a second side plate, a first convex block and a second convex block, an arc surface is formed at the bottom of the upper die, a pressing plate is fixedly installed at the top of the upper die, the pressing plate is provided with a pressing hole, a pressing valve is fixedly installed on the pressing plate, and the pressing valve is connected with a pressure source.The lower die is composed of a plurality of die parts, the manufacturing difficulty is reduced, and material loss is reduced compared with the integral die;the lower die can complete direct forming of the shell, the upper die only needs to play a sealing role, and processing is simple;the lower die can be disassembled, after the die parts constituting the lower die are disassembled in sequence after the shell forming is completed, the formed shell can be demolded, and the yield is improved.

Description

Technical Field

[0001] This invention relates to the field of shell molding technology, specifically to a complex irregular carbon fiber shell molding die and its molding method. Background Technology

[0002] Currently, when factories produce carbon fiber shells, they usually use molds to form them in one piece under pressure. These molds usually consist of two parts to facilitate workers to lay the material inside the mold to form the shell.

[0003] However, for complex irregular carbon fiber shells with high molding strength requirements, the mold making for the shell is quite troublesome because the shape of the shell to be formed is relatively complex. At the same time, it is also necessary to meet the requirement of integral molding of the shell with high strength requirements, which leads to high mold processing costs.

[0004] However, even with the high cost of manufacturing complex molds, the complex irregular carbon fiber shells are still prone to cracking during demolding, resulting in a low yield. Summary of the Invention

[0005] The purpose of this invention is to provide a molding die for a complex irregular carbon fiber shell and a molding method thereof, so as to solve the problems mentioned in the background art of high cost of manufacturing molds for complex shells with high strength integral molding and difficulty in demolding after molding.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] This invention provides a molding die for a complex irregular carbon fiber shell, comprising a carbon fiber shell and a die body for molding the carbon fiber shell. The die body includes an upper die and a lower die, wherein:

[0008] The lower mold and the upper mold form a cavity for laying carbon fiber prepreg. The lower mold includes a base, a first side plate and a second side plate symmetrically assembled on both sides of the base, and a first convex block and a second convex block symmetrically assembled on the base.

[0009] The bottom of the upper mold forms an arc-shaped surface that matches the top of the lower mold. A pressure plate is fixedly installed on the top of the upper mold. A pressure hole communicating with the cavity is opened through the middle of the pressure plate. A pressure valve is fixedly installed on the pressure plate. A pressure source is connected to the external pressure valve.

[0010] Furthermore, the base has a first mounting groove adapted to the first side plate and a second mounting groove adapted to the second side plate respectively on the opposite side wall. The first side plate and the second side plate are fixedly assembled in the first mounting groove and the second mounting groove by bolts.

[0011] Furthermore, a third mounting groove adapted to the first protrusion is provided on the side wall of the first mounting groove, and a fourth mounting groove adapted to the first protrusion is provided on the side wall of the second mounting groove.

[0012] Furthermore, both the first and second convex blocks are provided with positioning keys at their bottoms, and both the third and fourth mounting slots are provided with positioning slots adapted to the positioning keys. The positioning keys are embedded in the positioning slots to fix the first and second convex blocks.

[0013] Furthermore, the carbon fiber shell includes an outer shell, a first baffle is provided inside the outer shell, a second baffle is symmetrically provided on one side of the first baffle, and a support frame is symmetrically provided on the other side of the first baffle.

[0014] Furthermore, a sealing ring is installed on the arc-shaped surface.

[0015] A molding method for a complex irregular carbon fiber shell mold includes the following steps:

[0016] S1. The first side plate and the second side plate are fixedly installed in the first and second mounting slots on both sides of the base by bolts. The first convex block and the second convex block are fixed in the third and fourth mounting slots respectively by embedding positioning keys into the positioning slots, thereby assembling the lower mold.

[0017] S2. Lay the carbon fiber prepreg to be formed in the area of ​​the cavity located in the lower mold, so that the carbon fiber prepreg is initially attached to the inner wall of the cavity. The carbon fiber prepreg plays a sealing role and seals the gaps in the lower mold.

[0018] S3. The upper mold and the lower mold are fixedly connected by bolts. The sealing ring on the arc surface of the upper mold abuts against the top of the lower mold to form a sealed cavity.

[0019] S4. The pressure source injects positive pressure gas into the cavity through the pressure valve and pressure port, which further makes the carbon fiber prepreg fit tightly against the inner wall of the cavity to complete the molding of complex irregular carbon fiber shells.

[0020] Compared with existing technologies, one or more of the above technical solutions have the following beneficial effects:

[0021] This invention provides a complex irregular carbon fiber shell molding die and its molding method:

[0022] First, the lower mold is assembled from multiple mold parts. Compared with the overall mold, the manufacturing difficulty of each mold part is reduced, and the material loss generated during the manufacturing process is reduced.

[0023] Second, the lower mold can directly form the shell, while the upper mold only needs to play a sealing role. Therefore, the upper mold does not have the shell shape of the shell being formed, which simplifies the process and saves materials and processing costs.

[0024] Third, the lower mold is changed from a single mold to multiple detachable mold parts. After the irregular carbon fiber shell is formed in the mold, the mold parts that make up the lower mold are disassembled one by one, so that the formed shell can be demolded, and the yield rate is improved.

[0025] Fourth, no sealing treatment is required when assembling the lower mold. When laying the carbon fiber prepreg, the overlapping range between two adjacent pieces of material is ≤5mm by designing the laying method, and the material is filled with fine fragments to achieve a sealing effect.

[0026] 5. During the shell molding process, the resin inherent in the T700 or T300 carbon fiber prepreg is used to directly bond and fix the baffle to the shell, eliminating the need for secondary bonding or any form of physical connection of the internal first baffle, second baffle, and support frame. Attached Figure Description

[0027] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0028] In the attached diagram:

[0029] Figure 1 This is a schematic diagram of the structure of the mold body provided by the present invention;

[0030] Figure 2 This is a schematic diagram of the upper mold provided by the present invention;

[0031] Figure 3 This is a schematic diagram of the structure of the lower mold provided by the present invention;

[0032] Figure 4 This is a schematic diagram of the carbon fiber shell provided by the present invention;

[0033] Figure 5 A top view of the carbon fiber shell provided by the present invention.

[0034] In the picture:

[0035] 100. Carbon fiber shell;

[0036] 110. First baffle; 120. Second baffle; 130. Support frame;

[0037] 200. Mold body;

[0038] 210. Upper mold; 211. Pressure plate; 212. Pressure hole;

[0039] 220. Lower mold; 230. Base; 231. First mounting slot; 232. Second mounting slot; 233. Third mounting slot; 234. Fourth mounting slot; 240. First side plate; 250. Second side plate; 260. First convex block; 270. Second convex block. Detailed Implementation

[0040] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present application, and not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative effort should fall within the scope of protection of the present application.

[0041] Currently, when producing carbon fiber shells 100, factories typically use molds to form them in one piece under pressure. These molds usually consist of two parts to facilitate workers laying the material inside the mold to form the shell.

[0042] However, for complex irregular carbon fiber shells 100 with high molding strength requirements, the mold making for the shell is quite troublesome because the shape of the shell to be formed is relatively complex. At the same time, it is also necessary to meet the requirement of integral molding of the shell with high strength requirements, which leads to high mold processing costs.

[0043] However, even with the high cost of manufacturing complex molds, the complex irregular carbon fiber shells are prone to breakage during demolding due to their uneven and complex shape, resulting in a low yield.

[0044] To resolve the above issues, please refer to [link / reference]. Figures 1 to 5 The present invention provides a complex irregular carbon fiber shell molding die, including a carbon fiber shell 100 and a mold body 200 for molding the carbon fiber shell 100. The carbon fiber shell 100 includes an outer shell, a first baffle 110 is provided inside the outer shell, a second baffle 120 is symmetrically provided on one side of the first baffle 110, and a support frame 130 is symmetrically provided on the other side of the first baffle 110. The mold body 200 includes an upper mold 210 and a lower mold 220.

[0045] Please see Figures 1 to 3A cavity for laying carbon fiber prepreg is formed between the lower mold 220 and the upper mold 210. The bottom of the upper mold 210 forms an arc-shaped surface that matches the top of the lower mold 220. A sealing ring (not shown) is installed on the arc-shaped surface. Before molding, the upper mold 210 and the lower mold 220 are fixedly connected by bolts. The sealing ring can seal the gap between the upper mold 210 and the lower mold 220, so that a closed space is formed in the cavity. A pressure plate 211 is fixedly installed on the top of the upper mold 210 by bolts. A pressure hole 212 communicating with the cavity is opened through the middle of the pressure plate 211. A pressure valve (not shown) is installed on the pressure plate 211. The upper mold 210 is connected to a pressure source (not shown) through the pressure valve. The pressure source can be an air compressor. After the upper mold 210 and the lower mold 220 are fixedly connected by bolts, the air compressor is started and positive pressure gas is injected into the cavity through the pressure valve and the pressure hole 212, so that the laid carbon fiber prepreg is tightly attached to the cavity to complete the molding of the carbon fiber shell 100.

[0046] Please see Figure 3 The lower mold 220 is composed of multiple mold parts, including a base 230, a first side plate 240 and a second side plate 250 symmetrically assembled on both sides of the base 230, and a first convex block 260 and a second convex block 270 symmetrically assembled on the base 230. The side walls on opposite sides of the base 230 are respectively provided with a first mounting groove 231 adapted to the first side plate 240 and a second mounting groove 232 adapted to the second side plate 250. The first side plate 240 and the second side plate 250 are fixedly assembled in the first mounting groove 231 and the second mounting groove 232 by bolts. The side walls of the first side plate 240 and the second side plate 250 adjacent to each other can be laid with carbon fiber prepreg to form the outer wall of the shell.

[0047] The first mounting groove 231 has a third mounting groove 233 adapted to the first convex block 260 on its side wall, and the second mounting groove 232 has a fourth mounting groove 234 adapted to the first convex block 260 on its side wall. The bottom of the first convex block 260 and the second convex block 270 are provided with positioning keys. The third mounting groove 233 and the fourth mounting groove 234 are provided with positioning grooves adapted to the positioning keys. The positioning keys are embedded in the positioning grooves, so that the first convex block 260 and the second convex block 270 are fixed on the base 230.

[0048] The lower mold 220 is assembled from multiple mold parts. Compared with the overall mold, the manufacturing difficulty of each mold part is reduced, and the material loss generated during the manufacturing process is reduced.

[0049] The lower mold 220 can directly form the shell, while the upper mold 210 only needs to play a sealing role. Therefore, the upper mold 210 does not have the shell shape of the formed shell, which simplifies the process and saves materials and processing costs.

[0050] The lower mold 220 is transformed from a single mold into multiple detachable mold parts. After the irregular carbon fiber shell 100 is formed in the mold, the mold parts that make up the lower mold 220 can be disassembled in sequence to demold the formed shell, thereby improving the yield.

[0051] When assembling the lower mold 220, the first side plate 240 is first fixed on the assembly table. Then, the first convex block 260 and the second convex block 270 are installed into the third mounting groove 233 and the fourth mounting groove 234 in sequence. The first convex block 260 and the second convex block 270 are fixed by embedding the positioning key into the positioning groove. Then, the base 230 and the second side plate 250 are installed into the first mounting groove 231 and the second mounting groove 232 and fixed in place by bolts. In this way, the lower mold 220 is formed.

[0052] The lower mold 220 is an assembly of multiple mold parts with gaps at the joints. If rubber sealing products are used, it is easy to cause poor parallelism of the mold, which in turn leads to deviations in the size of the molded shell. If rubber is used for sealing, on the one hand, the rubber needs a certain amount of time to solidify, and on the other hand, it is inconvenient to disassemble when demolding the shell after it is formed.

[0053] To solve the above problems, the lower mold 220 in this application does not need to be sealed. Instead, a sealing effect is achieved by designing a laying method, in which T700 or T300 carbon fiber prepreg is laid and overlapped with each other. After the lower mold 220 is assembled, the workers lay carbon fiber prepreg for molding the shell on the inner wall of the cavity formed by the lower mold 220. The carbon fiber prepreg can seal the gaps at the connection positions of the various mold parts of the lower mold 220, thus achieving a sealing effect.

[0054] In order to achieve precise molding when forming complex irregular carbon fiber shell 100 structures, the shape of the carbon fiber prepreg needs to be precisely trimmed during the laying of T700 or T300 carbon fiber prepreg. In order to make the shell material distribution of complex shells uniform, an overlap method with an overlap range of ≤5mm is adopted between two adjacent pieces of material, and the two overlapping pieces of material have a fine fragmented structure. The fine fragmented structure can increase the contact area between the two pieces of material on the one hand, and reduce the overlap within a certain range on the other hand.

[0055] After the fabric is laid on the lower mold 220, the first baffle 110, the second baffle 120 and the support frame 130 are fixed in sequence in the cavity of the lower mold 220. During the shell molding process, the baffle is directly bonded to the shell by the resin of the T700 or T300 carbon fiber prepreg. There is no need to perform secondary bonding or any form of physical connection on the first baffle 110, the second baffle 120 and the support frame 130. The first baffle 110, the second baffle 120 and the support frame 130 are integrally formed with the shell, resulting in high structural strength and strong stability.

[0056] A molding method for a complex irregular carbon fiber shell mold includes the following steps:

[0057] S1. The first side plate 240 and the second side plate 250 are fixedly installed in the first mounting groove 231 and the second mounting groove 232 on both sides of the base 230 by bolts. The first convex block 260 and the second convex block 270 are fixed in the third mounting groove 233 and the fourth mounting groove 234 respectively by embedding positioning keys into the positioning groove, thereby assembling the lower mold 220.

[0058] S2. The carbon fiber prepreg to be formed is laid in the area of ​​the cavity located in the lower mold 220 according to the pre-defined laying method, so that the carbon fiber prepreg is initially attached to the inner wall of the cavity. After laying, the first baffle 110, the second baffle 120 and the support frame 130 are installed in the cavity. The carbon fiber prepreg plays a sealing role and seals the gaps in the lower mold 220. During the molding process, the resin of the carbon fiber prepreg itself will bond the first baffle 110, the second baffle 120 and the support frame 130 together to form a whole.

[0059] S3. The upper mold 210 and the lower mold 220 are fixedly connected by bolts. The sealing ring on the arc surface of the upper mold 210 abuts against the top of the lower mold 220, so that the cavity forms a sealed space, so that the carbon fiber shell 100 can be pressurized and formed.

[0060] S4. Start the air compressor and inject positive pressure gas into the cavity through the pressure valve and pressure port 212 to further make the laid carbon fiber prepreg fit tightly with the cavity, so as to complete the molding of the complex irregular carbon fiber shell 100.

[0061] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention can have various modifications and variations. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A molding method for a complex irregular carbon fiber shell molding die, comprising a carbon fiber shell (100) and a die body (200) for molding the carbon fiber shell (100), wherein the die body (200) comprises an upper die (210) and a lower die (220), wherein: The lower mold (220) and the upper mold (210) form a cavity for laying carbon fiber prepreg. The lower mold (220) includes a base (230), a first side plate (240) and a second side plate (250) symmetrically assembled on both sides of the base (230), and a first convex block (260) and a second convex block (270) symmetrically assembled on the base (230). The bottom of the upper mold (210) forms an arc-shaped surface that matches the top of the lower mold (220). A pressure plate (211) is fixedly installed on the top of the upper mold (210). A pressure hole (212) communicating with the cavity is opened through the middle of the pressure plate (211). A pressure valve is fixedly installed on the pressure plate (211). A pressure source is connected to the external pressure valve. The base (230) has a first mounting groove (231) adapted to the first side plate (240) and a second mounting groove (232) adapted to the second side plate (250) respectively on the opposite side wall. The first side plate (240) and the second side plate (250) are fixedly assembled in the first mounting groove (231) and the second mounting groove (232) by bolts. The first mounting groove (231) has a third mounting groove (233) adapted to the first protrusion (260) on its side wall, and the second mounting groove (232) has a fourth mounting groove (234) adapted to the first protrusion (260) on its side wall. The bottom of both the first convex block (260) and the second convex block (270) is provided with a positioning key, and the third mounting groove (233) and the fourth mounting groove (234) are both provided with positioning grooves adapted to the positioning key. The positioning key is embedded in the positioning groove to fix the first convex block (260) and the second convex block (270). The feature is that: Includes the following steps: S1. The first side plate (240) and the second side plate (250) are fixedly installed in the first mounting groove (231) and the second mounting groove (232) on both sides of the base (230) by bolts. The first convex block (260) and the second convex block (270) are fixed in the third mounting groove (233) and the fourth mounting groove (234) respectively by embedding the positioning key into the positioning groove, thereby assembling the lower mold (220). S2. The carbon fiber prepreg to be formed is laid in the area of ​​the cavity located in the lower mold (220), so that the carbon fiber prepreg is initially attached to the inner wall of the cavity. The carbon fiber prepreg plays a sealing role and seals the gap of the lower mold (220). S3. The upper mold (210) and the lower mold (220) are fixedly connected by bolts. The sealing ring on the arc surface of the upper mold (210) abuts against the top of the lower mold (220) to form a closed cavity. S4. The pressure source injects positive pressure gas into the cavity through the pressure valve and pressure hole (212) to further make the carbon fiber prepreg adhere tightly to the inner wall of the cavity, so as to complete the molding of the complex irregular carbon fiber shell (100). The lower mold (220) is made of overlapping T700 or T300 carbon fiber prepreg. After the lower mold (220) is assembled, carbon fiber prepreg for molding the shell is laid on the inner wall of the cavity formed by the lower mold (220). The carbon fiber prepreg can seal the gaps at the connection positions of the various mold parts of the lower mold (220) and play a sealing role.

2. The molding method of a complex irregular carbon fiber shell molding die according to claim 1, characterized in that: The carbon fiber shell (100) includes an outer shell, a first baffle (110) is provided inside the outer shell, a second baffle (120) is symmetrically provided on one side of the first baffle (110), and a support frame (130) is symmetrically provided on the other side of the first baffle (110).

3. The molding method of a complex irregular carbon fiber shell molding die according to claim 2, characterized in that: A sealing ring is installed on the arc-shaped surface.

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