Composite multi-part shaped busbar and method of forming same

Abstract

The present application relates to a kind of composite material multi-partition special-shaped collector ring and its forming method, composite material multi-partition special-shaped collector ring forming method includes to the structure is designed, and composite material multi-partition special-shaped collector ring is divided into integral skin and the multiple collector ring segments separated along the circumferential direction, one end of each collector ring segment has partition, the other end is open mouth, wherein the open end of one collector ring segment can be connected in the end of adjacent collector ring segment with partition.The collector ring segment core mould is used to make collector ring segment, after being punched on the partition of each collector ring segment obtained, it is assembled, the outer surface of assembled collector ring segment is coated with glue after pre-impregnated material is laid, after pre-impregnated material is laid, forming integral collector ring.The edge of the integral collector ring after forming is cut.This forming method realizes the forming of composite material multi-partition special-shaped collector ring, and the obtained composite material multi-partition special-shaped collector ring, overall weight is lighter, meet the lightweight demand.

Description

Technical Field

[0001] This invention relates to the field of composite material molding technology, and in particular to a composite material multi-partition irregular-shaped manifold ring, its molding method, and a manifold ring segment core mold. Background Technology

[0002] Currently, see Figures 1-3 As shown, the multi-partition irregular manifold ring 100 is mainly used for fluid confluence. It has an irregular curved surface structure and a relatively closed cavity 101 with multiple partitions 102. The partitions 102 are provided with confluence holes 103, which makes it impossible to process by general processing methods. Traditional processes often adopt metal 3D printing technology, but metal materials are heavy and difficult to meet the requirements of lightweighting. Summary of the Invention

[0003] The first objective of this invention is to provide a method for molding multi-partition irregular manifold rings made of composite materials.

[0004] The second objective of this invention is to provide a composite multi-partition irregular manifold ring that meets performance requirements and is relatively lightweight.

[0005] The third objective of this invention is to provide a mandrel mold for forming the mandrel segment of a composite multi-partition irregular mandrel.

[0006] To achieve the aforementioned first objective, in a first aspect, the present invention provides a method for molding a composite material multi-partition irregular-shaped manifold ring, comprising:

[0007] Partial design:

[0008] The composite multi-partition irregular bus ring is divided into an integral skin and multiple bus ring segments separated along the circumference. Each bus ring segment has a partition at one end and an open end at the other end. The open end of one bus ring segment can be fitted onto the partitioned end of an adjacent bus ring segment.

[0009] Prepreg is laid on the mandrel core mold, and the mandrel is made using a mandrel forming mold.

[0010] Drill holes in the partitions of each obtained bus loop segment;

[0011] Apply adhesive to the socketing area of ​​the punched busbar segment, and then assemble adjacent busbar segments by socketing them together.

[0012] After applying adhesive to the outer surface of the assembled bus ring section, prepreg is laid on top, and then the integral bus ring is formed.

[0013] The edges of the formed integral bus ring are trimmed.

[0014] Optionally, the bus loop section uses carbon fiber prepreg layup with a layup sequence of [(0, 90) / (±45)].n ; and / or

[0015] The integral skin uses carbon fiber prepreg and unidirectional prepreg layup, with the layup sequence being [(0, 90) / 0 / 45 / 90 / -45 / 0 / 0 / -45 / 90 / 45 / 0 / (0, 90)]. n The outermost and innermost layers are made of carbon fiber prepreg, while the middle layer is made of unidirectional prepreg.

[0016] Optionally, the individual busbar segments can be polished before assembly.

[0017] Optionally, the bus loop is formed using a thermal expansion molding die; and / or

[0018] The integral manifold is formed using a vacuum bag pressing process.

[0019] Optionally, the manifold core mold used for molding includes a metal occupant block, a polytetrafluoroethylene (PTFE) block, and a rubber core. The curvature of the PTFE block is consistent with that of the manifold segment to be molded. The rubber core covers the outside of the PTFE block and has a shape consistent with the cavity of the manifold segment to be molded. The PTFE block can be extracted from the rubber core. The metal occupant block is used to mold the end of the manifold segment with an open opening.

[0020] Optionally, when using a busbar forming mold to manufacture the busbar segment, a marking line is formed on the formed busbar segment.

[0021] Optionally, each bus ring segment is assembled by means of an adhesive bonding fixture, wherein the adhesive bonding fixture includes:

[0022] The base plate has through holes and positioning marks, the positioning marks being used for alignment with the marking lines;

[0023] The number of positioning blocks is the same as the number of busbar segments. Each positioning block is detachably mounted on the base plate and is distributed around the through holes at intervals. Each positioning block has the same curvature as the busbar segment to be positioned.

[0024] Optionally, when adjacent busbar segments are assembled together, the length of the splicing area is 15mm to 25mm.

[0025] To achieve the second objective mentioned above, in a second aspect, the present invention also provides a composite material multi-partition irregular-shaped bus ring, which is formed using a composite material multi-partition irregular-shaped bus ring forming method according to any of the implementation methods in the first aspect.

[0026] To achieve the third objective mentioned above, in a third aspect, the present invention also provides a mandrel for forming a multi-partition irregular busbar of composite material, comprising a metal occupant block, a polytetrafluoroethylene (PTFE) block, and a rubber core. The curvature of the PTFE block is consistent with that of the busbar segment to be formed. The rubber core covers the outside of the PTFE block and has a shape consistent with the cavity of the busbar segment to be formed. The PTFE block can be extracted from the rubber core. The metal occupant block is used to form the end of the busbar segment with an open opening.

[0027] The above-mentioned technical solution of the present invention has the following advantages: The composite material multi-partition irregular-shaped bus ring molding method provided by the present invention includes a parting design of the structure, dividing the composite material multi-partition irregular-shaped bus ring into an integral skin and multiple bus ring segments separated circumferentially. Each bus ring segment has a partition at one end and an open end at the other end. The open end of one bus ring segment can be fitted onto the partitioned end of an adjacent bus ring segment. Bus ring segments are fabricated using a mandrel. Prepreg is laid on the mandrel. Holes are punched in the partitions of each bus ring segment, and the segments are assembled. The outer surface of the assembled bus ring segments is coated with adhesive and then covered with prepreg. After the prepreg is laid, the integral bus ring is formed. The edges of the formed integral bus ring are trimmed. This molding method realizes the molding of composite material multi-partition irregular-shaped bus rings, resulting in a lighter overall weight, meeting the requirements for lightweighting.

[0028] The manifold core mold provided by this invention includes a metal occupant block, a polytetrafluoroethylene (PTFE) block, and a rubber core. The curvature of the PTFE block matches that of the manifold segment to be formed. The rubber core covers the outside of the PTFE block and its shape matches the cavity of the manifold segment to be formed, forming a soft-hard hybrid mold core. The metal occupant block is used to form the open end of the manifold segment to ensure docking accuracy. The PTFE block can be extracted from the rubber core, facilitating demolding while ensuring forming accuracy. Attached Figure Description

[0029] The accompanying drawings are provided for illustrative purposes only, and the proportions and quantities of the components in the drawings may not be consistent with the actual product.

[0030] Figure 1 This is a schematic diagram of the structure of a bus ring in the prior art;

[0031] Figure 2 yes Figure 1 A schematic diagram of the cross-section of the central bus ring;

[0032] Figure 3 yes Figure 1 A schematic cross-sectional view of the ring body of the central bus ring;

[0033] Figure 4This is a schematic diagram of the bus ring configuration in an embodiment of the present invention;

[0034] Figure 5 This is a schematic diagram of the structure of two adjacent bus loop segments in the unassembled state in an embodiment of the present invention;

[0035] Figure 6 This is a cross-sectional schematic diagram of a portion of the bus ring after assembly in an embodiment of the present invention;

[0036] Figure 7 This is a partial structural diagram of the bus ring after integral molding and edge trimming in an embodiment of the present invention;

[0037] Figure 8 This is a schematic diagram of the structure of a busbar segment forming mold in an embodiment of the present invention;

[0038] Figure 9 yes Figure 8 A schematic diagram of the exploded state structure of the middle busbar ring forming mold;

[0039] Figure 10 This is a cross-sectional structural diagram of the busbar segment core mold in an embodiment of the present invention;

[0040] Figure 11 This is a schematic diagram of the structure of an adhesive tooling in an embodiment of the present invention.

[0041] In the picture:

[0042] 100: Convergence ring;

[0043] 101: Cavity;

[0044] 102: Partition;

[0045] 103: Manifold;

[0046] 104: Skin;

[0047] 105: Bus loop segment;

[0048] 1051: Socket area;

[0049] 200: Busbar ring forming mold;

[0050] 201: Busbar segment core mold;

[0051] 2011: Metal placeholder block;

[0052] 2012: Polytetrafluoroethylene block;

[0053] 2013: Rubber core;

[0054] 202: Upload the template;

[0055] 2021: Locating pin hole;

[0056] 203: Download template;

[0057] 2031: Positioning pin;

[0058] 204: Side template;

[0059] 205: Inner border strip;

[0060] 206: Outer strip;

[0061] 300: Bonding fixture;

[0062] 301: Base plate;

[0063] 302: Positioning block. Detailed Implementation

[0064] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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, 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.

[0065] It should be noted that, compared to existing technologies, this invention primarily provides a method for molding multi-partition irregular-shaped busbars from composite materials, along with a mandrel structure for molding busbar segments that facilitates demolding. Since the shape of the busbar itself is the same as that of busbars manufactured using 3D printing technology in existing technologies, the accompanying background art is used when discussing the structure of busbar products in this invention. Figures 1-3 And the corresponding reference numerals in the attached diagrams.

[0066] The composite material multi-partition irregular manifold forming method provided in this embodiment of the invention includes performing a parting design on the structure, designing a forming process based on the parting design, and then performing forming to realize the forming of the composite material multi-partition irregular manifold.

[0067] See Figure 4 As shown, in this embodiment, the composite material multi-partition irregular manifold is divided into an integral skin 104 and multiple manifold segments 105 separated along the circumferential direction. Each manifold segment has a partition 102 at one end and an open end at the other end. The open end of one manifold segment 105 can be fitted onto the end of the adjacent manifold segment 105 with the partition 102.

[0068] Based on the above parting design, this embodiment provides a molding process, as follows:

[0069] See Figures 5-7 As shown, firstly, a busbar segment 105 is fabricated using a busbar segment mandrel 201. Prepreg is then laid on the busbar segment mandrel 201. After the prepreg is laid, the mold is closed, and the busbar segment 105 is fabricated using a busbar segment molding mold 200. Holes are drilled in the partitions 102 of each obtained busbar segment 105 to obtain busbar holes 103. Adhesive is applied to the fitting area 1051 of the drilled busbar segment 105, and adjacent busbar segments 105 are fitted together. After applying adhesive to the outer surface of the assembled busbar segment 105, prepreg is laid (which becomes the skin 104 after molding). After the prepreg is laid, the entire busbar is formed. The edges of the formed entire busbar are trimmed, see [reference needed]. Figure 7 As shown, the sealed cavity has an opening. This molding method enables the molding of composite multi-partition irregular manifold rings.

[0070] Following the parting line design, the layup design is performed based on the performance requirements of the bus ring. In some embodiments, the bus ring segment uses carbon fiber prepreg layup, with a layup sequence of [(0, 90) / (±45)]. n Where n is selected according to the thickness of the product to be molded, for example, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, etc. In one example, the layup sequence is [(0, 90) / (±45)]4.

[0071] In some embodiments, the integral skin employs carbon fiber prepreg and unidirectional prepreg layup, with the layup sequence being [(0, 90) / 0 / 45 / 90 / -45 / 0 / 0 / -45 / 90 / 45 / 0 / (0, 90)]. n The outermost and innermost layers are carbon fiber prepreg, the middle layer is unidirectional prepreg, and n is selected according to the required thickness of the molded product, for example, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, etc. In one example, the layup sequence is: [(0, 90) / 0 / 45 / 90 / -45 / 0 / 0 / -45 / 90 / 45 / 0 / (0, 90)] (0 degrees is circumferential).

[0072] To improve product quality, preferably, each busbar segment is polished before assembly to remove burrs and rough edges.

[0073] See Figure 9 and Figure 10As shown, the manifold core mold 201 for easy demolding provided in this embodiment includes a metal occupant block 2011, a polytetrafluoroethylene (PTFE) block 2012, and a rubber core 2013. The curvature of the PTFE block 2012 is consistent with that of the manifold 105 to be formed. The rubber core 2013 covers the outside of the PTFE block 2012 and its shape is consistent with the cavity of the manifold 105 to be formed. The PTFE block 2012 can be pulled out from the rubber core 2013. The metal occupant block 2011 is used to form the open end of the manifold 105 to ensure the docking accuracy. During molding, the prepreg used to make the manifold 105 is laid on the outside of the manifold core mold. After laying, it is inserted into the molding die for forming. When demolding the busbar core mold 201, first remove the metal occupant block 2011, then pull out the polytetrafluoroethylene block 2012, and then pull out the rubber core 2013 using its elasticity to complete the demolding of the busbar core mold 201.

[0074] It should be noted that, due to the curvature of each segment of the bus ring and its multiple partitions and cavities, the difficulty in its molding lies mainly in the internal shape of the cavities rather than the external shape. Therefore, the molding die does not require excessive specifications; it only needs to be able to cooperate with the core mold 201 of the bus ring segment to achieve molding. No limitations are imposed here. In some embodiments, the bus ring segment 105 is formed using a thermal expansion molding die. See [link to documentation]. Figure 8 and Figure 9 As shown, the busbar ring forming mold 200 includes a busbar ring core mold 201, an upper template 202, a lower template 203, side templates 204, an inner edge strip 205, and an outer edge strip 206. The upper template 202 has at least two positioning pin holes 2021, and the lower template 203 has positioning pins 2031 corresponding to the number of positioning pin holes. The busbar ring core mold 201, along with the inner edge strip 205 and outer edge strip 206, are installed within the cavity of the lower template 202. The two side templates 204 are installed within the cavity, with the upper template 202 and lower template 203 located between the two side templates 204. The positioning pins 2031 engage with the positioning holes 2021. The mold is secured with screws, then placed in a hot oven and cured according to a pre-set curing program. This completes the forming of the busbar ring.

[0075] In some implementations, a vacuum bag pressing process is used to form the integral skin after the prepreg is laid on it.

[0076] To facilitate positioning during the assembly of each busbar segment 105, in some embodiments, when the busbar segment is made using a busbar segment forming mold, marking lines are formed on the formed busbar segment to facilitate auxiliary positioning using the marking lines.

[0077] To further improve assembly efficiency and accuracy, in some embodiments, the various busbar segments are assembled by a bonding fixture 300, which includes a base plate 301 and positioning blocks 302. The base plate 301 has through holes 3011 and positioning marks (not shown in the figure), the positioning marks being used for alignment with the marking lines. The number of positioning blocks 302 is the same as the number of busbar segments 105, each positioning block 302 being detachably mounted on the base plate 301, and the positioning blocks 302 are spaced apart around the through holes 3011. Each positioning block 302 has the same curvature as the busbar segment 105 to be positioned, so as to fit snugly against the busbar segment 105 and achieve better positioning.

[0078] In this embodiment, preferably, when adjacent busbar segments 105 are assembled together, the length of the splicing area 1051 is 15mm to 25mm, for example, 15mm, 16mm, 18mm, 20mm, 23mm, etc.

[0079] This embodiment also provides a composite material multi-partition irregular-shaped bus ring obtained by any of the above molding methods, which is lighter in overall weight than the existing metal multi-partition irregular-shaped bus ring, thus meeting the requirements for lightweighting.

[0080] The present invention will be further explained and described below with reference to an exemplary specific embodiment.

[0081] 1. Production preparation

[0082] Prepare technical data and raw materials, and check personnel qualifications, process equipment and equipment status, and production environment conditions.

[0083] 2. Mold preparation

[0084] Clean the mold and apply a release agent.

[0085] 3. Preparation of mandrel molding (This step is unrelated to the composite multi-partition irregular mandrel molding method, and it can be prepared first or by other means. It is only an example of a specific implementation method here.)

[0086] 3.1 Prepare the rubber liquid and vacuum it to remove bubbles.

[0087] 3.2 Place a polytetrafluoroethylene block into the mold and inject a certain amount of rubber liquid.

[0088] 3.3 Place the mold at room temperature (15℃~35℃) for vulcanization for 24 hours.

[0089] 3.4 After the rubber core mold has cured, remove the upper mold and take out the manifold segment forming core mold.

[0090] 4. Material feeding

[0091] The prepreg is cut using a fabric cutting machine according to the electronic cutting template.

[0092] 5. Layup

[0093] 5.1 Wipe the metal spacer and rubber core with acetone and let them dry completely;

[0094] 5.2 Wipe the metal spacer and rubber core with release agent and allow them to dry completely;

[0095] 5.3 Take the cut prepreg and lay it on the surface of the mandrel forming core mold. The layup sequence is [(0, 90) / (±45)]4.

[0096] 6. Mold closing

[0097] Place the product on the lower template, then place the inner and outer edge strips, side templates, and upper mold, and tighten them with screws.

[0098] 7. Curing

[0099] Place the mold in a hot oven and heat it to cure according to the set curing program.

[0100] 8. Demolding

[0101] 8.1 When the mold temperature is within the range of (40-60)℃, remove the fastening screws of the mold plates on both sides and remove the mold plates on both sides;

[0102] 8.2 When the mold temperature is below 40℃, use a pin puller to remove the metal spacer block and PTFE block, and use pliers to remove the rubber core;

[0103] 8.3 Use a wrench to remove the upper mold fastening screws, then remove the upper template, outer edge strip, inner edge strip, and product in sequence. Use a file to grind off any burrs.

[0104] 9. Machining

[0105] According to the drawings, the middle partition of the bus loop section is drilled.

[0106] 10. Assembly

[0107] 10.1 Prepare the assembly and bonding fixtures;

[0108] 10.2 The busbar segments are assembled using assembly and bonding fixtures, with the marking lines on the product aligned with the positioning marking lines on the fixtures, and then fixed with adhesive.

[0109] 11. Overall skin layering

[0110] 11.1 Grind the assembled bus ring section and wipe it clean with acetone;

[0111] 11.2 Apply an appropriate amount of adhesive to the surface of the bus ring and attach a layer of adhesive film;

[0112] 11.3 Carbon fiber is integrally deposited on the bus ring, with the following layup sequence:

[0113] [(0, 90) / 0 / 45 / 90 / -45 / 0 / 0 / -45 / 90 / 45 / 0 / (0, 90)] (0 degrees is the circumferential direction).

[0114] 12. Packaging

[0115] 12.1 Seal the finished product into a vacuum bag;

[0116] 12.2 Evacuate a vacuum to ensure a vacuum level ≤ -0.095MPa.

[0117] 13. Curing

[0118] Push the product into a hot oven and cure it according to the curing procedure.

[0119] 14. Machining

[0120] After demolding, trim the edges according to the drawings.

[0121] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that not every embodiment contains only one independent technical solution, and in the absence of conflict between solutions, the various technical features mentioned in each embodiment can be combined in any way to form other implementation methods that can be understood by those skilled in the art.

[0122] Furthermore, without departing from the scope of the present invention, modifications to the technical solutions described in the foregoing embodiments, or equivalent substitutions of some of the technical features, shall not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for molding a composite multi-partition irregular-shaped manifold ring, characterized in that, include: Partial design: The composite multi-partition irregular manifold is divided into an integral skin and multiple manifold segments separated along the circumference. Each manifold segment has a partition at one end and an open end at the other end. The open end of one of the manifold segments can be fitted onto the partitioned end of the adjacent manifold segment. A prepreg is laid on the mandrel core mold, and the mandrel is made using a mandrel forming mold. The mandrel core mold includes a metal placeholder, a polytetrafluoroethylene (PTFE) block, and a rubber core. The curvature of the PTFE block is consistent with that of the mandrel to be formed. The rubber core covers the outside of the PTFE block and has a shape consistent with the cavity of the mandrel to be formed. The PTFE block can be pulled out from the rubber core. The metal placeholder is used to form the end of the mandrel with an open opening. Drill holes in the partition of each of the obtained busbar segments; Apply adhesive to the socketing area of ​​the punched busbar segment, and then assemble adjacent busbar segments by socketing. After applying adhesive to the outer surface of the assembled bus ring section, prepreg is laid on top, and then the integral bus ring is formed. The edges of the formed integral bus ring are trimmed.

2. The method for forming a composite multi-partition irregular manifold ring according to claim 1, characterized in that: The busbar loop section uses carbon fiber prepreg layup with a layup sequence of [(0, 90) / (±45)]. n ; and / or The integral skin uses carbon fiber prepreg and unidirectional prepreg layup, with the layup sequence being [(0, 90) / 0 / 45 / 90 / -45 / 0 / 0 / -45 / 90 / 45 / 0 / (0, 90)]. n The outermost and innermost layers are made of carbon fiber prepreg, while the middle layer is made of unidirectional prepreg.

3. The method for forming a composite multi-partition irregular manifold ring according to claim 1, characterized in that: Polishing is performed before assembling each of the aforementioned busbar segments.

4. The method for forming a composite multi-partition irregular manifold ring according to claim 1, characterized in that: The bus ring segment is formed using a thermal expansion molding die; and / or The integral manifold is formed using a vacuum bag pressing process.

5. The method for forming a composite multi-partition irregular manifold ring according to claim 1, characterized in that: When using a busbar forming mold to manufacture the busbar segment, marking lines are formed on the formed busbar segment.

6. The method for forming a composite multi-partition irregular manifold ring according to claim 5, characterized in that: Each of the aforementioned bus ring segments is assembled by means of an adhesive bonding fixture, wherein the adhesive bonding fixture includes: The base plate has through holes and positioning marks, the positioning marks being used to align with the marking lines; The number of positioning blocks is the same as the number of the busbar segments. Each positioning block is detachably mounted on the base plate and is distributed at intervals around the through hole. Each positioning block has the same curvature as the busbar segment to be positioned.

7. The method for forming a composite multi-partition irregular manifold ring according to claim 1, characterized in that: When adjacent busbar segments are assembled together, the length of the splicing area is 15mm to 25mm.

8. A composite material multi-partition irregular-shaped bus ring, characterized in that: The composite multi-partition irregular manifold ring is formed using the molding method described in any one of claims 1-7.

Images