Composite material integrated fuel tank forming die and forming method

Abstract

This invention discloses a molding die and molding method for an integrated composite fuel tank, comprising a curing module, a molding module, and a heating device. The curing module includes a first master mold section and a second master mold section; an installation cavity is provided in the curing module; the molding module is movably disposed in the installation cavity; an air nozzle communicating with the interior of the molding module is also provided on the curing module; the molding module includes a first sub-mold section and a second sub-mold section; a molding cavity for molding the integrated composite fuel tank is provided in the molding module; the heating device is used to heat the curing module, providing it with a temperature suitable for curing the composite material. The mold of this invention adopts a sub-mold and master mold structure, wherein the sub-mold is responsible for the composite material molding function, and the master mold is responsible for the heating and curing function. Furthermore, to facilitate demolding of complex-shaped integrated composite fuel tanks, a double parting surface structure is designed for the sub-mold and master mold, with the parting surface of the master mold in the horizontal direction and the parting surface of the sub-mold in the vertical direction.

Description

Technical Field

[0001] This invention relates to the field of composite material molding technology, specifically to an integrated composite material fuel tank molding die and molding method. Background Technology

[0002] While existing molds for integrated composite fuel tanks can meet most molding requirements, they become insufficient when the fuel tank shape becomes complex and must be molded as a single unit. Furthermore, existing molds with segmented molding methods pose a risk of demolding. Designing segmented structures for areas with demolding risk would affect assembly speed, consequently impacting production speed and hindering the continuous production of integrated composite fuel tanks. Summary of the Invention

[0003] The purpose of this invention is to address the problem that existing methods make it difficult to achieve continuous production of integrated composite fuel tanks. This invention designs a new molding die, which solves this problem.

[0004] This invention is achieved through the following technical solution:

[0005] A composite material integrated fuel tank molding die, characterized in that the molding die includes: a curing module, a molding module, and a heating device;

[0006] The curing module includes: a first master mold section and a second master mold section; the curing module is provided with an installation cavity; the molding module is movably disposed in the installation cavity; the curing module is also provided with an air nozzle communicating with the interior of the molding module;

[0007] The molding module includes: a first sub-mold block and a second sub-mold block; the molding module is provided with a molding cavity for molding the integrated fuel tank of the composite material;

[0008] The heating device is used to heat the curing module to provide it with the temperature required for the curing and molding of the composite material.

[0009] Specifically, the heating device can be configured as a plurality of heating rods.

[0010] In the molding die designed in this invention: ① Heating rods are connected one by one to external electrical control equipment. Thermocouples are used to provide feedback on the die temperature and control the process. The heating rods provide continuous and stable heating, ensuring that the curing modules (first and second master mold segments) remain within the temperature range required for curing the composite material product. ② Simultaneously, to achieve faster heat transfer and better thermal conductivity, the molding modules (first and second sub-mold segments) are designed to be relatively thin. While meeting the molding requirements, they can allow for a certain amount of deformation, which is resisted by the master mold.

[0011] Furthermore, a composite material fuel tank integrated molding die: the air nozzle is disposed at the mold closing point of the first master mold block and the second master mold block.

[0012] Furthermore, a composite material integrated fuel tank molding die includes a nozzle fixing component in the curing module for fixing the nozzle; the nozzle fixing component is connected to the nozzle.

[0013] Specifically, to prevent the air nozzle from detaching or becoming unstable during the inflation process of the bag, it needs to be fixed in place. Considering the factors of rapid and continuous production, it is most appropriate to position the air nozzle in the direction of press movement, that is, on the parting surface of the master mold (the parting point between the first and second master mold sections). When the upper and lower master molds are closed, the air nozzle fixing component is fixed, thereby achieving the purpose of fixing the air nozzle.

[0014] Furthermore, a composite material integrated fuel tank molding die includes a vacuum groove in the curing module, which is connected to the mounting cavity.

[0015] Specifically, the extraction groove is located at the mold-closing point of the first and second master mold segments. After the two are molded together, there is still a certain gap at the mold-closing point. When air is extracted through the extraction groove, the gas in the mounting cavity can be extracted. Simultaneously, after the first and second sub-mold segments are molded together, there is also a certain gap at their mold-closing point. Similarly, when air is extracted from the mounting cavity, some gas in the molding cavity can also be extracted. During the subsequent curing process, the prepreg is positioned between the inner expansion bag and the molding cavity, which is more conducive to the prepreg molding process.

[0016] Furthermore, a composite material integrated fuel tank molding die: the air extraction groove is disposed in the second master mold block.

[0017] Furthermore, a composite material integrated fuel tank molding die includes a sealing ring at the junction of the first and second master mold sections to ensure the airtightness of the mounting cavity. This sealing ring facilitates the sealing and evacuation of the mounting cavity, allowing the inner expansion bag to fit more closely to the inner wall (molding surface) of the molding cavity, thus aiding in the molding of the prepreg.

[0018] Furthermore, a composite material integrated fuel tank molding die: the molding module is provided with a through hole communicating with the molding cavity.

[0019] Furthermore, a composite material integrated fuel tank molding die: the first and second master mold blocks are respectively provided with a plurality of heating holes; the heating device is disposed in the heating holes.

[0020] Furthermore, a composite material integrated fuel tank molding die: the parting surfaces of the first master mold block and the second master mold block are perpendicular to the parting surfaces of the first sub-mold block and the second sub-mold block.

[0021] A molding method for an integrated composite fuel tank, the molding method employing the aforementioned molding die, the method comprising the following steps:

[0022] S1. Connect the first and second female mold blocks to the upper and lower pressure plates of the press respectively; control the opening and closing of the female mold through the press;

[0023] S2. Lay the prepreg required to form an integrated composite fuel tank on the surface of the inner expansion bag;

[0024] S3. After the prepreg is laid, the inner expansion bag is placed in the molding cavity and connected to the air nozzle fixing part through the through hole;

[0025] After the first sub-mold is divided into blocks and the second sub-mold is combined, it is placed in the mounting cavity, and the first master mold is divided into blocks and the second master mold is combined by a press.

[0026] S4. The mounting cavity is evacuated through the evacuation groove, the inner expansion bag is inflated through the air nozzle, and the first and second master mold blocks are heated through the heating device to give them pressure and temperature suitable for the curing and molding of the prepreg.

[0027] S5. After curing and molding, demold to obtain an integrated composite material fuel tank.

[0028] The molding method provided by the present invention is an internal expansion molding method. The air inlet of the internal expansion bag passes through the through hole in the second sub-mold block and is connected to the air nozzle fixing component. The air nozzle is connected through an external device, and the internal expansion bag is inflated and pressurized through the air nozzle fixing component. After the internal expansion bag expands, the composite material prepreg laid on the surface of the internal expansion bag adheres tightly to the inner wall of the sub-mold molding cavity and is cured and molded at the existing temperature of the master mold.

[0029] The beneficial effects of this invention are:

[0030] (1) In order to achieve continuous production of integrated composite fuel tanks, this invention designs a molding die, which is formed by a sub-mold and a master mold structure. The sub-mold (molding module) is responsible for the molding function of the composite material, and the master mold (curing module) is responsible for the heating and curing function. At the same time, in order to facilitate demolding of complex-shaped composite fuel tanks, the molding die provided by this invention is designed with a sub-mold and master mold double parting surface structure. The parting surface of the master mold is in the horizontal direction, and the parting surface of the sub-mold is in the vertical direction.

[0031] (2) By using the molding mold and molding method of the present invention, continuous production of composite material integrated oil tanks can be achieved, while avoiding the risk of demolding and improving the molding quality of the product. Attached Figure Description

[0032] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0033] Figure 1 This is a cross-sectional view of an integrated composite material fuel tank molding die of the present invention;

[0034] Figure 2 This is a cross-sectional view of the molding module in the molding die.

[0035] The markings in the diagram are: 1 Curing module, 2 Molding module, 1-1 First master mold segment, 1-2 Second master mold segment, 1-3 Mounting cavity, 1-4 Air nozzle, 1-5 Air nozzle fixing component, 1-6 Air extraction groove, 1-7 Sealing ring, 1-8 Heating hole, 2-1 First sub-mold segment, 2-2 Second sub-mold segment, 2-3 Molding cavity, 2-4 Through hole. Detailed Implementation

[0036] 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. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0037] In the description of this invention, it should be understood that the terms "upper," "lower," "left," "right," "top," and "bottom," etc., indicating orientation or positional relationships, are merely for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined with "first" and "second" may explicitly or implicitly include one or more of that feature. Moreover, the terms "first," "second," etc., are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein.

[0038] Example 1

[0039] like Figures 1-2 As shown, a composite material integrated fuel tank molding die is provided, characterized in that the molding die includes: a curing module 1, a molding module 2 and a heating device (the heating device may specifically be a plurality of heating rods);

[0040] The curing module 1 includes: a first female mold block 1-1 and a second female mold block 1-2; the curing module 1 is provided with an installation cavity 1-3 (specifically, the installation cavity 1-3 is respectively provided in the first female mold block 1-1 and the second female mold block 1-2, and a complete installation cavity 1-3 is formed after the first female mold block 1-1 and the second female mold block 1-2 are closed).

[0041] The molding module 2 is movably disposed in the mounting cavity 1-3; the curing module 1 is also provided with an air nozzle 1-4 communicating with the interior of the molding module 2 and an air nozzle fixing member 1-5 for fixing the air nozzle 1-4; wherein: the air nozzle 1-4 is disposed at the parting surface between the first female mold block 1-1 and the second female mold block 1-2, and the air nozzle 1-4 is mainly used to communicate with the inner expansion bag disposed inside the molding module 2 during molding;

[0042] The curing module 1 is also provided with an air extraction groove 1-6 that communicates with the mounting cavity 1-3; specifically, the air extraction groove 1-6 can be set in the second female mold block 1-2 and located at the mold closing point of the first female mold block 1-1 and the second female mold block 1-2. The mold closing point has a certain gap, and the gap and the mounting cavity 1-3 are not a sealed mechanism. Therefore, air can be extracted from the inside of the mounting cavity 1-3 from the air extraction groove 1-6.

[0043] A sealing ring 1-7 is also provided at the mold closing point (mold parting surface) of the first female mold block 1-1 and the second female mold block 1-2 to ensure the airtightness of the mounting cavity 1-3, so as to ensure airtightness when the mounting cavity 1-3 is evacuated.

[0044] To achieve faster heat transfer and better heat conduction, the molding module 2 is designed with a relatively thin structure. The molding module 2 includes a first sub-mold block 2-1 and a second sub-mold block 2-2. The molding module 2 is provided with a molding cavity 2-3 for molding the integrated composite material oil tank (similarly, the molding cavity 2-3 is located in the first sub-mold block 2-1 and the second sub-mold block 2-2, and the two are joined together to form a complete molding cavity 2-3, which corresponds to the shape of the integrated composite material oil tank). The molding module 2 is provided with a through hole 2-4 that communicates with the molding cavity 2-3 (specifically, the through hole 2-4 is located on the second sub-mold block 2-2). During molding, the air inlet of the inner expansion bag passes through the through hole 2-4 and communicates with the air nozzle fixing member 1-5. The air nozzle fixing member 1-5 is also connected to the air nozzle 1-4. The air nozzle 1-4 is connected to an external inflation device to inflate the inner expansion bag.

[0045] In order to achieve continuous production of the product, a plurality of heating holes 1-8 are respectively provided on the first master mold block 1-1 and the second master mold block 1-2; the heating device (heating rod) is respectively provided in the heating hole 1-8; the curing module 1 (first master mold block 1-1 and second master mold block 1-2) is heated by the heating device to provide it with the temperature required for the curing and molding of the composite material.

[0046] Example 2

[0047] A method for molding an integrated composite fuel tank is provided, characterized in that the molding method uses the molding die described in Example 1, and the method includes the following steps:

[0048] S1. Connect the first female mold block 1-1 and the second female mold block 1-2 to the upper and lower pressure plates of the press respectively, and control the opening / closing of the first female mold block 1-1 and the second female mold block 1-2 (female mold) through the press;

[0049] S2. Lay the prepreg required to form an integrated composite fuel tank on the surface of the inner expansion bag;

[0050] S3. After the prepreg is laid, place the inner expansion bag in the molding cavity 2-3, and connect the air inlet part of the inner expansion bag through the through hole 2-4 to the air nozzle fixing part 1-5. At this time, the inner expansion bag and the laid prepreg are in the molding cavity 2-3 of the molding module 2.

[0051] Then, the first sub-mold block 2-1 and the second sub-mold block 2-2 are joined together and placed in the mounting cavity 1-3. The first female mold block 1-1 and the second female mold block 1-2 are joined together by the press. At this time, the molding module 2 is in the mounting cavity 1-3 of the curing module 1, and the part of the inner expansion bag connected to the air nozzle fixing part 1-5 is pressed and fixed by the first female mold block 1-1 and the second female mold block 1-2.

[0052] S4. The mounting cavity 1-3 is evacuated through the evacuation groove 1-6. Since there is also a certain gap at the mold closing point of the first sub-mold block 2-1 and the second sub-mold block 2-2, some of the gas in the molding cavity 2-3 will also be extracted.

[0053] The inner expansion bag is inflated by air nozzles 1-4, which expands the inner expansion bag. By deflating the air, corners of the inner expansion bag that could not originally fit against the wall of the molding cavity 2-3 can easily fit together. The combination of deflating and inflating makes the prepreg laid on the surface of the inner expansion bag fit more tightly against the inner wall of the molding surface 2-3 in the sub-mold, which is more conducive to pressure molding.

[0054] The heating device heats the first master mold segment 1-1 and the second master mold segment 1-2 to a temperature suitable for curing the prepreg; under the aforementioned pressure and temperature, the laid prepreg is cured and molded.

[0055] S5. After curing and molding, the master mold is opened by the press, the sub-mold is moved away from the master mold by the equipment, the sub-mold is placed on the plane to cool naturally, and then demolded to obtain the integrated oil tank of composite material; during this process, a second set of the same sub-mold can be put into the master mold according to the above process for continuous production.

[0056] like Figure 1 As shown, since the structure of the integrated fuel tank of the composite material has a closed angle, when using the existing molding mold for molding and manufacturing, the following demolding methods are generally adopted: (1) rotate the closed angle direction by 90° to eliminate the influence of the closed angle on the demolding of the molded product; (2) make a segmented structure at the closed angle, and when demolding, the product and the segment are separated from the main structure together, and then the segment is removed separately. However, there are certain problems with the above method: if the method described in (1) is adopted, the direction of the air nozzle will change, and the air nozzle will be difficult to fix, which will not be conducive to rapid continuous production; if the method described in (2) is adopted, if there are many closed angle structures in the product, the segmented structure will also need to be increased accordingly, which will also not be conducive to achieving rapid production.

[0057] In summary, this invention designs a structure in which the sub-mold (forming module) has no segmented structure and the mother mold (curing module) can fix the air nozzle, namely a sub-mold and mother mold double parting surface forming mold structure, which realizes the function of rapid continuous production.

[0058] The above-described preferred embodiments of the present invention are for illustrative purposes only and are not intended to limit the scope of the invention. Any obvious variations or modifications derived from the technical solutions of the present invention are still within the protection scope of the present invention.

Claims

1. A composite material integrated fuel tank molding die, characterized in that, The molding die includes: a curing module (1), a molding module (2), and a heating device; The curing module (1) includes: a first female mold block (1-1) and a second female mold block (1-2); the curing module (1) is provided with an installation cavity (1-3); the molding module (2) is movably disposed in the installation cavity (1-3); the curing module (1) is also provided with an air nozzle (1-4) communicating with the interior of the molding module (2), and the air nozzle (1-4) is disposed at the mold closing point of the first female mold block (1-1) and the second female mold block (1-2); The molding module (2) includes: a first sub-mold block (2-1) and a second sub-mold block (2-2); the molding module (2) is provided with a molding cavity (2-3) for molding the integrated composite material oil tank; the parting surfaces of the first master mold block (1-1) and the second master mold block (1-2) are perpendicular to the parting surfaces of the first sub-mold block (2-1) and the second sub-mold block (2-2); The heating device is used to heat the curing module (1) to provide it with a temperature suitable for the curing and molding of the composite material.

2. The composite material integrated fuel tank molding die according to claim 1, characterized in that, The curing module (1) is also provided with a nozzle fixing component (1-5) for fixing the nozzle (1-4); the nozzle fixing component (1-5) is connected to the nozzle (1-4).

3. The composite material integrated fuel tank molding die according to claim 1, characterized in that, The curing module (1) is also provided with an air extraction groove (1-6), which is connected to the mounting cavity (1-3).

4. The composite material integrated fuel tank molding die according to claim 3, characterized in that, The air extraction groove (1-6) is located in the second master mold block (1-2).

5. The composite material integrated fuel tank molding die according to claim 3, characterized in that, A sealing ring (1-7) is also provided at the mold closing point of the first female mold block (1-1) and the second female mold block (1-2) to ensure the airtightness of the mounting cavity (1-3).

6. The composite material integrated fuel tank molding die according to claim 1, characterized in that, The molding module (2) is provided with a through hole (2-4) that communicates with the molding cavity (2-3).

7. The composite material integrated fuel tank molding die according to claim 1, characterized in that, The first female mold block (1-1) and the second female mold block (1-2) are respectively provided with a plurality of heating holes (1-8); the heating device is disposed in the heating holes (1-8).

8. A molding method for an integrated composite fuel tank, characterized in that, The molding method uses the molding die according to any one of claims 1 to 7, and the method includes the following steps: S1. Connect the first female mold block (1-1) and the second female mold block (1-2) to the upper and lower pressure plates of the press respectively; S2. A prepreg is laid on the surface of the inner expansion bag to form the integrated composite fuel tank; S3. After the prepreg is laid, the inner expansion bag is placed in the molding cavity (2-3) and connected to the air nozzle fixing part (1-5) through the through hole (2-4); After the first sub-mold block (2-1) and the second sub-mold block (2-2) are joined together, they are placed in the mounting cavity (1-3). The first female mold block (1-1) and the second female mold block (1-2) are joined together by a press. S4. The mounting cavity (1-3) is evacuated through the evacuation groove (1-6), the inner expansion bag is inflated through the air nozzle, and the first master mold block (1-1) and the second master mold block (1-2) are heated through the heating device to give them pressure and temperature suitable for the curing and molding of the prepreg. S5. After curing and molding, demold to obtain an integrated composite material fuel tank.

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