A method of forming a case having a lattice rib and a reinforcing region

Abstract

The application discloses a shell forming method with grid ribs and reinforcing areas. When the grid rib area is laid, the first direction laying and the second direction laying are adopted to keep the continuous and reliable laying between the grid ribs. When the reinforcing area is laid, the prepreg continues to be laid in the first direction and the second direction in the grid rib area, and the third direction folding is performed in the reinforcing area, so that the continuous laying is performed on the original grid rib, the continuity of the reinforcing area and the grid rib is kept, the overall stability is improved, the prepreg continuous extension laying is kept through the folding, the laying is performed in the third direction, the overall structure strength is uniformly improved, then the third direction continues to be filled, the thickness requirement of the reinforcing area is met, the continuity of the prepreg is not damaged, the local thickness accumulation and uncontrollability are avoided, the overall strength of the object after forming is higher, the mechanical property is improved, the internal quality of the product is ensured, and the bearing capacity is improved.

Description

Technical Field

[0001] This application relates to the field of composite material molding technology, and in particular to a shell molding method with mesh ribs and reinforcing zones. Background Technology

[0002] The information provided in this section is for the purpose of generally presenting the background of this disclosure. To the extent described in this section, the work of the currently named inventors and aspects of the description that may not constitute prior art at the time of filing are neither explicitly nor implicitly considered to be prior art of this disclosure.

[0003] Currently, carbon fiber composite shells with interlaced mesh reinforcement and localized reinforcing zones are formed using a lay-up process. Most existing carbon fiber shells contain interlaced mesh reinforcement and reinforcing zones to improve load-bearing capacity and avoid localized stress concentration, thereby altering the structure's inherent strength. However, the interlacing of mesh reinforcement and reinforcing zones is complex. In actual lay-up processes, continuous lay-up of the mesh reinforcement and reinforcing zones results in uneven thickness at the interlacing points, leading to uneven surfaces on the subsequent product, compromised fiber continuity, and compromised internal quality, ultimately affecting the overall structural strength. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this application provides a shell forming method with mesh reinforcement and reinforcing zones, thereby solving the problems of uneven plying or poor continuity affecting strength in existing forming methods.

[0005] The above-mentioned objectives of this application are mainly achieved through the following technical solutions:

[0006] A shell forming method with mesh ribs and reinforcing zones, the shell forming method comprising the following steps:

[0007] Arrange the layup mold;

[0008] Take the prepreg and lay it in the groove of the grid in the first direction along the first direction, lay it in the groove of the grid in the second direction along the second direction, and repeat the grid laying operation until the grid groove is filled.

[0009] Take prepreg and lay it on the mesh reinforcement along the first or second direction toward the reinforcement area. When the prepreg extends to the boundary with the reinforcement area, fold it over and lay it on the reinforcement area in the third direction. Then take prepreg and fill it in the reinforcement area in the third direction. Repeat the reinforcement area laying operation until the target height of the reinforcement area is reached.

[0010] Demolding after curing and shaping.

[0011] In an optional implementation, the first direction is perpendicular to the second direction.

[0012] In an optional implementation, the angle between the third direction and the first or second direction is 45°.

[0013] In an optional embodiment, during the mesh reinforcement layup, one end of the prepreg in the mesh reinforcement groove in the first direction is dispersed and folded to both sides, and then laid in the mesh reinforcement groove in the second direction along the second direction; and / or, one end of the prepreg in the mesh reinforcement groove in the second direction is dispersed and folded to both sides, and then laid in the mesh reinforcement groove in the first direction along the first direction.

[0014] In an optional implementation, when the prepreg is filled into the reinforcing zone in a third direction, the single-layer thickness of the reinforcing zone is always kept consistent.

[0015] In an optional implementation, when the reinforcing zone is laid up, if the thickness of the reinforcing zone is uniform, the prepreg extends in a third direction to the boundary of the reinforcing zone.

[0016] In an optional implementation, when the thickness of the reinforcing zone is inconsistent during the layup, a greater thickness is obtained by repeatedly folding the prepreg in a third direction.

[0017] In an optional implementation, during the mesh reinforcement layup, the mesh reinforcement is alternately laid up in the mesh reinforcement grooves in the first direction and in the mesh reinforcement grooves in the second direction.

[0018] In an optional implementation, after the mesh reinforcement layer is laid, the mesh reinforcement area is compacted and repaired until the top of the mesh reinforcement is flush with the bottom of the reinforced area.

[0019] In an optional embodiment, the reinforced zone is pre-pressed in a tank at a temperature not exceeding 100°C after being laid up, followed by skin lay-up, mold closing, and vacuum sealing, and then placed in an autoclave for curing and molding.

[0020] Compared with the prior art, the advantages of this application are:

[0021] The shell molding method in this application is used for molding shells with mesh ribs and reinforcing zones. First, a layup mold is prepared. Prepreg is taken and laid up along the first direction in the grooves of the mesh ribs in the first direction, and then along the second direction in the grooves of the mesh ribs in the second direction. This mesh rib laying up is repeated until the grooves are filled. Then, prepreg is taken and laid up along either the first or second direction towards the reinforcing zone on the mesh ribs. When the prepreg extends to the boundary with the reinforcing zone, it is folded over and laid up in a third direction onto the reinforcing zone. Then, prepreg is taken and filled into the reinforcing zone in a third direction. This reinforcing zone laying up is repeated until the target height of the reinforcing zone is reached. Finally, after curing and molding, the shell is demolded. During the mesh rib area layup, the first direction layup and... The second-direction layup maintains a continuous and reliable layup between the mesh reinforcements. During the reinforcement zone layup, the prepreg continues to be laid up in the mesh reinforcement area in both the first and second directions, and is folded in the third direction in the reinforcement zone to ensure continuous layup on the original mesh reinforcements. This maintains the continuity between the reinforcement zone and the mesh reinforcements, improves overall stability, and maintains continuous extension of the prepreg layup through folding while laying up in the third direction to uniformly improve the overall structural strength. Then, by continuing to fill in the third direction, the thickness requirements of the reinforcement zone are met without disrupting the continuity of the prepreg, while avoiding local thickness accumulation and uncontrollable issues. The resulting molded object has higher overall strength, improved mechanical properties, ensured internal product quality, and improved load-bearing capacity. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 A schematic flowchart of a shell forming method is provided for embodiments of this application;

[0024] Figure 2 A schematic diagram of the shell structure provided in the embodiments of this application;

[0025] Figure 3 This application provides a schematic diagram of the first and second direction layups for embodiments of the present application.

[0026] Figure 4 Schematic diagrams of first-direction, second-direction, and third-direction ply layups provided for embodiments of this application;

[0027] In the diagram: 100, reinforced zone; 200, mesh reinforcement. Detailed Implementation

[0028] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. It should be noted that the description of these embodiments is intended to aid in understanding the invention, but does not constitute a limitation thereof. The specific structural and functional details disclosed herein are merely for describing exemplary embodiments of the invention. However, the invention can be embodied in many alternative forms and should not be construed as being limited to the embodiments described herein.

[0029] Figure 1 This application provides a schematic flowchart of a shell forming method for embodiments of the present application. Figure 2 This is a schematic diagram of the shell structure provided in an embodiment of this application. Figure 3 This is a schematic diagram of the first and second ply directions provided in an embodiment of this application. Figure 4 This is a schematic diagram of the first direction, second direction, and third direction of the layup provided for embodiments of this application.

[0030] Figure 3 and Figure 4 In the diagram, 'a' refers to a schematic diagram of the first-direction ply prepreg, 'b' refers to a schematic diagram of the second-direction ply prepreg, and 'c' refers to a schematic diagram of the third-direction ply prepreg.

[0031] like Figure 1 As shown, a shell forming method with mesh ribs and reinforcing zones is disclosed, the shell forming method comprising the following steps:

[0032] Arrange the layup mold;

[0033] like Figure 3 As shown, take the prepreg, lay it in the groove of the grid in the first direction along the first direction, lay it in the groove of the grid in the second direction along the second direction, and repeat the operation of laying the grid 200 layers until the grid groove is filled.

[0034] like Figure 4 As shown, take prepreg and lay it on the mesh reinforcement 200 along the first direction or the second direction toward the reinforcement area 100. When the prepreg extends to the boundary with the reinforcement area 100, fold it over and lay it on the reinforcement area 100 in the third direction. Then take prepreg and fill it in the reinforcement area 100 in the third direction. Repeat the layup operation in the reinforcement area 100 until the target height of the reinforcement area 100 is reached.

[0035] Demolding after curing and shaping.

[0036] In some embodiments, the working principle of the shell molding method with mesh ribs and reinforcing zones is as follows: The shell molding method is used for molding shells with mesh ribs and reinforcing zones. First, a layup mold is arranged. Prepreg is taken and laid up along the first direction in the mesh rib grooves in the first direction, and then laid up along the second direction in the mesh rib grooves in the second direction. This process of laying up the mesh ribs 200 is repeated until the mesh rib grooves are filled. Then, prepreg is taken and laid up along the first or second direction toward the reinforcing zone 100 on the mesh ribs 200. When the prepreg extends to the boundary with the reinforcing zone 100, it is folded over and laid up in a third direction onto the reinforcing zone 100. Then, prepreg is taken and filled into the reinforcing zone 100 in a third direction. This process of laying up the reinforcing zone 100 is repeated until the target height of the reinforcing zone 100 is reached. Finally, after curing and molding, the shell is demolded, and then the mesh ribs 200 are laid up again. During the regional layup, continuous and reliable layup between the grid bars 200 is maintained through layup in the first and second directions. When laying up the reinforcing zone 100, the prepreg continues to be laid up in the grid bar 200 area in the first and second directions, and is folded in the third direction in the reinforcing zone 100 to make continuous layup on the original grid bars 200, maintaining the continuity between the reinforcing zone 100 and the grid bars 200, improving overall stability. At the same time, the folding maintains the continuous extension of the prepreg layup, while laying up in the third direction, uniformly improving the overall structural strength. Then, by continuing to fill in the third direction, the thickness requirements of the reinforcing zone 100 are met without destroying the continuity of the prepreg, while avoiding local thickness accumulation and uncontrollability. The overall strength of the molded object is higher, the mechanical properties are improved, the internal quality of the product is guaranteed, and the load-bearing capacity is improved.

[0037] In an optional embodiment, the first direction and the second direction are perpendicular to each other. On the inner wall of the shell after molding, mutually perpendicular mesh ribs 200 are formed to improve the structural performance of the shell and maintain a more stable state under the external force in different directions. In actual operation, the length or width direction of the shell can be used as a reference, the first direction can be arranged as 0° direction and the second direction can be arranged as 90° direction.

[0038] In an optional embodiment, the angle between the third direction and the first or second direction is 45°. Through the angles formed between the third direction and the first and second directions respectively, the reinforcing zone 100 and the mesh reinforcement 200 after the layup is completed have stronger integration, and the whole can be more stable in more complex stress directions.

[0039] In an optional embodiment, when the mesh reinforcement 200 is laid up, one end of the prepreg in the mesh reinforcement groove in the first direction is dispersed and folded to both sides, and laid in the mesh reinforcement groove in the second direction along the second direction, and / or, one end of the prepreg in the mesh reinforcement groove in the second direction is dispersed and folded to both sides, and laid in the mesh reinforcement groove in the first direction along the first direction.

[0040] like Figure 2 As shown, it should be noted that the grooves of the first-direction mesh reinforcement and the grooves of the second-direction mesh reinforcement are arranged in an alternating manner. In order to better control the layup height and uniformity in the grooves of the first-direction mesh reinforcement and the grooves of the second-direction mesh reinforcement, the prepreg in the groove of the first-direction mesh reinforcement is dispersed at one end to form a relatively narrow bundle, and then folded into the groove of the second-direction mesh reinforcement in the second direction. Alternatively, the prepreg in the groove of the second-direction mesh reinforcement is dispersed at one end to form a relatively narrow bundle, and then folded into the groove of the second-direction mesh reinforcement in the first direction. This avoids the direct overlapping of the prepreg in the grooves of the first-direction mesh reinforcement and the groove of the second-direction mesh reinforcement, thus avoiding the inevitable difference in thickness between the overlapping and non-overlapping parts when laying the mesh reinforcement 200. While controlling the layup thickness, it also avoids cutting the prepreg before laying the mesh reinforcement 200, which would greatly reduce the overall structural strength of the mesh reinforcement 200. This maintains the integrity, improves the structural strength, controls the layup thickness, and improves the ease of construction and the forming effect.

[0041] In an optional embodiment, when the prepreg is filled into the reinforcing zone 100 in a third direction, the single-layer thickness of the reinforcing zone 100 is always kept consistent. By repeatedly performing single-layer lay-up, and performing lay-up operation at the next height after the single-layer operation is completed, the single layer maintains a complete and continuous structural state. Moreover, when it is necessary to adjust the height, corresponding measures can be taken between lay-up operations.

[0042] In an optional implementation, when the reinforcing zone 100 is laid up, if the thickness of the reinforcing zone 100 is consistent, the prepreg extends in a third direction to the boundary of the reinforcing zone 100, and the thickness of the entire reinforcing zone 100 is consistent. The prepreg is directly laid up in a third direction to the boundary of the reinforcing zone 100 through continuous and complete prepreg, thus maintaining the layup efficiency and the uniformity of the overall thickness of the reinforcing zone 100.

[0043] In an optional implementation, when the reinforcing zone 100 is laid up, if the thickness of the reinforcing zone 100 is inconsistent, a greater thickness can be obtained by repeatedly folding the prepreg in a third direction. According to the design requirements, the shell is set with different thicknesses in different areas of the reinforcing zone 100. This can reduce the overall weight and also locally strengthen the shell according to the stress analysis, thereby improving the structural strength. By repeatedly folding the area with increased thickness, the local thickness can be flexibly increased without cutting the prepreg fibers, which improves the convenience of operation. Specifically, each folding is carried out at the edge of the area with greater thickness.

[0044] In an optional embodiment, when the mesh reinforcement 200 is laid up, it is alternately laid up in the mesh reinforcement groove in the first direction and in the mesh reinforcement groove in the second direction. Compared with the reinforcement area 100, the mesh reinforcement 200 improves the connection stability between the mesh reinforcement 200 layups by alternating layups, resulting in higher overall strength.

[0045] In an optional implementation, after the mesh reinforcement 200 is laid, the mesh reinforcement 200 is compacted and repaired until the top of the mesh reinforcement 200 is flush with the bottom of the reinforcement area 100.

[0046] In an optional embodiment, the reinforced zone 100 is pre-pressed in a can after being laid up at a temperature not exceeding 100°C, and then the skin is laid up, molded, and vacuum-sealed in sequence, before being placed in an autoclave for curing and molding.

[0047] In actual operation, the following steps are performed:

[0048] 1) Arrange the molds and complete the assembly;

[0049] 2) Determine the parameter information of the mesh reinforcement 200 and the reinforcing zone 100 of the shell, select T800 carbon fiber and bismaleimide resin as prepreg, and the curing temperature is 200℃.

[0050] 3) The thickness of a single layer of prepreg is 0.125mm. The number of layers required for the mesh reinforcement 200 is determined based on the height of the mesh reinforcement 200; the number of layers required for the reinforcement zone 100 is determined based on the thickness of the reinforcement zone 100.

[0051] 4) Before laying the mesh reinforcement 200, the mesh reinforcement 200 is laid in an alternating manner. The laying direction of the mesh reinforcement 200 is the extension direction of the mesh reinforcement groove. When laying the alternating layers, take the prepreg and lay 2 layers in the 0° mesh reinforcement groove at 0°, then take the prepreg and lay 2 layers in the 90° mesh reinforcement groove at 90°. Repeat the alternating laying until the mesh reinforcement groove on the mold is filled.

[0052] 5) After the 200 mesh reinforcement layer is laid, compact the 200 mesh reinforcement area and repair it to ensure that it is level with the depression in the reinforcement area 100.

[0053] 6) Take the prepreg and continue to lay it in the groove of the grid reinforcement at 0°. After the prepreg extends to the reinforcement zone 100, it is folded over and laid in the reinforcement zone 100 at 45°. Also, take the prepreg and continue to lay it in the groove of the grid reinforcement at 90°. After the prepreg extends to the reinforcement zone 100, it is folded over and laid in the reinforcement zone 100 at 45°.

[0054] 7) Take the prepreg and fill it into the reinforcing zone 100 at a 45° angle to complete the single-layer layup of the reinforcing zone 100. Repeat until the reinforcing zone 100 reaches the target thickness. In the thicker reinforcing zone 100, repeatedly fold the prepreg so that it is always stacked at a 45° angle to complete the thickness increase layup.

[0055] 8) The contents are pre-pressurized in the autoclave. The pre-pressurization vacuum is -0.09MPa, the autoclave pressure is 0.3MPa, the temperature is 90℃, and the pre-pressurization time is 2h.

[0056] 9) Repair the missing material areas after pre-pressing the mesh reinforcement 200 and the reinforcing zone 100, and then proceed with the subsequent skin layering. After the skin layering is completed, close the mold, apply vacuum, and then send it into the autoclave for curing. The curing vacuum is -0.09MPa, the autoclave pressure is 0.3MPa, and the curing temperature is 200℃.

[0057] 10) Demolding: Remove the covering material sequentially, disassemble the mold, and obtain a shell with mesh ribs 200 and reinforcing zone 100;

[0058] 11) Machining the end face and opening of the housing.

[0059] It should be understood that the terms "first," "second," etc., are used only for distinguishing descriptions and should not be construed as indicating or implying relative importance. Although the terms "first," "second," etc., may be used herein to describe various units, these units should not be limited by these terms. These terms are only used to distinguish one unit from another. For example, a first unit may be referred to as a second unit, and similarly, a second unit may be referred to as a first unit, without departing from the scope of the exemplary embodiments of the invention.

[0060] It should be understood that the term "and / or" in this article is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can mean: A exists alone, B exists alone, and A and B exist simultaneously. The term " / and" in this article describes another relationship between related objects, indicating that two relationships can exist. For example, A / and B can mean: A exists alone, and A and B exist alone. In addition, the character " / " in this article generally indicates that the related objects before and after it are in an "or" relationship.

[0061] It should be understood that in the description of this invention, the terms "upper," "vertical," "inner," "outer," etc., indicate the orientation or positional relationship as commonly placed when the disclosed product is used, or the orientation or positional relationship commonly understood by those skilled in the art. They are only for the convenience of describing this 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. Therefore, they should not be construed as limitations on this invention.

[0062] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," and "connect" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0063] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments of the invention. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the terms “comprising,” “including,” “containing,” and / or “including” as used herein specify the presence of the stated features, integers, steps, operations, units, and / or components, and do not exclude the presence or addition of one or more other features, quantities, steps, operations, units, components, and / or combinations thereof.

[0064] Specific details are provided in the following description to provide a complete understanding of the exemplary embodiments. However, those skilled in the art will understand that the exemplary embodiments can be implemented without these specific details. In other embodiments, well-known processes, structures, and techniques may be omitted in the depiction of non-essential details to avoid obscuring the exemplary embodiments.

[0065] The above are merely specific embodiments of this application, enabling those skilled in the art to understand or implement this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features claimed herein.

[0066] It should be noted that the information disclosed in the background section above is only used to enhance the understanding of the background of this disclosure, and therefore may include information that does not constitute prior art known to those skilled in the art.

Claims

1. A method for forming a shell with mesh ribs and reinforcing zones, characterized in that, The shell forming method includes the following steps: Arrange the layup mold; Take the prepreg and lay it in the groove of the grid in the first direction along the first direction, lay it in the groove of the grid in the second direction along the second direction, and repeat the grid laying operation until the grid groove is filled. Take prepreg and lay it on the mesh reinforcement along the first or second direction toward the reinforcement area. When the prepreg extends to the boundary with the reinforcement area, fold it over and lay it on the reinforcement area in the third direction. Then take prepreg and fill it in the reinforcement area in the third direction. Repeat the reinforcement area laying operation until the target height of the reinforcement area is reached. Demolding after curing and shaping.

2. The shell forming method with mesh ribs and reinforcing zones as described in claim 1, characterized in that: The first direction and the second direction are perpendicular to each other.

3. The shell forming method with mesh ribs and reinforcing zones as described in claim 1, characterized in that: The angle between the third direction and the first direction or the second direction is 45°.

4. The shell forming method with mesh ribs and reinforcing zones as described in claim 1, characterized in that: During the mesh reinforcement layup, one end of the prepreg in the mesh reinforcement groove in the first direction is dispersed and folded to both sides, and then laid in the mesh reinforcement groove in the second direction along the second direction; and / or, one end of the prepreg in the mesh reinforcement groove in the second direction is dispersed and folded to both sides, and then laid in the mesh reinforcement groove in the first direction along the first direction.

5. The shell forming method with mesh ribs and reinforcing zones as described in claim 1, characterized in that: When prepreg is used to fill the reinforcing zone in a third direction, the thickness of a single layer in the reinforcing zone should always be consistent.

6. The shell forming method with mesh ribs and reinforcing zones as described in claim 1, characterized in that: When the reinforcing zone is laid up, if the thickness of the reinforcing zone is consistent, the prepreg extends in a third direction to the boundary of the reinforcing zone.

7. The shell forming method with mesh ribs and reinforcing zones as described in claim 1, characterized in that: When the thickness of the reinforcing zone is inconsistent during the layup, a greater thickness can be obtained by repeatedly folding the prepreg in a third direction.

8. The shell forming method with mesh ribs and reinforcing zones as described in claim 1, characterized in that: During the mesh reinforcement layup, the mesh reinforcement is laid up alternately in the grooves of the first direction and the grooves of the second direction.

9. The shell forming method with mesh ribs and reinforcing zones as described in claim 1, characterized in that: After the mesh reinforcement layer is laid, the mesh reinforcement area is compacted and repaired until the top of the mesh reinforcement is flush with the bottom of the reinforced area.

10. The shell forming method with mesh ribs and reinforcing zones as described in claim 1, characterized in that: After the reinforced zone is laid up, the temperature is not higher than 100°C. The material is then pre-pressed in the autoclave, followed by skin layup, mold closing, and vacuum sealing. Finally, it is placed in an autoclave for curing and molding.

Images