A shield body structure and production process of a protective shield

Abstract

The application discloses a cover body structure and production process of a protective cover and belongs to the field of special vehicles, comprising a left cover body and a right cover body, wherein the left cover body and the right cover body are both arranged with a foam structure layer, a reinforcing rib layer and an outer skin layer, and the outer skin layer is wrapped around the periphery of the foam structure layer and the reinforcing rib layer. The reinforcing rib layer comprises a foam sandwich, embedded iron and an inner skin layer, the embedded iron is embedded on both sides of the foam sandwich, and the inner skin layer is wrapped around the periphery of the foam sandwich. The outer skin, the foam structure layer and the reinforcing rib layer with the foam sandwich wrapped by the inner skin layer are integrally formed through a vacuum introduction process, which can realize the integral forming of the reinforcing rib and the cover body in a special-shaped structure, including the forming of the reinforcing rib in various modeling curved surfaces such as reinforcing rib turning and arc shape, and the strength of the reinforcing rib and the product bonding degree have no difference compared with a flat product. The light weight of the protective cover is met while the structural strength of the protective cover is ensured.

Description

Technical Field

[0001] This invention belongs to the field of special vehicles, specifically a protective cover structure and manufacturing process. Background Technology

[0002] Currently, a range of products, including driver's cabs, transport compartments, equipment compartments, and carbon fiber helmets, are facing increasingly stringent requirements for weight reduction, assuming the actual usage environment remains unchanged. To enhance structural strength while reducing weight, composite material products typically employ the following methods when incorporating reinforcing ribs: 1. Installation via secondary molding after the main body is formed; 2. Installation via bonding after the main body is formed; 3. Using metal components for the reinforcing ribs, integrally molded with the main body.

[0003] Method 1 involves separately molding the product body and reinforcing ribs (metal or non-metal), then connecting and fixing the ribs using a skin-like structure through a secondary molding process. This method may result in the reinforcing ribs not fitting snugly to the product body, leading to reduced connection strength during secondary molding and affecting the overall structural strength of the product. Method 2 involves separately molding the product body and reinforcing ribs (metal or non-metal), then bonding them together. This method may also result in the reinforcing ribs not fitting snugly to the product body, and the adhesive layer at the joints may age over time, leading to potential adhesive failure. Method 3 involves integrally molding the product body and metal reinforcing ribs. This method may result in the metal-clad core reinforcing ribs not fitting snugly to the mold during manufacturing, leading to numerous resin-rich areas within the product and directly impacting the overall structural strength. Summary of the Invention

[0004] The purpose of this invention is to provide a protective cover structure and manufacturing process to solve the problems mentioned in the prior art.

[0005] A protective cover structure is provided, comprising:

[0006] The left cover and the right cover are provided with a foam structure layer, a reinforcing rib layer and an outer skin layer. The foam structure layer and the reinforcing rib layer together form the inner lining of the cover, and the outer skin layer covers the periphery of the foam structure layer and the reinforcing rib layer.

[0007] The reinforcing rib layer includes a foam core, embedded iron, and an inner skin layer. The embedded iron is embedded on both sides of the foam core, and the inner skin layer covers the periphery of the foam core.

[0008] As a further aspect of the present invention: a flange is provided at the bottom opening end of the cover structure formed by the left cover and the right cover.

[0009] As a further aspect of the present invention, a sealing component is provided at the connection between the left and right covers.

[0010] In another aspect, the present invention provides a manufacturing process for a protective cover, used to produce the aforementioned cover structure, characterized in that it includes:

[0011] S1. Spray a release agent on the inner wall surface of the mold, lay the outer skin layer along the inner wall of the mold, arrange the foam structure layer and the reinforcing rib layer on the outer skin layer, and then cover the entire outer surface of the foam structure layer and the reinforcing rib layer with the outer skin layer.

[0012] S2. Lay out the release cloth, perforated release film and flow guide net in sequence, arrange flow guide pipes around the mold, lay out vacuum bags, and connect vacuum tubes and glue inlet tubes to the vacuum bags respectively.

[0013] S3. Connect the vacuum tube to the vacuum pump and conduct a vacuum test to ensure sealing. Then, introduce resin through the glue inlet tube, maintain pressure, cure, and demold.

[0014] As a further embodiment of the present invention: after the resin is introduced in step S3, it is subjected to pressure holding and curing at a temperature of 22℃~24℃ for 22h~26h, and then heated to 75℃~85℃ for curing for 4h.

[0015] As a further aspect of the present invention: the left and right covers are made from a set of fiberglass molds.

[0016] As a further aspect of the present invention, it also includes step S4: bonding the left cover and the right cover together. Before bonding, the bonding surfaces are polished and cleaned, and the bonding surfaces are cleaned with anhydrous ethanol. The anhydrous ethanol is allowed to dry for more than 10 minutes, and the bonding is cured for more than 1 hour after completion.

[0017] As a further aspect of the present invention: during the bonding process of the left and right covers and within 24 hours after bonding, the ambient temperature is maintained at 10℃~30℃ and the humidity is maintained at 30%RH~70%RH.

[0018] As a further aspect of the present invention, step S5 is also included: paint spraying of the cover, specifically comprising the following steps:

[0019] S5.1 Shielding: Shielding the parts of the enclosure that do not require painting according to the product drawings or technical requirements;

[0020] S5.2 Primer: Apply epoxy two-component primer to the product. After spraying, bake at 55℃~65℃ for 1.5h~2.5h, cool to room temperature and leave for more than 24h. The spray thickness is ≥80μm.

[0021] S5.3, Putty: Use epoxy modified polyester putty to fill the product surface. Each coat should be ≤0.5mm thick and the total thickness should be ≤1mm. After the putty is applied, let it dry for 1 to 2 hours, bake it at 55℃ to 65℃ for more than 30 minutes, and then leave it at room temperature for more than 24 hours.

[0022] S5.4 Sanding: Use 120-180 grit sandpaper to sand the putty patching surface and the primer surface;

[0023] S5.5, Intermediate Coat: Apply an epoxy two-component intermediate coat to the product. After spraying, bake at 55℃~65℃ for 1.5h~2.5h and leave at room temperature for more than 24h. The thickness requirement is ≥60μm.

[0024] S5.6 Topcoat: Apply a two-component polyurethane topcoat to the product. After being left at room temperature for 30 minutes, bake at 55℃~65℃ for 1.5h~2.5h, and then leave at room temperature for 6d~8d.

[0025] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0026] The outer skin layer, foam structure layer, and reinforcing rib layer consisting of an inner skin layer covering a foam core are integrally molded using a vacuum infusion process. This allows for the seamless integration of irregularly shaped reinforcing ribs with the cover body, including reinforcing ribs with bends, arcs, and other curved surfaces. The strength of the reinforcing ribs and the product's bonding strength are indistinguishable from those of flat products. This achieves both lightweight design and ensures the structural strength of the protective cover. Attached Figure Description

[0027] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to the accompanying drawings.

[0028] Figure 1 This is a partial structural diagram of a protective shield.

[0029] Figure 2 A cross-sectional view of the structure of a protective shield;

[0030] Figure 3 for Figure 2 A magnified view of region A in the middle.

[0031] In the diagram: 1. Left cover; 2. Right cover; 3. Foam structure layer; 4. Reinforcing rib layer; 41. Foam core; 42. Embedded iron; 43. Inner skin layer; 5. Outer skin layer; 6. Flange; 7. Sealing assembly. Detailed Implementation

[0032] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only for explaining the invention and are not intended to limit the invention; that is, the described embodiments are merely some embodiments of the invention, and not all embodiments. The components of the embodiments of the invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0033] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0034] Please see Figure 1-3 As shown, in this embodiment of the invention, the enclosure includes a left cover 1 and a right cover 2. Both the left cover 1 and the right cover 2 are provided with a foam structure layer 3, a reinforcing rib layer 4, and an outer skin layer 5. The foam structure layer 3 and the reinforcing rib layer 4 together form the inner lining of the enclosure, and the outer skin layer 5 covers the periphery of the foam structure layer 3 and the reinforcing rib layer 4. The reinforcing rib layer 4 includes a foam core 41, embedded iron 42, and an inner skin layer 43. The embedded iron 42 is embedded on both sides of the foam core 41, and the inner skin layer 43 covers the periphery of the foam core 41.

[0035] The protective cover is mainly composed of two parts: the left cover 1 and the right cover 2. The left cover 1 and the right cover 2 are multifaceted, thin-walled, open-sided structures that serve as the framework for the overall structure and provide protection. The protective cover is equipped with horizontal and vertical movement mechanisms, with threaded holes for embedded metal parts at the locations of the movement mechanisms. Waterproofing and dustproofing seals are also designed into the cover.

[0036] The overall structure of the left cover 1 and right cover 2 can be divided into four parts: the outer skin layer 5, the foam structure layer 3, the reinforcing foam core 41, and the reinforcing inner skin layer 43. The outer skin layer 5 uses glass fiber, carbon fiber, or prepreg (thermosetting) according to the structural design. The foam structure layer 3 can use PVC foam, polyurethane foam, or other low-density sandwich layer materials, depending on the product's weight reduction and structural strength requirements. The reinforcing foam core 41 can use the same or other low-density sandwich layer materials as the foam structure layer 3, depending on the product's weight reduction and structural strength requirements. The reinforcing inner skin layer 43 can use carbon fiber cloth or carbon fiber prepreg (thermosetting) according to the structural design requirements.

[0037] The product has an open structure, which is prone to deformation under stress. The motion mechanism has high requirements for the shape and size of the installation position. In order to reduce product deformation, a flange 6 is provided at the bottom opening end of the cover structure formed by the left cover 1 and the right cover 2.

[0038] To ensure the product has good waterproof and rainproof performance, a sealing component 7 is provided at the connection between the left cover 1 and the right cover 2. The cover adopts a triple sealing method of hollow sealing strip, water-blocking edge and rain eaves to achieve waterproof and rainproof effect.

[0039] Another aspect of the present invention provides a manufacturing process for a protective cover, used to produce the aforementioned cover structure, mainly including the following steps:

[0040] S1. Spray a release agent on the inner wall surface of the mold to facilitate the removal of the workpiece from the mold. Lay the outer skin layer 5 along the inner wall of the mold, arrange the foam structure layer 3 and the reinforcing rib layer 4 on the outer skin layer 5, and then cover the entire outer surface of the foam structure layer 3 and the reinforcing rib layer 4 with the outer skin layer 5.

[0041] The specific steps for laying the reinforcing layer include: laying the outer skin layer 5 on the inner wall of the mold, then laying an inner skin layer 43 on top of it; installing the outer embedded iron 42 of the protective cover at the predetermined position of the inner skin layer 43; laying the foam core 41 on the outer embedded iron 42; then installing the inner embedded iron 42 on the foam core 41; and finally covering the entire outer surface of the foam core 41 with the inner skin layer 43, thus completing the laying of the reinforcing layer 4.

[0042] S2. Lay out the release cloth, perforated release film and flow guide net in sequence, arrange flow guide pipes around the mold, lay out vacuum bags, and connect vacuum tubes and glue inlet tubes to the vacuum bags respectively.

[0043] Release cloths are used to separate the mold from the workpiece. This ensures that the workpiece can be easily removed from the mold after the molding process is complete without damaging the workpiece surface or structure. Using release cloths during the pouring process reduces the adhesion or bonding of resin or composite materials to the mold surface. Release cloths also protect the mold surface, reducing the risk of wear and damage.

[0044] Perforated release membranes are used to disperse resin to the desired areas. Through the pores in the membrane, the resin can be precisely controlled and guided to ensure uniform distribution throughout the entire workpiece. This helps prevent resin from accumulating in certain areas during molding, thus reducing porosity or inhomogeneity within the workpiece. By adjusting the size and distribution of the pores in the release membrane, the volume of resin can be precisely controlled to fit the specific shape and size of the workpiece. This helps avoid using too much or too little resin, thus reducing material waste.

[0045] A flow guide net is placed in the mold to guide and control the flow of resin within the workpiece. Its mesh structure allows the resin to flow between the meshes, ensuring a uniform distribution of resin throughout the entire workpiece. The presence of the flow guide net disperses and diffuses the resin flow, ensuring that the resin completely fills every area within the workpiece.

[0046] A ring of guide tubes is laid around the mold as an air extraction port, and a ring of sealing tape is attached around the perimeter to seal the vacuum bag film.

[0047] Unfold the vacuum bag onto the mold, align the center of the bag film with the center of the mold, and secure it tightly. Then, peel off the release paper from the sealing tape and adhere it to both sides. Apply extra tape at the bends and curves of the mold and press it flat to prevent bridging during vacuuming.

[0048] S3. Connect the vacuum tube to the vacuum pump and conduct a vacuum test to ensure sealing. Then, introduce resin through the glue inlet tube, maintain pressure, cure, and demold.

[0049] Insert a vacuum tube into the pre-placed T-connector inside the vacuum bag and seal it tightly. Conduct a vacuum test. During vacuuming, all air in the system must be evacuated. Check the airtightness, turn off the vacuum pump valve for 30 minutes, and then check if the air pressure index changes. If there is a change, it indicates that there is still a leak, and further checks are required. Resin can only be introduced if there is no leak.

[0050] Weigh the resin, stir it thoroughly, and insert the inlet tube into the resin tank. Following the feeding sequence, start with the middle inlet tube, ensuring it is completely saturated before opening the next inlet tube. Then stop the previous inlet tube and clamp it tightly with pliers. Repeat this process until the layer is completely saturated with resin. Remember to replenish the resin tank regularly to prevent air from entering during the filling process.

[0051] In step S3, after the resin is introduced, it is kept under pressure and cured for 22-26 hours at a temperature of 22-24°C, and then heated to 75-85°C for 4 hours to accelerate the curing speed and improve the quality of the resin molding.

[0052] When the product cools to room temperature, the vacuum bag, flow guide net, perforated isolation film, and release cloth are removed from the product in sequence to expose the carbon fiber product, and the surface is cleaned.

[0053] To save manufacturing costs, the left cover 1 and right cover 2 are manufactured using a shared mold, that is, one fiberglass mold and two sets of movable mold blocks are made to complete the manufacturing of the left and right covers. The model is CNC machined using a wooden mold, and the mold uses fiberglass + metal frame to ensure the accuracy and rigidity of the mold. The mold is inspected using 3D inspection equipment for overall scanning, and inspection templates for key dimensions and contours are made to ensure the overall accuracy of the product. Considering the consistency of the product contour structure, to facilitate mold assembly and disassembly, and to improve the positioning accuracy of the movable blocks and their mutual fit after molding, both the mold and the movable blocks are CNC machined and positioned.

[0054] After demolding, the left cover 1 and right cover 2 need to be bonded together. During bonding, the work area and workpieces must be clean, dust-free, free of moisture and other air pollution, and must be isolated from pollution caused by nearby production. Grinding, welding, and any work activities involving solvents or materials containing silicone resin are prohibited within a 30m radius of the work area. Before bonding, the bonding surfaces must be ground and cleaned, and then cleaned with anhydrous ethanol to ensure cleanliness. The anhydrous ethanol should be allowed to dry for at least 10 minutes to ensure complete evaporation. After bonding, curing should last for at least 1 hour to ensure sufficient molding strength of the bonded workpiece.

[0055] During the bonding process of the left cover 1 and the right cover 2, and within 24 hours after bonding, the ambient temperature should be maintained between 10℃ and 30℃, and the humidity between 30%RH and 70%RH. This temperature and humidity range is conducive to the curing of the adhesive and ensures the molding strength and bonding effect of the adhesive.

[0056] Next, proceed with the eaves bonding. Load the adhesive into the caulking gun, cut off the cap, attach the nozzle, and use a blade to cut off the tip of the nozzle to a suitable diameter to ensure sufficient adhesive filling. Apply the adhesive continuously and evenly to the bonding surface in one direction using the caulking gun. The adhesive type is NS-870M100. Before applying the adhesive, dispense a length of approximately 10cm of adhesive. The application time is 40 minutes and must be completed within 40 minutes. For any areas with insufficient adhesive, fill them with adhesive until it overflows from the gap. Immediately after completion, use a scraper to smooth the adhesive strip and refine the surface to a smooth, even finish. If necessary, use a gloss compound to smooth it.

[0057] Use 3M strong double-sided tape to evenly adhere the hollow sealing strip to the protective cover, and press firmly to ensure a secure bond.

[0058] After the bonding is completed, the cover is painted, which includes the following steps:

[0059] S5.1 Shielding: Shielding the parts of the cover that do not require painting according to the product drawings or technical requirements.

[0060] S5.2 Primer: Apply an epoxy two-component primer to the product. After spraying, bake at 55℃~65℃ for 1.5h~2.5h, cool to room temperature, and let stand for at least 24h. The spray thickness should be ≥80μm. The epoxy two-component primer brand is RAL-3012.

[0061] S5.3, Putty: Use epoxy-modified polyester putty to fill and repair the product surface. Each coat should be ≤0.5mm thick, with a total thickness ≤1mm. After application, allow the putty to dry for 1-2 hours, then bake at 55℃-65℃ for at least 30 minutes, and finally leave it at room temperature for at least 24 hours. The grade of epoxy-modified polyester putty is ST-2911-D.

[0062] S5.4 Sanding: Use 120-180 grit sandpaper to sand the putty patching surface and primer surface to ensure that all products are sanded in place. For areas that cannot be reached by the sanding machine, perform manual sanding.

[0063] S5.5, Intermediate Coat: Apply an epoxy two-component intermediate coat to the product. After spraying, bake at 55℃~65℃ for 1.5h~2.5h, and leave at room temperature for at least 24h. The thickness should be ≥60μm. The epoxy two-component intermediate coat grade is RAL-1002.

[0064] S5.6 Topcoat: Apply a two-component polyurethane topcoat to the product. After standing at room temperature for 30 minutes, bake at 55℃~65℃ for 1.5h~2.5h, and then stand at room temperature for 6d~8d. The coating adhesion should meet the requirements of ISO-2409, with an adhesion level ≤1.

[0065] The above description is merely an example and illustration of the structure of the present invention. Those skilled in the art can make various modifications or additions to the specific embodiments described, or use similar methods to replace them, as long as they do not deviate from the structure of the invention or exceed the scope defined in the claims, all of which should fall within the protection scope of the present invention.

Claims

1. A manufacturing process for a protective cover, characterized in that, include: The cover structure consists of a left cover and a right cover. Both the left cover and the right cover are provided with a foam structure layer, a reinforcing rib layer and an outer skin layer. The foam structure layer and the reinforcing rib layer together form the inner lining of the cover. The outer skin layer covers the periphery of the foam structure layer and the reinforcing rib layer. The reinforcing rib layer includes a foam core, embedded iron, and an inner skin layer. The embedded iron is embedded on both sides of the foam core, and the inner skin layer covers the periphery of the foam core. The bottom opening of the cover structure formed by the left cover and the right cover is provided with a flange. The production process includes the following steps: S1. Spray a release agent on the inner wall surface of the mold, lay the outer skin layer along the inner wall of the mold, arrange the foam structure layer and the reinforcing rib layer on the outer skin layer, and then cover the entire outer surface of the foam structure layer and the reinforcing rib layer with the outer skin layer. S2. Lay out the release cloth, perforated release film and flow guide net in sequence, arrange flow guide pipes around the mold, lay out vacuum bags, and connect vacuum tubes and glue inlet tubes to the vacuum bags respectively. S3. Connect the vacuum tube to the vacuum pump and conduct a vacuum test to ensure the seal. Then, introduce the resin through the glue inlet tube, hold the pressure, cure, and demold. After introducing the resin, hold the pressure and cure for 22h~26h in an atmosphere of 22℃~24℃, and then heat to 75℃~85℃ to cure for 4h. S4: Bond the left and right covers together. Before bonding, grind and clean the bonding surfaces. Clean the bonding surfaces with anhydrous ethanol. Allow the anhydrous ethanol to dry for more than 10 minutes. After bonding, cure for more than 1 hour. During the bonding process and for 24 hours after bonding, keep the ambient temperature between 10℃ and 30℃ and the humidity between 30%RH and 70%RH. S5: Paint spraying of the cover; The left and right covers are made from a set of fiberglass molds; S5 specifically includes the following steps: S5.1 Shielding: Shielding the parts of the enclosure that do not require painting according to the product drawings or technical requirements; S5.2 Primer: Apply epoxy two-component primer to the product. After spraying, bake at 55℃~65℃ for 1.5h~2.5h, cool to room temperature and leave for more than 24h. The coating thickness is ≥80μm. S5.3, Putty: Use epoxy modified polyester putty to fill the product surface. Each coat should be ≤0.5mm thick and the total thickness should be ≤1mm. After the putty is applied, let it dry for 1 to 2 hours, bake it at 55℃ to 65℃ for more than 30 minutes, and then leave it at room temperature for more than 24 hours. S5.4 Sanding: Use 120-180 grit sandpaper to sand the putty patching surface and the primer surface; S5.5, Intermediate Coating: Apply an epoxy two-component intermediate coating to the product. After spraying, bake at 55℃~65℃ for 1.5h~2.5h and leave at room temperature for more than 24h. The thickness requirement is ≥60μm. S5.6 Topcoat: Apply a two-component polyurethane topcoat to the product. After being left at room temperature for 30 minutes, bake at 55℃~65℃ for 1.5h~2.5h, and then leave at room temperature for 6d~8d.

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