A manufacturing method of a composite integrated shelter door and the shelter door

Abstract

This invention relates to the field of hatch technology, specifically to a manufacturing method for an integrated composite material modular cabin hatch, comprising: Step 1, fabricating a main frame, inner skin, outer skin, and sealing structural components; Step 2, installing pre-embedded metal parts within the main frame, using screw connections and adhesive bonding; Step 3, cutting the core component according to the internal dimensions of the main frame, applying adhesive around the core component, and placing it inside the main frame; Step 4, placing the inner and outer skins on both sides of the main frame, connecting them with room temperature adhesive, pressing them firmly, and wiping away excess adhesive; Step 5, installing the sealing structural components around the main frame, using screw connections and adhesive bonding. The main frame, inner and outer skins, and sealing structural components manufactured using the above method have only 60% of the density of aluminum alloy and 20% of the density of steel, and the main frame is manufactured using an integrated molding process, which is simple.

Description

Technical Field

[0001] This invention relates to the field of cabin technology, specifically to a manufacturing method and a cabin door made of integrated composite materials. Background Technology

[0002] With the continuous development of mobile cabin technology in my country, mobile cabins have been widely used in various fields, including: communications, command, power stations, medical care, meteorology, combat, and logistics support.

[0003] As a crucial component of the modular shelter, the hatch's main function is to ensure the overall structural integrity of the shelter and meet its functional, performance, and usage requirements. Currently, the functionality of modular shelters has expanded beyond load-bearing, insulation, and sealing; lightweight, integrated functional shelters are increasingly being researched and produced. However, existing shelter hatches are primarily made of metal, resulting in significant weight and failing to meet lightweighting requirements. Furthermore, due to the inherent properties of metal, they cannot fulfill the shelter's specialized functions such as impact resistance, wave penetration, and radar stealth. Therefore, designing a composite material integrated functional shelter hatch can effectively address these issues. Summary of the Invention

[0004] Therefore, the technical problem to be solved by the present invention is to overcome the problem that the existing modular cabin doors are mainly made of metal materials, which result in heavy products that cannot meet the requirements of lightweighting, and thus provide a manufacturing method and a modular cabin door made of composite materials.

[0005] To address the aforementioned technical problems, this invention provides a manufacturing method for an integrated composite material modular cabin door, comprising the following steps: Step 1, fabricating the main frame, inner skin, outer skin, and sealing structural components; Step 2, installing pre-embedded metal components within the main frame, using screw connections and adhesive bonding; Step 3, cutting the core component according to the internal dimensions of the main frame, applying adhesive around the core component, and placing it inside the main frame; Step 4, placing the inner and outer skins on both sides of the main frame, connecting them with room temperature adhesive, pressing them firmly, and wiping away excess adhesive from the surface; Step 5, installing the sealing structural components around the main frame, using screw connections and adhesive bonding.

[0006] Furthermore, the manufacturing of the main frame includes the following steps: Step 1, material preparation: The prepreg is prepared using a hot-melt prepreg method. Under predetermined temperature and pressure, epoxy resin is fully impregnated with fibers to obtain the prepreg; Step 2, the prepreg is cut into sizes that are easy to lay out, and the prepreg is laid out cyclically on the segmented surface according to the lay-up angle θ. When laying out, attention should be paid to ensuring that the prepreg fits the mold, and that the layers at each angle are firmly bonded together, while removing air bubbles between the prepreg layers; Step 3, after laying out several segments, they are fixed to the bottom mold with bolts, the four side molds are placed on the bottom mold, and the top cover is placed on the four side molds and the carbon fiber prepreg. Step 1: Place pressure bolts on the assembled mold of several segments and tighten the assembled mold; Step 4: The main frame product should be cured according to the curing regime of epoxy resin. Put the assembled mold into the curing oven. After curing, the assembled mold will be cooled with the oven. The main frame product can be disassembled and demolded only after the assembled mold has cooled to 30℃ or below; Step 5: When demolding, it should be done in the reverse order of the assembled mold. Demold in the order of the top, four side molds, and segments. Then take out several segments from the main frame product. After the main frame product is demolded, the surface should be repaired. Use a file to grind the surface burrs and protrusions smooth.

[0007] Furthermore, in step four, the curing regime is 100℃ / 2h-150℃ / 2h. The curing process is that the curing oven gradually heats up from 0℃ to 100℃ at a set heating rate, holds at 100℃ for 2 hours, and then heats up from 100℃ to 150℃ at a set heating rate, and holds at 150℃ for 2 hours.

[0008] Further, the manufacturing of the inner and outer skins includes the following steps: Step 1, material preparation: The prepreg is prepared using the hot-melt prepreg method. Under certain temperature and pressure, epoxy resin is fully impregnated with fibers to obtain the prepreg; Step 2, the prepreg is cut into a size that is easy to lay out. The prepreg is then laid out cyclically on the surface of the lower mold according to the lay-up angle θ. When laying out the prepreg, care should be taken to ensure that the prepreg fits the skin mold, and that the layers at each angle are firmly bonded. At the same time, air bubbles between the layers of prepreg should be removed; Step 3, after laying out the lower mold, the upper mold is placed, and the pressure bolts are placed to secure the skin mold; Step 4, the skin product is cured according to the curing regime of epoxy resin. The skin mold is placed in the curing oven. After curing, the skin mold is cooled with the oven. The product can only be disassembled and demolded after the skin mold has cooled to 30°C or below; Step 5, when demolding, first remove the fastening bolts, remove the upper mold and the skin product, and then trim the surface by using a file to smooth out any burrs and protrusions.

[0009] Furthermore, in step four, the curing regime is 100℃ / 2h-150℃ / 2h. The curing process is that the curing oven gradually heats up from 0℃ to 100℃ at a set heating rate, maintains the temperature at 100℃ for 2 hours, and then heats up from 100℃ to 150℃ at a set heating rate, and maintains the temperature at 150℃ for 2 hours.

[0010] Furthermore, the manufacturing of the sealing structure includes the following steps: Step 1, Equipment preparation: Inspect all production equipment, including: electronic scale, mixer, oven, pultrusion machine, and cutting machine; confirm that all equipment is working properly and the records are complete; Step 2, Material preparation: Prepare the required fiber bundles and resin according to the usage; Step 3, Molding mold, tooling installation, and yarn threading: Fix the molding mold, scraper, injection box, pre-forming plate, and guide plate to the operating table; according to the calculated amount of yarn used in the process, pull out the yarn ends and evenly thread them into the corresponding guide plates; Step 4, Pultrusion machine heating: Set the temperature of each zone of the pultrusion machine and preheat for 2-3 hours, with a temperature fluctuation range of ±2℃; Step 5, Mixing: Weigh the resin, curing agent, accelerator, release agent, and filler by weight, and stir evenly with a mixer for at least 20 minutes. The amount of adhesive to be mixed depends on the size of the sealing structure product; Step 6, Starting the machine: Pour the prepared adhesive into the adhesive tank. After the adhesive has fully impregnated the fiber bundle yarn, start the pultrusion machine; Step 7, Appearance inspection and dimensional cutting: After the sealing structure product is pultruded and passes the surface self-inspection, cut it to the required size.

[0011] This invention also provides a composite material integrated modular cabin door manufactured using a method for manufacturing composite material integrated modular cabin doors, comprising: a main frame, wherein a core member is provided on the main frame and the core member is embedded within the main frame; an inner skin and an outer skin, wherein the inner skin is located on one side of the main frame and the outer skin is located on the other side of the main frame, and the inner skin and the outer skin are in contact with the surface of the core member; and a sealing structure fitted onto the main frame, wherein the main frame, the inner skin, the outer skin, and the sealing structure are all fiber resin-based composite material components.

[0012] Furthermore, the main frame includes: multiple longitudinal bars, which are spaced apart; multiple transverse bars, which are spaced apart along the extension direction of the longitudinal bars; and end bars, which are located at both ends of the longitudinal bars.

[0013] Furthermore, the side walls of the longitudinal rod and the end rod are provided with grooves, and the clamping member is engaged in the grooves.

[0014] Furthermore, the inner and outer skins are composites of low-dielectric glass fiber, quartz fiber, and high-molecular-weight polyethylene fiber.

[0015] The technical solution of this invention has the following advantages:

[0016] The manufacturing method of the integrated composite material cabin door provided by this invention includes the following steps: Step 1, fabricating the main frame, inner skin, outer skin, and sealing structure; Step 2, installing the pre-embedded metal parts inside the main frame, using screw connections and adhesive bonding; Step 3, cutting the core component according to the internal dimensions of the main frame, applying adhesive around the core component, and placing it inside the main frame; Step 4, placing the inner skin and outer skin on both sides of the main frame, connecting them with room temperature adhesive, pressing them firmly, and wiping away excess adhesive from the surface; Step 5, installing the sealing structure around the main frame, using screw connections and adhesive bonding.

[0017] The main frame, inner skin, outer skin, and sealing structure components manufactured using the above methods have a density of only 60% of that of aluminum alloy and 20% of that of steel. Furthermore, the main frame is manufactured using an integrated molding process, which is simple and eliminates the need for metal parts to connect the main frame, saving time and labor costs. The main frame made of fiber resin-based composite materials has a higher strength than that of aluminum alloy frames and can reduce weight by more than 40%.

[0018] The original modular shelter doors used steel or aluminum alloy, requiring splicing, welding, and screw connections between the frame structure itself, the frame and skin, and the sealing components. Furthermore, the original metal doors, due to the inherent properties of the material, could not achieve multi-functionality or versatility, and required regular maintenance to prevent oxidation, corrosion, fatigue damage, and other problems. This new integrated composite material modular shelter door, depending on the different uses and functions of the modular shelter, can achieve functions such as thermal insulation, electromagnetic shielding, stealth, wave absorption, wave transmission, and corrosion resistance through different combinations of reinforcing materials in the main frame, inner skin, outer skin, and sealing components.

[0019] The summary section is provided to present the chosen concepts in a simplified form, which will be further described in the detailed description below. The summary section is not intended to identify essential or necessary features of this disclosure, nor is it intended to limit the scope of this disclosure. Attached Figure Description

[0020] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0021] Figure 1 This is a structural schematic diagram of the integrated composite material modular cabin door provided by the present invention;

[0022] Figure 2 Exploded view of the integrated composite material modular cabin door provided by the present invention;

[0023] Figure 3 A schematic diagram of the combined mold for the integrated composite material cabin door provided by the present invention;

[0024] Figure 4 A schematic diagram of the skin mold structure for the integrated composite material modular cabin door provided by the present invention;

[0025] Figure 5 A schematic diagram of the pultrusion molding structure of the integrated composite material cabin door provided by the present invention.

[0026] Explanation of reference numerals in the attached figures:

[0027] 1. Main frame; 2. Sandwich component; 3. Inner skin; 4. Outer skin; 5. Sealing structure; 6. Longitudinal bar; 7. Cross bar; 8. End bar; 9. Bottom mold; 10. Top cover; 11. Side mold; 12. Main frame product; 13. Segment; 14. Lower mold; 15. Upper mold; 16. Skin product; 17. Molding mold; 18. Scraper; 19. Injection box; 20. Preformed plate; 21. Yarn guide plate. Detailed Implementation

[0028] In the following description, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments can be modified in various ways without departing from the spirit or scope of this disclosure. Therefore, the drawings and description are to be considered exemplary in nature and not restrictive.

[0029] In the description of this disclosure, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are used only for the convenience of describing this disclosure 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 this disclosure. 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 as "first" or "second" may explicitly or implicitly include one or more of the stated features. In the description of this disclosure, "a plurality of" means two or more, unless otherwise explicitly specified.

[0030] In the description of this disclosure, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "joint" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections, electrical connections, or connections that allow for communication; they can refer to direct connections or indirect connections through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this disclosure according to the specific circumstances.

[0031] In this disclosure, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0032] The following disclosure provides numerous different embodiments or examples for implementing various structures of this disclosure. To simplify the disclosure, specific examples of components and arrangements are described below. These are merely examples and are not intended to limit the scope of this disclosure. Furthermore, reference numerals and / or letters may be repeated in different examples; such repetition is for simplification and clarity and does not in itself indicate a relationship between the various embodiments and / or arrangements discussed. In addition, various specific examples of processes and materials are provided in this disclosure, but those skilled in the art will recognize the application of other processes and / or the use of other materials.

[0033] The preferred embodiments of this disclosure are described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit this disclosure.

[0034] Please see Figures 1 to 5As shown, the present invention provides a method for manufacturing an integrated composite material cabin door, comprising the following steps: Step 1, fabricating a main frame 1, an inner skin 3, an outer skin 4, and a sealing structure 5; Step 2, installing pre-embedded metal parts inside the main frame 1, using screw connections and adhesive bonding; Step 3, cutting the core component 2 according to the internal dimensions of the main frame 1, applying adhesive around the core component 2, and placing it inside the main frame 1; Step 4, placing the inner skin 3 and outer skin 4 on both sides of the main frame 1, connecting them with room temperature adhesive, pressing them firmly, and wiping away excess adhesive from the surface; Step 5, installing the sealing structure 5 around the main frame 1, using screw connections and adhesive bonding.

[0035] The manufacturing of the main frame 1 includes the following steps: Step 1: Material preparation: The prepreg is prepared using a hot-melt prepreg method. Under predetermined temperature and pressure, epoxy resin is fully impregnated with the fiber to obtain the prepreg; Step 2: The prepreg is cut to a size convenient for laying. According to the layup angle θ, specifically 0° / 90° / 45° / -45°, the prepreg is cyclically laid on the surface of the segments 13. During laying, care is taken to ensure the prepreg adheres to the mold, and that the layers at each angle are firmly bonded. Air bubbles between the prepreg layers are also removed; Step 3: After laying several segments 13, they are fixed to the bottom mold 9 with bolts. Four side molds 11 are placed on the bottom mold 9, and the top cover 10 is placed on the four side molds 11. Place pressure bolts on the combined mold of carbon fiber prepreg and several segments 13, and tighten the combined mold; Step 4: The main frame product 12 shall be cured according to the curing regime of epoxy resin. Place the combined mold into the curing oven. After curing, the combined mold shall be cooled with the oven. The main frame product 12 can be disassembled and demolded after the combined mold is cooled to 30°C or below; Step 5: When demolding, it shall be done in the reverse order of the combined mold. Demold in the order of the top, four side molds 11, and segments 13. Then remove several segments 13 from the main frame product 12. After the main frame product 12 is demolded, the surface shall be repaired. Use a file to grind the burrs and protrusions on the surface smooth.

[0036] In some optional embodiments, in step four, the curing regime is 100℃ / 2h-150℃ / 2h, and the curing process is that the curing oven gradually heats up from 0℃ to 100℃ at a set heating rate, holds at 100℃ for 2 hours, and then heats up from 100℃ to 150℃ at a set heating rate, and holds at 150℃ for 2 hours.

[0037] By using finite element analysis, the wall thickness and ply of the main frame product 12 can be appropriately adjusted during the molding process, and different reinforcing materials can be selected to meet the requirements of different load-bearing and different functions, thereby improving the adaptability of the composite material hatch main frame product 12. Among them, the reinforcing materials can be glass fiber, quartz fiber, carbon fiber, aramid fiber and other materials.

[0038] In some optional embodiments, the manufacturing of the inner skin 3 and outer skin 4 includes the following steps: Step 1, material preparation: The prepreg is prepared using a hot-melt prepreg method. Under certain temperature and pressure, epoxy resin is fully impregnated with fibers to obtain the prepreg; Step 2, the prepreg is cut into a size that is easy to lay out, and laid out cyclically on the surface of the lower mold 14 according to the lay-up angle θ, specifically 0° / 90° / 45° / -45°. When laying out, attention should be paid to ensuring that the prepreg fits the skin mold, and that the lay-up layers at each angle are firmly attached. Step 3: After laying the lower mold 14, place the upper mold 15, place the pressure bolts, and tighten the skin mold; Step 4: The skin product 16 should be cured according to the curing regime of epoxy resin. Place the skin mold in the curing oven. After curing, the skin mold will cool with the oven. The product can be disassembled and demolded only after the skin mold has cooled to 30°C or below; Step 5: When demolding, first remove the fastening bolts, remove the upper mold 15 and the skin product 16, and then repair the surface. Use a file to smooth out the burrs and protrusions on the surface.

[0039] In some optional embodiments, the curing regime in step four is 100℃ / 2h-150℃ / 2h. The curing process is that the curing oven gradually heats up from 0℃ to 100℃ at a set heating rate, maintains the temperature at 100℃ for 2 hours, and then heats up from 100℃ to 150℃ at a set heating rate, and maintains the temperature at 150℃ for 2 hours.

[0040] The inner skin 3 and outer skin 4 can be reinforced with aramid fiber, PBO fiber, high molecular weight polyethylene material or mixed fiber to improve the impact resistance of the hatch; low dielectric glass fiber, quartz fiber, high molecular weight polyethylene fiber can also be used as reinforcement materials to improve the wave transmission performance of the hatch; when the composite inner skin 3 is formed, copper mesh and nickel mesh are added to improve the conductivity of the inner skin 3 and increase the electromagnetic shielding effectiveness.

[0041] In some optional embodiments, the manufacturing of the sealing structure 5 includes the following steps:

[0042] Step 1: Equipment Preparation: Inspect all production equipment, including: electronic scale, mixer, oven, pultrusion machine, and cutting machine; confirm that all equipment is working properly and that records are complete. Step 2: Material Preparation: Prepare the required fiber bundles and resin according to the usage. Step 3: Molding Die 17, Tooling Installation and Yarn Threading: Fix the molding die 17, scraper 18, injection box 19, pre-forming plate 20, and guide plate 21 to the operating table; according to the calculated yarn usage, pull out the yarn ends and evenly thread them into the corresponding guide plate 21. Step 4: Pultrusion Machine Heating: Set the pultrusion machine... Temperature in each zone: Preheat for 2-3 hours, with a temperature fluctuation range of ±2℃; Step 5: Glue preparation: Weigh the resin, curing agent, accelerator, release agent, and filler by weight, and stir evenly with a mixer for at least 20 minutes. The amount of glue prepared depends on the size of the sealing structure component 5; Step 6: Start-up: Pour the prepared glue solution into the glue tank. After the glue solution has fully soaked the fiber bundle yarn, start the pultrusion machine; Step 7: Appearance inspection and dimensional cutting: After the sealing structure component 5 is pultruded and passes the surface self-inspection, cut it to the required size.

[0043] The specific operation method for assembling the hatch is as follows: Step 1: Install the pre-embedded metal parts, which are used for lock body connection, inside the main frame 1. The connection method is screw connection and adhesive bonding. Step 2: Cut the sandwich core 2 according to the internal dimensions of the main frame 1, apply adhesive around it, and place it inside the main frame 1. Step 3: Place the inner skin 3 and outer skin 4 on both sides of the main frame 1, connect them with room temperature adhesive, press them firmly, and wipe off any excess adhesive from the surface. Step 4: Install the sealing structure 5 around the hatch main frame 1. The connection method is screw connection and adhesive bonding.

[0044] The present invention also provides an integrated composite material cabin door, comprising: a main frame 1, wherein a core member 2 is provided on the main frame 1 and the core member 2 is embedded in the main frame 1; an inner skin 3 and an outer skin 4, wherein the inner skin 3 is provided on one side of the main frame 1 and the outer skin 4 is provided on the other side of the main frame 1, and the inner skin 3 and the outer skin 4 are in contact with the surface of the core member 2; and a sealing structure 5, which is sleeved on the main frame 1, wherein the main frame 1, the inner skin 3, the outer skin 4, and the sealing structure 5 are all fiber resin-based composite material parts.

[0045] By using fiber-reinforced resin composite materials for the main frame 1, inner skin 3, outer skin 4, and sealing structure 5, the density of the fiber-reinforced resin composite material is low, only 60% of that of aluminum alloy and 20% of that of steel. The main frame 1 is made using an integral molding process, which is simple and eliminates the need for metal parts to connect the frame, saving time and labor costs. The main frame 1 made of fiber-reinforced resin composite materials has better strength than aluminum alloy frames and can reduce weight by more than 40%.

[0046] The original modular shelter doors used steel or aluminum alloy, requiring splicing, welding, and screw connections between the frame structure itself, the frame and skin, and the sealing components 5. Furthermore, the original metal doors, due to the inherent properties of the material, could not achieve multi-functionality or versatility, and required regular maintenance to prevent oxidation, corrosion, fatigue damage, and other problems. This composite material integrated modular shelter door, depending on the different uses and functions of the modular shelter, can achieve functions such as heat insulation, electromagnetic shielding, stealth, wave absorption, wave transmission, and corrosion resistance through different combinations of reinforcing materials in the main frame 1, inner skin 3, outer skin 4, and sealing components 5.

[0047] In some optional embodiments, the main frame 1 includes multiple longitudinal bars 6, which are spaced apart; multiple horizontal bars 7, which are spaced apart along the extension direction of the longitudinal bars 6; and end bars 8, which are located at both ends of the longitudinal bars 6.

[0048] The longitudinal bar 6, the transverse bar 7, and the end bar 8 together form the main frame 1, which facilitates the installation and fixation of the sandwich member 2 inside the main frame 1.

[0049] In some alternative embodiments, the side walls of the longitudinal rod 6 and the end rod 8 are provided with grooves, and the core member 2 is snapped into the grooves.

[0050] There are three longitudinal bars 6 and three transverse bars 7, and two end bars 8. The number of longitudinal bars 6, transverse bars 7, and end bars 8 can be set according to the actual situation.

[0051] In some alternative embodiments, the inner skin 3 and the outer skin 4 are composites of low-dielectric glass fiber, quartz fiber, and high-molecular-weight polyethylene fiber, which, as additives in the composite material, enable the door to have wave-transmitting capabilities.

[0052] The outer skin 4 is made of low-dielectric glass fiber or quartz fiber as an additive material in the composite material. This arrangement enables the door to transmit waves. At the same time, it is combined with the core component 2 to use wave-absorbing PMI foam, thereby improving stealth capability.

[0053] In some optional embodiments, the outer skin 4 and the main frame 1 are reinforced with a composite of aramid fiber, PBO fiber and high molecular weight polyethylene, and the sandwich 2 is made of high-strength PMI foam, thereby improving the product strength and impact resistance. If higher bulletproof performance is required, the skin material can be a ceramic matrix composite material.

[0054] In some optional embodiments, depending on the thermal insulation performance requirements, the sandwich element 2 is made of polyurethane foam, polypropylene foam, polystyrene foam, or VIM foam to improve the thermal insulation performance of the cabin.

[0055] During the molding of the inner skin 3, copper mesh and nickel mesh can be added to improve the conductivity of the inner skin 3 and increase the electromagnetic shielding effectiveness.

[0056] The present invention also provides an integrated composite material container, including the aforementioned integrated composite material container door.

[0057] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.

Claims

1. A method for manufacturing an integrated composite material modular cabin door, characterized in that, Includes the following steps: Step 1: Make the main frame (1), inner skin (3), outer skin (4), and sealing structural components (5); Step 2: Install the pre-embedded metal parts inside the main frame (1) by screw connection and adhesive bonding. Step 3: Cut the sandwich part (2) according to the internal dimensions of the main frame (1), apply adhesive around the sandwich part (2), and place it inside the main frame (1); Step 4: Place the inner skin (3) and outer skin (4) on both sides of the main frame (1), connect them with room temperature adhesive, press them firmly, and wipe off any excess adhesive from the surface. Step 5: Install the sealing structure (5) around the main frame (1) using screw connection and adhesive bonding. The manufacturing of the main frame (1) includes the following steps: Step 1, Material Preparation: The prepreg is prepared by hot melt prepreg method. Under predetermined temperature and pressure, epoxy resin is fully impregnated with the fiber to obtain the prepreg. Step 2: Cut the prepreg to a size that is easy to lay out. Lay the prepreg in a loop on the surface of the segment (13) according to the lay-up angle θ. When laying, make sure that the prepreg fits the mold and that the layers at each angle are close together. At the same time, remove the air bubbles between the layers of prepreg. Step 3: After laying several segments (13), fix them to the bottom mold (9) with bolts. Place four side molds (11) on the bottom mold (9). Place the top cover (10) on the combined mold of the four side molds (11), carbon fiber prepreg, and several segments (13). Place pressure bolts and tighten the combined mold. Step 4: The main frame product (12) should be cured according to the curing regime of epoxy resin. The combined mold is placed in the curing oven. After curing, the combined mold is cooled with the oven. When the combined mold is cooled to below 30°C, the main frame product (12) is disassembled and demolded. Step 5: When demolding, the order should be reversed from that of the combined mold. Demold the top cover (10), the four side molds (11), and the segments (13) in sequence. Then, remove the segments (13) from the main frame product (12). After demolding the main frame product (12), trim the surface and use a file to smooth out the burrs and protrusions on the surface. In step four, the curing regime is 100℃ / 2h-150℃ / 2h. The curing process is that the curing oven gradually heats up from 0℃ to 100℃ at a set heating rate, holds at 100℃ for 2 hours, and then heats up from 100℃ to 150℃ at a set heating rate, and holds at 150℃ for 2 hours. The manufacturing of the inner skin (3) and outer skin (4) includes the following steps: Step 1: Material preparation: The prepreg is prepared by hot melt prepreg method. Under certain temperature and pressure, epoxy resin is fully impregnated with fiber to obtain prepreg. Step 2: Cut the prepreg to a size that is easy to lay out. Lay the prepreg on the surface of the lower mold (14) in a loop according to the lay-up angle θ. When laying, make sure that the prepreg fits the skin mold and that the layers at each angle are close together. At the same time, remove the air bubbles between the layers of prepreg. Step 3: After laying the lower mold (14), place the upper mold (15), place the pressure bolts, and tighten the skin mold; Step 4: The skin product (16) should be cured according to the curing regime of epoxy resin. Place the skin mold into the curing oven. After curing, the skin mold is cooled with the oven. When the skin mold is cooled to below 30°C, the product is disassembled and demolded. Step 5: When demolding, first remove the fastening bolts, remove the upper mold (15), and the skin product (16). Then, repair the surface and use a file to smooth out the burrs and protrusions on the surface. In step four, the curing regime is 100℃ / 2h-150℃ / 2h. The curing process is that the curing oven gradually heats up from 0℃ to 100℃ at a set heating rate, maintains the temperature at 100℃ for 2 hours, and then heats up from 100℃ to 150℃ at a set heating rate, and maintains the temperature at 150℃ for 2 hours. The manufacturing of the sealing structure (5) includes the following steps: Step 1: Equipment Preparation: Inspect all production equipment, including: electronic scales, mixers, ovens, pultrusion machines, and cutting machines; confirm that all equipment is working properly and that records are complete; Step 2, Material Preparation: Prepare the required fiber bundles and resin according to the usage amount; Step 3, molding mold (17), tooling installation and yarn threading: Fix the molding mold (17), scraper (18), glue injection box (19), pre-forming plate (20) and yarn guide plate (21) to the operating table; according to the calculated amount of yarn used in the process, pull out the yarn ends and thread them evenly into the corresponding yarn guide plate (21). Step 4: Pultrusion machine heating: Set the temperature of each zone of the pultrusion machine, preheat for 2-3 hours, with a temperature fluctuation range of ±2℃; Step 5, mixing the adhesive: Weigh the resin, curing agent, accelerator, release agent and filler in order of weight, and stir evenly with a mixer for no less than 20 minutes. The amount of adhesive to be mixed depends on the size of the sealing structure (5) product. Step 6: Start the machine: Pour the prepared adhesive into the adhesive tank. After the adhesive has fully soaked the fiber bundle yarn, start the pultrusion machine. Step 7, Appearance Inspection and Size Cutting: After the sealing structure (5) product is extruded and passes the surface self-inspection, it is cut to size according to requirements; The main framework (1) includes: There are multiple longitudinal bars (6), and the multiple longitudinal bars (6) are spaced apart; The crossbars (7) are multiple, and the multiple crossbars (7) are spaced apart along the extension direction of the longitudinal bar (6); End rods (8) are provided at both ends of the longitudinal rod (6); The longitudinal rod (6) and the end rod (8) have grooves on their side walls, and the core member (2) is snapped into the grooves.

2. A composite material integrated modular cabin door manufactured using the manufacturing method of the composite material integrated modular cabin door according to claim 1, characterized in that, include: The main frame (1) is provided with a core member (2), which is embedded in the main frame (1); Inner skin (3) and outer skin (4), the inner skin (3) is located on one side of the main frame (1), and the outer skin (4) is located on the other side of the main frame (1). The inner skin (3) and the outer skin (4) are in contact with the surface of the sandwich member (2). The sealing structure (5) is sleeved on the main frame (1). The main frame (1), inner skin (3), outer skin (4), and sealing structure (5) are all fiber resin-based composite material parts.

3. The integrated composite material cabin door according to claim 2, characterized in that, The inner skin (3) and outer skin (4) are composites of low dielectric glass fiber, quartz fiber, and high molecular weight polyethylene fiber.

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