A device and method for split-molding a wedge-shaped metal honeycomb core bonded product

Abstract

This invention discloses a molding apparatus and method for wedge-shaped metal honeycomb core adhesive products. The molding apparatus includes a tooling plate, multiple corner supports, segmented core molds, gaskets, a primary curing and equalizing plate, and a secondary curing and equalizing plate. The segmented core molds are placed along the inner walls of the beams and ribs of the wedge-shaped metal honeycomb core adhesive product. The multiple corner supports are fixed on the tooling plate and block one side of the segmented core molds. The gaps between the segmented core molds and the beams, ribs, and corner supports are adjusted using gaskets. After the wedge-shaped metal honeycomb core adhesive parts, core molds, and corner supports are assembled, secondary curing and molding are performed using the primary and secondary curing and equalizing plates. This invention solves the problems of mismatch between the wedge-shaped metal adhesive core mold and the parts, and uneven quality of the adhesive layer. It improves the quality of the manufactured parts while simplifying the assembly process, eliminating the need for continuous cold pressing to check the fit between the skin and the beams and ribs, and saving manufacturing time and money.

Description

Technical Field

[0001] This invention patent relates to the field of adhesive molding of metal honeycomb core parts in composite material molding technology, and particularly to a mold-separation molding device and method for wedge-shaped metal honeycomb core adhesive products. Background Technology

[0002] Aircraft wedge-shaped metal honeycomb core adhesive products are formed by bonding and curing the upper and lower skins, beams, ribs, tail fins, and honeycomb cores with an adhesive film. The molding process typically employs an integrated mandrel molding method. The mandrel has a Z-shaped structure, with the bottom surface of the Z-shape connecting to the tooling for positioning, and the upper part of the Z-shape supporting and positioning the beam components. Since the cross-section of the wedge-shaped metal honeycomb component is wedge-shaped, when manufactured using the integrated mandrel molding method, the mandrel base serves as the positioning reference, and the mandrel support surface is fixed, leading to reference transfer issues. This structure requires high manufacturing precision for both the tooling base plate and the mandrel. Any deviation in tooling manufacturing often causes gaps or excessive extrusion between the beams and the skin / honeycomb core, resulting in a component of the molding pressure perpendicular to the honeycomb core cells, thus reducing the quality of the molded part. Wedge-shaped metal honeycomb core adhesive products manufactured using this molding method will exhibit defects such as extrusion deformation, cavities, delamination, and excessive waviness. To address these defects, it is necessary to design a molding stop for the wedge-shaped metal honeycomb core adhesive product and solve the balance problem between the stop and the edge of the honeycomb core. Summary of the Invention

[0003] To address existing technical challenges, this invention provides a mold-forming device and method for wedge-shaped metal honeycomb core adhesive products. By using segmented core molds with padding, the manufacturing precision requirements of the tooling core molds and the inner cavities of beams and ribs are reduced, thus solving the problem of uneven quality caused by tooling manufacturing or tooling deformation.

[0004] The objective of this invention is achieved through the following technical solution:

[0005] A mold-forming device for a wedge-shaped metal honeycomb core adhesive product includes a tooling plate, multiple corner supports, segmented core molds, gaskets, a primary curing pressure plate, and a secondary curing pressure plate. The segmented core molds are placed along the inner walls of the beams and ribs. The multiple corner supports are fixed on the tooling plate and block one side of the segmented core molds. The gaps between the segmented core molds and the beams, ribs, and corner supports are adjusted by the gaskets. After the wedge-shaped metal honeycomb core adhesive product, core mold, and corner supports are assembled, secondary curing and forming are performed using the primary curing pressure plate and the secondary curing pressure plate.

[0006] The corner bracket and the tooling plate are fixed by positioning pins and slotted pan head screws.

[0007] The thickness of the gasket is 0.1mm-1mm, and it is progressively thicker in layers of 0.1mm.

[0008] The primary curing uniform pressing plate is made of a primary curing cover plate and a layer of silicone rubber soft film. The primary curing cover plate has a notch at the tail edge, and the notch is filled with a layer of silicone rubber soft film.

[0009] The secondary curing uniform pressing plate is made of a secondary curing cover plate and two layers of silicone rubber soft film.

[0010] The segmented core mold has a 1mm shim gap in thickness and width. A threaded pin hole is provided on one side of the segmented core mold facing the corner seat. The axis of the pin hole is parallel to the bottom surface of the segmented core mold for quick demolding.

[0011] The method for molding using this mold-forming device includes the following steps:

[0012] Step 1: Lay a layer of non-porous release film on the surface of the tooling template. The release film should be at least 30mm larger than the edge line of the part. Then place the lower skin with the adhesive film on the release film.

[0013] Step 2: Place the beams and ribs on the lower skin according to the position lines, put the segmented core molds into the inner cavities of the beams and ribs, and select appropriate shims to adjust the gaps according to the gap size until the segmented core molds are tightly attached to the beams and ribs;

[0014] Step 3: Place the honeycomb core between the beams and ribs, install the corner brackets, and after the corner brackets are in place, insert the positioning pins first, and then tighten them with slotted pan head screws.

[0015] Step 4: Install the tail strip and check if there is a gap between the corner bracket and the segmented core mold. If there is a gap, fill the gap with shims until it is pressed tightly.

[0016] Step 5: Lay a non-porous release film on the surface of the wedge-shaped metal honeycomb core adhesive product, connect the first-cured cover plate and a layer of silicone rubber soft film with plastic tape, place them on the release film, make bags, perform vacuum leakage testing, and complete the first curing.

[0017] Step 6: Remove the bag and check the step difference between the honeycomb core and the beams, ribs and tail edge strips. If the step difference exceeds 0.05mm, perform dust-free grinding and repair on the area of ​​the honeycomb core within 50mm of the beams, ribs and tail edge strips.

[0018] Step 7: After polishing, check the step difference. If it meets the requirements, use methyl ethyl ketone (MEK) to activate the surface of the beams, ribs, and tail edge strips.

[0019] Step 8: Lay the adhesive film on the upper skin, place the upper skin on the honeycomb core, then add the isolation film, and finally add the secondary curing cover plate and two layers of silicone rubber soft film to make the bag and cure it.

[0020] Step 9: Remove the bag, remove the slotted pan head screws on the corner bracket, then remove the positioning pin, and take out the segmented core mold and gasket from the inner cavity of the beam and rib.

[0021] The beneficial effects of this invention are as follows:

[0022] 1) The integral core mold was changed to a segmented core mold, and the gap was adjusted by adding shims, which reduced the manufacturing precision requirements of the tooling core mold and the inner cavity of the beam and rib;

[0023] 2) The two pressure plates effectively control the pressure transmission in the bonding area, ensuring the uniformity of the adhesive layer in the product.

[0024] 3) The segmented core mold is no longer restricted by the dual stress of the curing pressure of the parts and the tooling plate, and is in a free state, avoiding the problem of deformation of the tooling core mold after multiple uses. The service life of the tooling core mold can be extended from 60 curing cycles to 200 curing cycles.

[0025] 4) Fewer connections, simpler assembly, easier operation, convenient demolding, stable product quality without damage, saving manufacturing time and costs.

[0026] The present application will be further described in detail below with reference to the accompanying drawings of the embodiments. Attached Figure Description

[0027] Figure 1 Schematic diagram of the mold forming device

[0028] Figure 2 Schematic diagram of the cross-section of the segmented core mold corner seat assembly.

[0029] Figure 3 Schematic diagram of a single-stage curing uniform pressure plate

[0030] Figure 4 Schematic diagram of cross-section of the single-curing uniform pressure plate AA

[0031] Figure 5 Schematic diagram of the secondary curing uniform pressing plate structure.

[0032] Figure 6 Schematic diagram of cross-section of the secondary curing uniform pressing plate AA

[0033] Numbering in the diagram: 1. Tooling template; 2. Slotted pan head screw; 3. Locating pin; 4. Angle bracket; 5. Washer; 6. Segmented core mold; 7. First-stage curing cover plate; 8. One layer of silicone rubber film; 9. Second-stage curing cover plate; 10. Two layers of silicone rubber film; Detailed Implementation

[0034] See the attached diagram, such as Figure 1-6As shown, a mold-forming device for a wedge-shaped metal honeycomb core adhesive product includes a tooling plate 1, multiple corner seats 4, segmented core molds 6, gaskets 5, a primary curing pressure plate, and a secondary curing pressure plate. The segmented core molds 6 are placed along the inner walls of the beams and ribs. The multiple corner seats 4 are fixed on the tooling plate 1 and block one side of the segmented core molds 6. The gaps between the segmented core molds 6 and the beams, ribs, and corner seats 4 are adjusted by the gaskets 5. After the wedge-shaped metal honeycomb core adhesive product, the segmented core molds 6, and the corner seats 4 are assembled, secondary curing and forming are performed by using the primary curing pressure plate and the secondary curing pressure plate.

[0035] The corner bracket 4 is fixed to the tooling plate 1 by the locating pin 3 and the slotted pan head screw 2.

[0036] The thickness of gasket 5 is 0.1mm-1mm, and it is progressively increased in thickness by 0.1mm.

[0037] The primary curing uniform pressing plate is made of a primary curing cover plate 7 and a layer of silicone rubber soft film 8. The primary curing cover plate 7 has a notch at the tail edge, and the notch is filled with a layer of silicone rubber soft film 8.

[0038] The secondary curing uniform pressing plate is made of a secondary curing cover plate 9 and two layers of silicone rubber soft film 10.

[0039] The segmented core mold 6 has a 1mm shim gap in thickness and width. A threaded pin hole is provided on one side of the segmented core mold 6 facing the corner seat 4. The axis of the pin hole is parallel to the bottom surface of the segmented core mold 6 for quick demolding.

[0040] The method for molding using this mold-forming device includes the following steps:

[0041] Step 1: Lay a layer of non-porous release film on the surface of tooling plate 1. The release film should be at least 30mm larger than the edge line of the part. Then place the lower skin with the adhesive film on the release film.

[0042] Step 2: Place the beams and ribs on the lower skin according to the position lines, put the segmented core mold 6 into the inner cavity of the beams and ribs, and select appropriate shims 5 to adjust the gap according to the gap size until the segmented core mold 6 is tightly attached to the beams and ribs.

[0043] Step 3: Place the honeycomb core between the beam and rib, install the corner bracket 4. After the corner bracket 4 is in place, first insert the positioning pin 3, and then use the slotted pan head screw 2 to tighten it.

[0044] Step 4: Install the tail strip and check if there is a gap between the corner seat 4 and the segmented core mold 6. If there is a gap, fill the gap with shims 5 until it is pressed tightly.

[0045] Step 5: Lay a non-porous release film on the surface of the wedge-shaped metal honeycomb core adhesive product, connect the first-cured cover plate 7 and a layer of silicone rubber soft film 8 with plastic tape, place them on the release film, make bags, perform vacuum leakage testing, and perform first-curing.

[0046] Step 6: Remove the bag and check the step difference between the honeycomb core and the beams, ribs and tail edge strips. If the step difference exceeds 0.05mm, perform dust-free grinding and repair on the area of ​​the honeycomb core within 50mm of the beams, ribs and tail edge strips.

[0047] Step 7: After polishing, check the step difference. If it meets the requirements, use methyl ethyl ketone (MEK) to activate the surface of the beams, ribs, and tail edge strips.

[0048] Step 8: Lay the adhesive film on the upper skin, place the upper skin on the honeycomb core, then place the isolation film, and finally place the secondary curing cover plate 9 and two layers of silicone rubber soft film 10, and then make the bag and cure it.

[0049] Step 9: Remove the bag, remove the slotted pan head screws 2 on the corner seat 4, then remove the positioning pins 3, and take out the segmented core mold 6 and the gasket 5 from the inner cavity of the beam and rib.

[0050] The basic technical approach of this invention is to segment and disassemble the complex integrated core mold structure and a single pressure equalizing plate. This segmentation alters the connection and pressure transmission methods between the core mold, tooling, and parts. In this invention, the different corner supports and the core mold, as well as the primary and secondary curing pressure equalizing plates, are relatively independent. The technical solution employed in this invention decomposes the complex and uncontrollable stress relationship of the integrated core mold and pressure equalizing plate into two or more non-interfering unit processes, solving the problems of mismatch between the wedge-shaped metal adhesive core mold and tooling parts, and uneven quality within the adhesive layer. This improves part quality while simplifying the assembly process, eliminating the need for continuous cold pressing to check the fit between the skin and beams / ribs, and saving manufacturing time and money.

[0051] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. It should be noted that any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A mold-forming device for a wedge-shaped metal honeycomb core adhesive product, characterized in that... The product includes a tooling template, multiple corner brackets, segmented core molds, gaskets, a primary curing pressure plate, and a secondary curing pressure plate. The segmented core molds are placed along the inner walls of the beams and ribs. Multiple corner brackets are fixed on the tooling template and block one side of the segmented core molds. The gaps between the segmented core molds and the beams, ribs, and corner brackets are adjusted using gaskets. After the wedge-shaped metal honeycomb core adhesive product, core mold, and corner brackets are assembled, secondary curing and molding are performed using the primary curing pressure plate and the secondary curing pressure plate.

2. The mold-forming device for a wedge-shaped metal honeycomb core adhesive product according to claim 1, characterized in that... The corner bracket and the tooling plate are fixed together by locating pins and slotted pan head screws.

3. The mold-forming device for a wedge-shaped metal honeycomb core adhesive product according to claim 1, characterized in that... The thickness of the gasket is 0.1mm-1mm, and it is progressively thicker in layers of 0.1mm.

4. The mold-forming device for a wedge-shaped metal honeycomb core adhesive product according to claim 1, characterized in that... The primary curing uniform pressing plate is made of a primary curing cover plate and a layer of silicone rubber soft film. The primary curing cover plate has a notch at the tail edge, and the notch is filled with a layer of silicone rubber soft film.

5. The mold-forming device for a wedge-shaped metal honeycomb core adhesive product according to claim 1, characterized in that... The secondary curing uniform pressing plate is made of a secondary curing cover plate and two layers of silicone rubber soft film.

6. The mold-forming device for a wedge-shaped metal honeycomb core adhesive product according to claim 1, characterized in that... The segmented core mold has a 1mm shim gap in thickness and width. A threaded pin hole is provided on one side of the segmented core mold facing the corner seat. The axis of the pin hole is parallel to the bottom surface of the segmented core mold for quick demolding.

7. A method for molding a wedge-shaped metal honeycomb core adhesive product using a mold-forming apparatus according to any one of claims 1-6, characterized in that... Includes the following steps: Step 1: Lay a layer of non-porous release film on the surface of the tooling plate. The release film should be at least 30mm larger than the edge line of the wedge-shaped metal honeycomb core adhesive product. Then place the lower skin with the adhesive film on the release film. Step 2: Place the beams and ribs on the lower skin according to the position lines, put the segmented core molds into the inner cavities of the beams and ribs, and select appropriate shims to adjust the gaps according to the gap size until the segmented core molds are tightly attached to the beams and ribs; Step 3: Place the honeycomb core between the beams and ribs, install the corner brackets, and after the corner brackets are in place, insert the positioning pins first, and then tighten them with slotted pan head screws. Step 4: Install the tail strip and check if there is a gap between the corner bracket and the segmented core mold. If there is a gap, fill the gap with shims until it is pressed tightly. Step 5: Lay a non-porous release film on the surface of the wedge-shaped metal honeycomb core adhesive product, connect the first-cured cover plate and a layer of silicone rubber soft film with plastic tape, place them on the release film, make bags, perform vacuum leakage testing, and complete the first curing. Step 6: Remove the bag and check the step difference between the honeycomb core and the beams, ribs and tail edge strips. If the step difference exceeds 0.05mm, perform dust-free grinding and repair on the area of ​​the honeycomb core within 50mm of the beams, ribs and tail edge strips. Step 7: After polishing, check the step difference. If it meets the requirements, use methyl ethyl ketone (MEK) to activate the surface of the beams, ribs, and tail edge strips. Step 8: Lay the adhesive film on the upper skin, place the upper skin on the honeycomb core, then add the isolation film, and finally add the secondary curing cover plate and two layers of silicone rubber soft film to make the bag and cure it. Step 9: Remove the bag, remove the slotted pan head screws on the corner bracket, then remove the positioning pin, and take out the segmented core mold and gasket from the inner cavity of the beam and rib.

Images