Manufacturing methods for conductive carbon fiber composite embedded parts, photovoltaic panels and embedded parts

Abstract

This invention belongs to the field of aerospace technology. It discloses a conductive carbon fiber composite embedded part, a photovoltaic panel, and a method for manufacturing the embedded part, comprising: a first conductive layer; multiple carbon fiber prepreg layers stacked and fixed to form a composite material layer, the first conductive layer being located on one end face of the composite material layer; a second conductive layer disposed within the composite material layer and located between two adjacent carbon fiber prepreg layers; the first conductive layer, the composite material layer, and the second conductive layer having at least one threaded hole, with a threaded sleeve fixed inside the threaded hole; the first conductive layer being a low-area-density first conductive aluminum mesh; and the second conductive layer being a conductive copper mesh or a second conductive aluminum mesh. This invention enables the carbon fiber composite embedded part to replace the aluminum alloy embedded part in satellites. The embedded part can be machined to achieve its shape, has a lower density than the aluminum alloy embedded part, meets strength and conductivity requirements, reduces the weight of the embedded part and solar panel, and improves commercial payload capacity.

Description

Technical Field

[0001] This invention belongs to the field of aerospace technology, and particularly relates to a conductive carbon fiber composite embedded part, a photovoltaic panel, and a method for manufacturing the embedded part. Background Technology

[0002] New satellites are placing increasingly stringent demands on structural load-bearing capacity and weight limitations. Aerospace designers are continuously striving to reduce the weight of satellite structures and components to improve the effective commercial payload of launch vehicles. Common aluminum alloy honeycomb sandwich panels / antenna mounting metal inserts are heavy, creating an urgent need for new structural inserts to meet the demands for high load-bearing and lightweight design. Currently, satellite structures often use aluminum alloy block-shaped metal inserts with filler adhesives such as J-47D for fixation, resulting in relatively large masses in the honeycomb sandwich panels or antenna structures.

[0003] Although traditional carbon fiber composite materials can replace aluminum alloy materials and meet the mechanical strength requirements, their weak electrical conductivity cannot meet the requirements for solar panel conduction.

[0004] Furthermore, in the prior art, for example, the patent with publication number CN109291575A, entitled "A Surface Protective Conductive Composite Material and Its Preparation Method", the conductive function is achieved by adding various conductive materials to eliminate charge and current. The main product is aerospace composite material plates with regular shapes, and the main purpose is to improve the sealing protection and damage resistance of composite materials. However, it cannot meet the connection and strength requirements of special aerospace structures such as solar panels.

[0005] Therefore, a conductive carbon fiber composite embedded part, a photovoltaic panel, and a method for manufacturing the embedded part are provided to solve the above problems. Summary of the Invention

[0006] To address the aforementioned technical problems, this invention proposes a conductive carbon fiber composite embedded part, a photovoltaic panel, and a method for manufacturing the embedded part. This method enables the carbon fiber composite embedded part to replace the aluminum alloy embedded part in satellites. The embedded part can be obtained through machining, has a lower density than the aluminum alloy embedded part, meets the strength and conductivity requirements, reduces the weight of the embedded part and the solar panel, and improves the commercial load capacity.

[0007] To achieve the above objectives, the present invention provides a conductive carbon fiber composite material embedded part, comprising:

[0008] First conductive layer;

[0009] Multiple carbon fiber prepreg layers are stacked and fixed to form a composite material layer, with the first conductive layer located on one end face of the composite material layer.

[0010] The second conductive layer is disposed within the composite material layer and located between two adjacent carbon fiber prepreg layers.

[0011] Furthermore, the first conductive layer, the composite material layer, and the second conductive layer are provided with at least one threaded hole, and a threaded sleeve is fixed in the threaded hole.

[0012] Furthermore, the first conductive layer is a low-area-density first conductive aluminum mesh.

[0013] Furthermore, the second conductive layer is a conductive copper mesh or a second conductive aluminum mesh.

[0014] A photovoltaic panel includes the aforementioned conductive carbon fiber composite material embedded part.

[0015] A method for manufacturing a conductive carbon fiber composite embedded part, used to manufacture the aforementioned conductive carbon fiber composite embedded part, comprising the following steps:

[0016] Two adjacent carbon fiber prepreg layers are laid to form a composite material layer. A first conductive layer is laid on the end face of the composite material layer, and a second conductive layer is laid between two adjacent carbon fiber prepreg layers.

[0017] The first conductive layer, the composite material layer, and the second conductive layer are cured and molded to form a plate.

[0018] Processing sheet metal to form embedded parts of a predetermined shape.

[0019] Furthermore, after processing the sheet metal to form the embedded part of the predetermined shape, threaded holes are drilled into the embedded part.

[0020] Furthermore, after drilling the threaded hole, a threaded sleeve is fixed into the threaded hole.

[0021] Furthermore, after fixing the threaded sleeve into the threaded hole, the conductivity of the embedded part is tested.

[0022] Compared with the prior art, the present invention has the following advantages and technical effects:

[0023] Carbon fiber composite embedded parts can replace aluminum alloy embedded parts in satellites. The shape of the embedded parts can be obtained through machining. The density is lower than that of aluminum alloy embedded parts. It can meet the requirements of strength and conductivity, reduce the weight of embedded parts and solar panels, and improve commercial load capacity. Attached Figure Description

[0024] The accompanying drawings, which form part of this application, are used to provide a further understanding of this application. The illustrative embodiments and descriptions of this application are used to explain this application and do not constitute an undue limitation of this application. In the drawings:

[0025] Figure 1This is a structural schematic diagram of the embedded parts;

[0026] Figure 2 Exploded view of the embedded parts;

[0027] Figure 3 A three-dimensional view of a rectangular embedded slot within an insert;

[0028] Figure 4 for Figure 3 A sectional view;

[0029] Figure 5 A three-dimensional view of a circular pre-embedded part groove being created within the insert;

[0030] Wherein, 1-first conductive layer, 2-carbon fiber prepreg layup, 3-second conductive layer, 4-screw sleeve, 5-insertion. Detailed Implementation

[0031] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0033] Reference Figures 1-5 The present invention provides a conductive carbon fiber composite material embedded part, comprising: a first conductive layer 1; a plurality of carbon fiber prepreg lay-ups 2, stacked and fixed to form a composite material layer, wherein the first conductive layer 1 is located on one end face of the composite material layer; and a second conductive layer 3, disposed in the composite material layer and located between two adjacent carbon fiber prepreg lay-ups 2.

[0034] Specifically, multiple carbon fiber prepreg layers 2 are laid and stacked to form a composite material layer. A first conductive layer 1 is laid and fixed on one end face of the composite material layer, and a second conductive layer 3 is disposed in the composite material layer and laid between two adjacent carbon fiber prepreg layers 2.

[0035] Specifically, a conductive composite carbon fiber sheet is fabricated by applying a first conductive layer 1 and a second conductive layer 3 to the surface and intermediate layers of the carbon fiber composite material. By adding conductive material to the composite material layers and intermediate layers, surface and internal conductivity of the embedded part is achieved, thus ensuring conductivity between the substrate, structure, internal threaded holes, and the satellite, maintaining potential balance. The addition of a threaded sleeve 4 gives the carbon fiber embedded part the same connection strength as aluminum alloy inserts and meets the requirements for repeated assembly and disassembly. The embedded metal conductive mesh meets co-curing requirements and aerospace low-resistance standards. It is suitable for manufacturing inserts with different structural forms, meeting the requirements of no venting and zero potential difference under high-energy radiation conditions in space.

[0036] Preferably, the second conductive layer 3 is disposed in the middle of the composite material layer.

[0037] In one specific embodiment of the present invention, four layers of carbon fiber prepreg layup 2 are laid on the first conductive layer 1, a second conductive layer 3 is laid on the end face of the four layers of carbon fiber prepreg layup 2 away from the first conductive layer 1, and four layers of carbon fiber prepreg layup 2 are laid on the end face of the second conductive layer 3 away from the first conductive layer 1 to form an embedded part.

[0038] The embedded parts are used for the connection between the solar panel and the substrate, and for the connection of the metal parts mechanism for unfolding and unlocking. The original connection used aluminum alloy, which required the embedding of threaded bushings to enhance the strength of the aluminum alloy threads, thereby improving the pressure resistance and wear resistance of the threads. After using carbon fiber, threaded bushings are also used, and glue is added to fix them to increase the wear resistance and torsional torque of the threaded bushings.

[0039] This embedded part is used in the foam, honeycomb and other sandwich structures of satellites and other aircraft to connect with other components in the satellite, and has functions such as pressure bearing, load bearing and electrical conductivity.

[0040] This embedded component has the same function as existing aluminum alloy embedded components and can replace aluminum alloy materials in satellites. The shape of the embedded component is obtained through machining and other methods, and its density is lower than that of aluminum alloy materials. The specific gravity of the composite material embedded component is 1.6 g / cm³. 3 The specific gravity of the aluminum alloy parts is approximately 2.7 g / cm³. 3 The embedded parts made of carbon fiber composite materials are used instead of the currently used lightweight aluminum alloy materials, and the weight of the same embedded parts is reduced by about 30-40%.

[0041] Among them, composite embedded parts are used in sandwich structures such as satellite solar panels and antennas, which can meet the requirements of strength and conductivity, reduce the weight of embedded parts and solar panels, and improve commercial load capacity.

[0042] Among them, reference Figure 3 , Figure 4 , Figure 5The embedded part 5 has a pre-embedded part groove, and the pre-embedded part is installed in the pre-embedded part groove. Depending on the different shapes of the groove in the embedded part 5, the pre-embedded part is machined to set the pre-embedded part in the embedded part 5.

[0043] In this embodiment, refer to Figure 1 The first conductive layer 1, the composite material layer, and the second conductive layer 3 are provided with at least one threaded hole, and a threaded sleeve 4 is fixed in the threaded hole.

[0044] Specifically, if the embedded parts need to be connected or disassembled multiple times, a threaded sleeve 4 needs to be embedded into the embedded parts. The threaded sleeve 4 is used to reinforce and protect the internal threads of the composite material embedded parts. The threaded sleeve 4 can achieve functions such as high connection strength, seismic resistance, impact resistance and wear resistance, and can also disperse stress to protect the threads of the composite material embedded parts and extend the service life of the embedded parts.

[0045] Specifically, embedded parts are made by machining sheet metal. These embedded parts are installed into the base plate and can be connected and communicated with other satellite components. The threaded hole is reinforced with threaded sleeve 4 to achieve connection and communication with the satellite body and various base plates, meeting the high overload requirements during satellite launch and ascent and the load-bearing strength requirements during deployment in space.

[0046] In a preferred embodiment of the present invention, the threaded sleeve 4 is a wire threaded sleeve.

[0047] In this embodiment, refer to Figure 1 , Figure 2 The first conductive layer 1 is a low-area-density first conductive aluminum mesh.

[0048] Among them, a first conductive aluminum mesh with low surface density is selected and laid on the surface of the composite material layer.

[0049] In this embodiment, refer to Figure 1 , Figure 2 The second conductive layer 3 is a conductive copper mesh or a second conductive aluminum mesh.

[0050] Conductive copper mesh or conductive aluminum mesh is selected as the intermediate conductive layer, and carbon fiber prepreg layer 2 is laid to the thickness of the embedded part in the design drawings. During the laying process, air is vented and compacted.

[0051] A photovoltaic panel includes the aforementioned conductive carbon fiber composite material embedded part.

[0052] The photovoltaic panel is a solar panel with pre-embedded parts, and it is used in satellites.

[0053] The surface layer uses a low-area-density metal mesh, and the aluminum honeycomb used in the substrate interlayer is made of the same metal material to eliminate static electricity generated by high-energy radiation from space. The inner layer uses a medium-area-density metal mesh.

[0054] Each solar panel uses 6 to 18 or more pre-embedded components. The volume of a single component is approximately 10 to 70 cubic centimeters, and the volume of 10 components is approximately 100 to 700 cubic centimeters. Using pre-embedded components can reduce the weight of a single solar panel by approximately 40 to 280 grams. A satellite requires 2 to 16 solar panels. The significant weight reduction effect of composite material pre-embedded components can effectively increase the commercial payload of satellites / spacecraft and reduce rocket launch / operation costs.

[0055] A method for manufacturing a conductive carbon fiber composite embedded part, used to manufacture the aforementioned conductive carbon fiber composite embedded part, comprising the following steps:

[0056] S1. Select conductive materials with different areal densities and carbon fiber prepreg layer 2, wherein the Tg of the resin system of carbon fiber prepreg layer 2 is greater than 150℃.

[0057] S2. Lay two adjacent carbon fiber prepreg layers 2 to form a composite material layer, lay a first conductive layer 1 on the end face of the composite material layer, and lay a second conductive layer 3 between two adjacent carbon fiber prepreg layers 2.

[0058] Specifically, a low-area-density conductive aluminum mesh is selected and laid on the surface of the carbon fiber prepreg layer 2. The second conductive layer 3 can be a conductive copper mesh or a second conductive aluminum mesh. The carbon fiber prepreg layer 2 is then laid up to the thickness of the embedded part in the design drawings. During the laying process, air is vented and compacted.

[0059] S3. Curing and molding the first conductive layer 1, composite material layer, and second conductive layer 3 to form a sheet. Using custom-made thickness tooling and a pressure plate, the sheet is cured according to material specifications.

[0060] S4. Process the sheet metal to form the embedded part of the predetermined shape. Using the prepared embedded part sheet metal, machine the embedded part to the shape and size according to the drawing dimensions to form the finished embedded part.

[0061] S5. After processing the sheet metal to form the embedded part of the predetermined shape, drill threaded holes in the embedded part. Use a special threaded insert tool to drill threaded holes in the embedded part.

[0062] S6. After drilling the threaded hole, fix the threaded sleeve 4 into the threaded hole. Use a special tool to install the threaded sleeve 4 into the threaded hole.

[0063] S7. After fixing the threaded sleeve 4 into the threaded hole, perform a conductivity test on the embedded part. After the threaded sleeve 4 is installed, use an ohmmeter to test the resistance value to perform a conductivity test on the embedded part.

[0064] The above are merely preferred embodiments of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. An electrically conductive carbon fiber composite preform, characterized by: The conductive carbon fiber composite material embedded part comprises: a first conductive layer (1); a plurality of carbon fiber prepreg layers (2) stacked and fixed to form a composite material layer, the first conductive layer (1) being arranged on one end surface of the composite material layer; a second conductive layer (3) arranged in the composite material layer and between two adjacent carbon fiber prepreg layers (2).

2. The electrically conductive carbon fiber composite preform of claim 1, wherein: The first conductive layer (1), the composite material layer and the second conductive layer (3) are provided with at least one threaded hole, and a screw sleeve (4) is fixed in the threaded hole.

3. The electrically conductive carbon fiber composite preform of claim 1, wherein: The second conductive layer (3) is a conductive copper mesh or a second conductive aluminum mesh.

4. A photovoltaic panel, characterized by: The conductive carbon fiber composite material embedded part of any one of claims 1-3.

5. A method for manufacturing the electrically conductive carbon fiber composite material embedded member according to claim 2, characterized by: The manufacturing steps comprise: arranging two adjacent carbon fiber prepreg layers (2) to form a composite material layer, arranging the first conductive layer (1) on the end surface of the composite material layer, and arranging the second conductive layer (3) between the two adjacent carbon fiber prepreg layers (2); curing and forming the first conductive layer (1), the composite material layer and the second conductive layer (3) to form a plate; processing the plate to form an embedded part with a predetermined shape.

6. The method of claim 5, wherein the method further comprises the step of: After the plate is processed to form the embedded part with the predetermined shape, a threaded hole is drilled in the embedded part. ​ 7. The method of claim 6, wherein the method further comprises the step of: After the threaded hole is drilled, a screw sleeve (4) is fixed in the threaded hole. ​ 8. The method of claim 7, wherein the method further comprises the step of: After the screw sleeve (4) is fixed in the threaded hole, the embedded part is tested for electrical conductivity. ​

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