Arcuate carbon fiber foam sandwich CT couch top and method of making same

Abstract

The application belongs to the technical field of CT bed plate manufacturing, and discloses an arc-shaped carbon fiber foam sandwich CT bed plate and a manufacturing method thereof. The manufacturing method of the arc-shaped carbon fiber foam sandwich CT bed plate comprises the following steps: S1, hot bending forming of a PMI foam core material; S2, laying of carbon fiber prepreg; and S3, mold pressing and curing. The manufacturing method of the arc-shaped carbon fiber foam sandwich CT bed plate adopts a hot bending forming mode to obtain an arc-shaped PMI foam core material, and has the advantages of low processing cost, low material loss rate, no need for special jigs and clamps and the like for auxiliary processing, simple operation, low cost and high efficiency. In addition, when the carbon fiber prepreg is laid on the surface of the arc-shaped PMI foam core material, the laying is performed with the aid of a lower mold of a forming mold, so that the carbon fiber prepreg and the profile of the lower mold of the forming mold follow the shape, and the appearance design quality of the bed plate is ensured. Meanwhile, the vacuum pre-pressing operation in the laying process is also performed with the aid of the lower mold of the forming mold, and low-temperature auxiliary heating is adopted, so that the compactness and strength of the structure are increased.

Description

Technical Field

[0001] This invention relates to the field of CT bed panel manufacturing technology, and in particular to an arc-shaped carbon fiber foam sandwich CT bed panel and its manufacturing method. Background Technology

[0002] Curved CT slabs can be structurally categorized into solid carbon fiber slabs, carbon fiber foam sandwich slabs, and hollow carbon fiber slabs. Among these, the carbon fiber foam sandwich slab uses carbon fiber composite material as the skin and low-density polymethacrylimide (PMI) foam as the internal core. This significantly reduces structural weight while maintaining overall strength, and allows for customized structural design and integrated molding to meet specific usage requirements. Furthermore, due to the very low aluminum equivalent of the carbon fiber foam sandwich medical panel, it exhibits extremely low X-ray absorption and excellent transmission uniformity, resulting in superior imaging performance.

[0003] For this type of curved CT bed board, a thermosetting curing method can be used. This involves laying carbon fiber prepreg on the surface of the foam core material, and then placing it in a molding mold for thermosetting and curing. In existing technologies, the internal PMI foam is typically machined using CNC machining, resulting in high processing costs and material loss rates. Furthermore, the PMI foam core material requires specialized jigs and fixtures for auxiliary processing, further increasing manufacturing costs. Moreover, existing technologies for laying carbon fiber prepreg on the PMI foam core material are prone to wrinkling or deformation, failing to guarantee the aesthetic design quality of the bed board. Summary of the Invention

[0004] The purpose of this invention is to provide an arc-shaped carbon fiber foam sandwich CT bed panel and its manufacturing method. The manufacturing method of the arc-shaped carbon fiber foam sandwich CT bed panel has low processing cost, simple operation, and does not require special jigs and fixtures for auxiliary processing. At the same time, the carbon fiber prepreg can conform to the shape of the mold, which can ensure the appearance design quality of the arc-shaped carbon fiber foam sandwich CT bed panel, and the structure has good density and strength.

[0005] To achieve this objective, the present invention adopts the following technical solution:

[0006] On the one hand, a method for manufacturing an arc-shaped carbon fiber foam sandwich CT bed panel is provided, comprising:

[0007] S1. Hot bending of PMI foam core material: The flat PMI foam core material is placed in the lower mold of the molding die. A non-porous release film and a breathable felt are sequentially laid on the surface of the flat PMI foam core material. Then, the flat PMI foam core material with the laid-out material is sealed between the lower mold of the molding die and the vacuum bag. The flat PMI foam core material is heated and pressurized to form an arc-shaped PMI foam core material by following the shape of the lower mold of the molding die.

[0008] S2. Carbon fiber prepreg laying: The arc-shaped PMI foam core material is taken out from the lower mold of the molding die. A layer of resin film is uniformly coated on the surface of the arc-shaped PMI foam core material. The coated arc-shaped PMI foam core material is then placed in the lower mold of the molding die for vacuum pre-compression. Then, the carbon fiber prepreg is laid on the surface of the arc-shaped PMI foam core material in the lower mold according to the designed number of layers and angle. During the laying process, the lower mold of the molding die is subjected to low-temperature auxiliary heating, and vacuum pre-compression is performed once for each set number of carbon fiber prepreg layers to form a carbon fiber skin and obtain a preform. Afterwards, the lower mold of the molding die is continued to be subjected to low-temperature auxiliary heating, and the preform is vacuum pre-compressed in the lower mold of the molding die.

[0009] S3. Molding and curing: The preformed body after vacuum pre-compression is placed into the lower mold of the molding mold. After the upper mold of the molding mold and the lower mold of the molding mold are closed, the preformed body is hot-pressed and cured to obtain an arc-shaped carbon fiber foam sandwich CT bed board.

[0010] Preferably, in step S1, the fabrication of the flat PMI foam core material includes: determining the dimensional parameters of the flat PMI foam core material and performing machining based on the design dimensions of the arc-shaped carbon fiber foam sandwich CT bed board and the high-temperature compression creep characteristics of the PMI foam material.

[0011] Preferably, in step S1, heating and pressurizing the flat PMI foam core material includes:

[0012] Place the lower mold of the molding die on the press platform, turn on the press heating system, and heat the lower mold of the molding die to 180°C, then start timing for heat preservation; after 15 minutes, turn on the press vacuum system to make the flat PMI foam core material fit the surface of the lower mold of the molding die, and start heat preservation and pressure preservation when the vacuum pressure is -0.1Mpa;

[0013] After heat preservation and pressure maintenance for 60 minutes, the heating system and the vacuum system are turned off, and the lower mold of the molding die is allowed to cool down naturally. The die is demolded when the temperature drops below 60°C.

[0014] Preferably, in step S2, placing the coated arc-shaped PMI foam core material in the lower mold of the molding mold for vacuum pre-compression includes: sequentially laying a non-porous isolation film and a breathable felt on the surface of the arc-shaped PMI foam core material, and then sealing the coated arc-shaped PMI foam core material between the lower mold of the molding mold and the vacuum bag for vacuum pre-compression.

[0015] Preferably, in step S2, the carbon fiber prepreg is laid on the surface of the arc-shaped PMI foam core material according to the designed number of layers and angles in the lower mold of the molding mold. During the laying process, the lower mold of the molding mold is subjected to low-temperature auxiliary heating, and a vacuum pre-compression is performed once for each set number of layers of carbon fiber prepreg laid. Specifically, the lower mold of the molding mold is placed on the press platform, the heating system of the press is turned on, the lower mold of the molding mold is heated to 30-35°C and then kept warm. The carbon fiber prepreg is laid on the upper and lower surfaces and four sides of the arc-shaped PMI foam core material. The lower layer of carbon fiber prepreg is laid in the lower mold of the molding mold, the arc-shaped PMI foam core material is laid on the lower layer of carbon fiber prepreg, and the upper layer of carbon fiber prepreg is laid on the arc-shaped PMI foam core material. A vacuum pre-compression is performed in the lower mold of the molding mold every three layers of carbon fiber prepreg laid.

[0016] Preferably, the carbon fiber prepreg is applied to the top and bottom surfaces and four sides of the curved PMI foam core material using a 0° and 90° cross-layout method. The length direction of the curved PMI foam core material is defined as the 0° direction. Specifically, the 0° direction layout involves applying one layer of carbon fiber prepreg above and below the curved PMI foam core material along the 0° direction, and then joining or overlapping the two layers of carbon fiber prepreg at the four sides. The direction perpendicular to the 0° direction is the 90° direction. Specifically, the 90° direction layout involves applying one layer of carbon fiber prepreg to the surface of the curved PMI foam core material along the 90° direction. One layer of carbon fiber prepreg is circumferentially wrapped around the entire curved PMI foam core material, and then joining or overlapping the sides along the length direction of the curved PMI foam core material. Furthermore, a vacuum pre-compression is performed on the lower mold of the molding die every three layers of carbon fiber prepreg applied cross-layout.

[0017] Preferably, in step S2, the lower mold of the molding die is subjected to low-temperature auxiliary heating, and the preform is subjected to vacuum pre-compression on the lower mold of the molding die, which includes: sequentially laying a non-porous isolation film and a breathable felt on the surface of the preform, then sealing the preform with the film laid on between the lower mold of the molding die and the vacuum bag, placing the lower mold of the molding die on the press platform, turning on the heating system and vacuum system of the press, heating the lower mold of the molding die to 35°C, and when the vacuum pressure is -0.1 MPa, starting the timer, and keeping it warm and pressurized for 15 minutes.

[0018] Preferably, in step S2, before laying the carbon fiber prepreg, the shape and size of the carbon fiber prepreg sheet are designed according to the laying requirements, and an automatic fabric cutting machine is used to cut the material.

[0019] Preferably, before step S1, the method further includes: step A1, preparing the upper mold and the lower mold of the molding mold, inspecting and wiping the surfaces of the upper mold and the lower mold of the molding mold, and attaching high-temperature sealing strips and the vacuum bag along the edge of the lower mold line;

[0020] Following step S3, the following is also included:

[0021] S4. Machining: Trimming, milling, and drilling of the arc-shaped carbon fiber foam sandwich CT bed board;

[0022] S5. Spray painting: After cleaning the surface of the arc-shaped carbon fiber foam sandwich CT bed board, spray water-soluble ceramic paint evenly onto the surface.

[0023] On the other hand, an arc-shaped carbon fiber foam sandwich CT bed board is provided, comprising an arc-shaped PMI foam core material and a carbon fiber skin, wherein the arc-shaped carbon fiber foam sandwich CT bed board is manufactured by the manufacturing method of the arc-shaped carbon fiber foam sandwich CT bed board described in any of the above embodiments.

[0024] The beneficial effects of this invention are:

[0025] The present invention provides a method for manufacturing an arc-shaped carbon fiber foam sandwich CT bed panel, comprising: step S1, hot bending of PMI foam core material; step S2, laying of carbon fiber prepreg; and step S3, molding and curing. This method for manufacturing an arc-shaped carbon fiber foam sandwich CT bed panel utilizes hot bending to obtain the arc-shaped PMI foam core material, avoiding the high processing costs and material loss rates associated with CNC machining. The flat foam core material is placed in the lower mold of the molding die and sealed between the lower mold and a vacuum bag. Utilizing the softening properties of PMI foam material upon heating, it is heated and pressurized, thus conforming to the shape of the lower mold surface to obtain the arc-shaped PMI foam core material. This method eliminates the need for specialized jigs and fixtures, resulting in simple operation, low cost, and high efficiency. Furthermore, the hot bending of the PMI foam core material and the forming of the arc-shaped carbon fiber foam sandwich CT bed panel share a single mold, eliminating the need for a separate hot bending mold and saving manufacturing costs. Furthermore, during the carbon fiber prepreg application process, the lower mold of the molding die is used to apply the carbon fiber prepreg to the surface of the curved PMI foam core material. This ensures that the carbon fiber prepreg conforms to the shape of the lower mold, providing support and preventing wrinkles or deformation, thus guaranteeing the appearance design quality of the curved carbon fiber foam sandwich CT bed board. Additionally, the vacuum preloading operation during the carbon fiber prepreg application process is also performed using the lower mold, ensuring that the carbon fiber prepreg conforms to the shape of the lower mold. Low-temperature auxiliary heating is used during vacuum preloading to effectively expel air trapped between the carbon fiber prepreg layers, eliminating internal pore defects and increasing the density and strength of the structure.

[0026] The arc-shaped carbon fiber foam sandwich CT bed panel provided by this invention has low processing cost. The carbon fiber prepreg can conform to the shape of the lower mold of the molding die, which ensures the appearance design quality of the arc-shaped carbon fiber foam sandwich CT bed panel, and the structure has good density and strength. Attached Figure Description

[0027] Figure 1 This is a flowchart of the manufacturing method of the arc-shaped carbon fiber foam sandwich CT bed plate provided by the present invention. Detailed Implementation

[0028] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, and not all of the structures.

[0029] In the description of this invention, unless otherwise explicitly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection 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 invention based on the specific circumstances.

[0030] In this invention, unless otherwise explicitly 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 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 directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0031] In the description of this embodiment, the terms "upper," "lower," "right," etc., refer to the orientation or positional relationship shown in the accompanying drawings. They are used only for ease of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention. In addition, the terms "first" and "second" are used only for distinction in description and have no special meaning.

[0032] like Figure 1 As shown, the present invention provides a method for manufacturing an arc-shaped carbon fiber foam sandwich CT bed plate, specifically including the following steps:

[0033] A1. Preparation of the molding die. Specifically, step A1 includes the following steps:

[0034] Step A11: Visually inspect the surfaces of the upper and lower molds of the molding die to check for any foreign matter or damage such as dried glue, stains, scratches, etc., and use a lint-free cloth dampened with a small amount of alcohol to wipe the surfaces of the upper and lower molds of the molding die clean.

[0035] Step A12: Attach high-temperature sealing strips and vacuum bags along the edge of the lower mold line of the forming mold. The purpose of prefabricating vacuum bags is to prepare for the hot bending forming of PMI foam core material.

[0036] S1. PMI foam core material hot bending forming. Step S1 specifically includes the following steps:

[0037] S11: Fabrication of flat PMI foam core material. Based on the design dimensions of the curved carbon fiber foam sandwich CT bed board and the high-temperature compression creep characteristics of PMI foam material, the dimensional parameters of the flat PMI foam core material are determined and then machined to obtain the flat PMI foam core material. Processing is based on the flat PMI foam core material, which offers a simple processing method and high material utilization.

[0038] S12: Place the flat PMI foam core material into the lower mold of the molding die. Then, sequentially lay a non-porous release liner and a breathable felt on the surface of the flat PMI foam core material. Afterward, seal the laid-out flat PMI foam core material between the lower mold and the vacuum bag for vacuum pre-compression. Using a vacuum bag for vacuuming and pressurization results in low processing costs. Laying the non-porous release liner and breathable felt facilitates air extraction.

[0039] S13: The flat PMI foam core material is heated and pressurized, and an arc-shaped PMI foam core material is formed by conforming to the shape of the lower mold of the molding die. Specifically, the lower mold of the molding die is placed on the press platform, and the heating system of the press is turned on to provide a heat source for the hot bending of the flat PMI foam core material. When the lower mold of the molding die is heated to 180°C, the timer for heat preservation begins, and the heat from the lower mold of the molding die is transferred to the flat PMI foam core material, so that the flat PMI foam core material is heated evenly. After 15 minutes, the vacuum system of the press is turned on to make the flat PMI foam core material conform to the shape of the lower mold of the molding die. When the vacuum pressure is -0.1Mpa, heat preservation and pressure preservation begin; after heat preservation and pressure preservation for 60 minutes, the heating system and vacuum system are turned off, and the lower mold of the molding die is allowed to cool down naturally. When the temperature drops below 60°C, the mold is demolded. In this embodiment, the upper surface and the lower surface of the formed arc-shaped carbon fiber foam sandwich CT bed board have the same curvature, so only the lower mold of the molding die is needed for hot bending.

[0040] A hot bending process is used to prepare the internal curved PMI foam core material required for curved carbon fiber foam sandwich CT bed panels, avoiding the high processing costs and material loss rates associated with CNC machining. The flat foam core material is placed in the lower mold of a molding die and sealed between the lower mold and a vacuum bag. Utilizing the softening properties of PMI foam, it is heated and pressurized, conforming to the shape of the lower mold surface to obtain the curved PMI foam core material. No special jigs or fixtures are required, making the operation simple, low-cost, and highly efficient. Furthermore, the hot bending of the PMI foam core material and the subsequent molding and curing of the curved carbon fiber foam sandwich CT bed panel share the same mold, eliminating the need for a separate hot bending mold and saving manufacturing costs.

[0041] S2, Carbon fiber prepreg laying. Step S2 specifically includes the following steps:

[0042] S21: Remove the curved PMI foam core material from the lower mold of the molding die. Evenly coat the surface of the curved PMI foam core material with a layer of resin film. Then place the coated curved PMI foam core material into the lower mold of the molding die for vacuum pre-compression. Using the lower mold, the resin film is pressed firmly onto the surface of the curved PMI foam core material, ensuring a tight bond between the resin film and the surface of the curved PMI foam core material, facilitating subsequent application of the carbon fiber prepreg. Specifically, after evenly coating the surface of the curved PMI foam core material with a layer of resin film, a non-porous release film and a breathable felt are sequentially laid on the surface of the curved PMI foam core material. Then, the finished flat PMI foam core material is sealed between the lower mold of the molding die and a vacuum bag for vacuum pre-compression. Using a vacuum bag for vacuum pre-compression reduces processing costs.

[0043] S22: Design the shape and size of the carbon fiber prepreg sheet according to the paving requirements, and use an automatic fabric cutter to cut the material.

[0044] S23: Using the lower mold of the molding die, carbon fiber prepreg is laid on the surface of the arc-shaped PMI foam core material according to the designed number of layers and angle. During the laying process, the lower mold of the molding die is heated at low temperature, and vacuum pre-compression is performed once for each set number of carbon fiber prepreg layers to form a carbon fiber skin and obtain a preform.

[0045] Specifically, the lower mold of the molding die is placed on the press platform, and the press's heating system is turned on. The lower mold is heated to 30-35℃ and then kept at that temperature. Carbon fiber prepreg is then applied to the top and bottom surfaces and four sides of the curved PMI foam core material. The lower layer of carbon fiber prepreg is placed in the lower mold, and the curved PMI foam core material is placed on top of it. The upper layer of carbon fiber prepreg material is then placed on top of the curved PMI foam core material. Vacuum pre-pressing is performed every three layers of carbon fiber prepreg applied in the lower mold. The lower mold is used to apply the carbon fiber prepreg to the surface of the curved PMI foam core material, ensuring the carbon fiber prepreg conforms to the shape of the lower mold. Vacuum pre-pressing is also performed using the lower mold to ensure the carbon fiber prepreg conforms to the shape of the lower mold. The lower mold is then heated at a low temperature and kept at that temperature to facilitate the application of the carbon fiber prepreg. Every three layers of carbon fiber prepreg are laid on the top and bottom, and vacuum pre-compression is performed once in the lower mold of the molding die. During the vacuum pre-compression process, the lower mold of the molding die is kept warm to promote the effective expulsion of air trapped between the carbon fiber prepreg layers.

[0046] Furthermore, applying carbon fiber prepreg to the top and bottom surfaces and four sides of the curved PMI foam core material using a 0° and 90° cross-layout method is beneficial for improving the mechanical properties of the curved carbon fiber foam sandwich CT bed board. The length direction of the curved PMI foam core material is defined as the 0° direction. Specifically, the 0° direction laying involves laying a layer of carbon fiber prepreg above and below the curved PMI foam core material along the 0° direction, and then butt-jointing or overlapping the upper and lower layers of carbon fiber prepreg at the four sides. Optionally, in this embodiment, the area of ​​the lower carbon fiber prepreg is larger than that of the upper carbon fiber prepreg, and the lower carbon fiber prepreg overlaps the upper carbon fiber prepreg, simplifying the operation and achieving good laying results. The direction perpendicular to the 0° direction is the 90° direction. Specifically, the 90° direction laying involves laying a layer of carbon fiber prepreg along the 90° direction on the surface of the curved PMI foam core material. This layer of carbon fiber prepreg is circumferentially applied to the entire curved PMI foam core material, and is butted or overlapped along the side of the curved PMI foam core material along its length. Vacuum pre-compression is performed every three layers of carbon fiber prepreg laid at an intersection. Using the 90° direction improves the overall continuity of the carbon fiber, facilitating tension and adhesion; furthermore, the circumferential approach allows for the simultaneous laying of both upper and lower layers of carbon fiber prepreg, resulting in high laying efficiency.

[0047] S24: Continue low-temperature auxiliary heating of the lower mold of the molding die, while simultaneously performing vacuum pre-compression on the preform within the lower mold. During vacuum pre-compression, the lower mold of the molding die is subjected to low-temperature auxiliary heating to further eliminate air trapped within the internal structure of the preform. Furthermore, vacuum pre-compression of the preform using the lower mold ensures that the carbon fiber prepreg conforms to the shape of the lower mold. Specifically, a non-porous release film and a breathable felt are sequentially laid on the surface of the preform. The preform is then sealed between the lower mold and the vacuum bag. The lower mold is placed on the press platform, and the press's heating and vacuum systems are turned on. When the lower mold reaches 35°C and the vacuum pressure is -0.1 MPa, timing begins, and the temperature and pressure are maintained for 15 minutes. Using a vacuum bag for vacuum pre-compression results in low processing costs.

[0048] During the carbon fiber prepreg application process, the carbon fiber prepreg is applied to the surface of the curved PMI foam core material using a lower mold. This ensures that the carbon fiber prepreg conforms to the shape of the lower mold, providing support and preventing wrinkles or deformation, thus guaranteeing the appearance quality of the curved carbon fiber foam sandwich CT bed panel. The vacuum preloading process is also performed using the lower mold, ensuring that the carbon fiber prepreg conforms to its shape. Furthermore, low-temperature auxiliary heating is used during vacuum preloading to effectively expel air trapped between the carbon fiber prepreg layers, eliminating internal pore defects and increasing the density and strength of the structure.

[0049] S3. Molding and Curing. The preformed body, after vacuum pre-compression, is placed into the lower mold of the molding die. After closing the upper and lower molds, the preformed body is hot-pressed and cured to obtain an arc-shaped carbon fiber foam sandwich CT bed board. Step S3 specifically includes the following steps:

[0050] S31: Mold closing. A 0.045mm thick PET film is laid on the upper and lower surfaces of the preform and wiped clean with a lint-free cloth to ensure that the surface is free of particles and foreign objects, so as to improve the appearance design quality of the arc-shaped carbon fiber foam sandwich CT bed board. Then, the preform is placed into the cavity of the lower mold of the molding mold, the four corner positioning rods are installed, and the upper mold of the molding mold is slowly closed on the lower mold of the molding mold along the positioning rods to complete the mold closing.

[0051] S32: Transfer the upper and lower molds of the molding die as a whole to the press platform, set the heating and pressurizing program for molding and curing. The curing process is as follows: heating rate 1.5℃ / min, curing temperature-pressure-time variation: 90℃, 0.8Mpa, 10min—110℃, 1.6Mpa, 10min—130℃, 2.6Mpa, 120min, cooling rate 2.0℃ / min. Demolding is performed when the temperature of the upper and lower molds drops below 60℃. The curing process is mainly determined based on the properties of the carbon fiber prepreg.

[0052] S4. Machining. According to the design drawings, the curved carbon fiber foam sandwich CT bed plate is trimmed, milled, and drilled to facilitate the installation of other components later.

[0053] S5. Spray painting treatment. After cleaning the surface of the curved carbon fiber foam sandwich CT bed board, water-soluble ceramic paint is evenly sprayed onto the surface to further improve the adhesion and wear resistance of the coating on the surface of the curved carbon fiber foam sandwich CT bed board.

[0054] S6. Final inspection and warehousing.

[0055] The present invention also provides an arc-shaped carbon fiber foam sandwich CT bed board, comprising an arc-shaped PMI foam core material and a carbon fiber skin. The arc-shaped carbon fiber foam sandwich CT bed board is manufactured using the above-mentioned manufacturing method, which has low processing cost, ensures the appearance design quality of the arc-shaped carbon fiber foam sandwich CT bed board, and has good structural density and strength.

[0056] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art will be able to make various obvious changes, readjustments, and substitutions without departing from the scope of protection of the present invention. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A method for manufacturing an arc-shaped carbon fiber foam sandwich CT bed panel, characterized in that, include: S1. Hot bending of PMI foam core material: The flat PMI foam core material is placed in the lower mold of the molding die. A non-porous release film and a breathable felt are sequentially laid on the surface of the flat PMI foam core material. Then, the flat PMI foam core material with the laid-out material is sealed between the lower mold of the molding die and the vacuum bag. The flat PMI foam core material is heated and pressurized to form an arc-shaped PMI foam core material by following the shape of the lower mold of the molding die. S2. Carbon fiber prepreg laying: The arc-shaped PMI foam core material is taken out from the lower mold of the molding die. A layer of resin film is uniformly coated on the surface of the arc-shaped PMI foam core material. The coated arc-shaped PMI foam core material is then placed in the lower mold of the molding die for vacuum pre-compression. Then, the carbon fiber prepreg is laid on the surface of the arc-shaped PMI foam core material in the lower mold according to the designed number of layers and angle. During the laying process, the lower mold of the molding die is subjected to low-temperature auxiliary heating, and vacuum pre-compression is performed once for each set number of carbon fiber prepreg layers to form a carbon fiber skin and obtain a preform. Afterwards, the lower mold of the molding die is continued to be subjected to low-temperature auxiliary heating, and the preform is vacuum pre-compressed in the lower mold of the molding die. S3. Molding and curing: The preformed body after vacuum pre-compression is placed into the lower mold of the molding mold. After the upper mold of the molding mold and the lower mold of the molding mold are closed, the preformed body is hot-pressed and cured to obtain an arc-shaped carbon fiber foam sandwich CT bed board.

2. The manufacturing method of the arc-shaped carbon fiber foam sandwich CT bed plate according to claim 1, characterized in that, In step S1, the fabrication of the flat PMI foam core material includes: determining the dimensional parameters of the flat PMI foam core material and machining it according to the design dimensions of the arc-shaped carbon fiber foam sandwich CT bed board and the high-temperature compression creep characteristics of the PMI foam material.

3. The manufacturing method of the arc-shaped carbon fiber foam sandwich CT bed plate according to claim 1, characterized in that, In step S1, heating and pressurizing the flat PMI foam core material includes: Place the lower mold of the molding die on the press platform, turn on the press heating system, and heat the lower mold of the molding die to 180°C, then start timing for heat preservation; after 15 minutes, turn on the press vacuum system to make the flat PMI foam core material fit the surface of the lower mold of the molding die, and start heat preservation and pressure preservation when the vacuum pressure is -0.1Mpa; After heat preservation and pressure maintenance for 60 minutes, the heating system and the vacuum system are turned off, and the lower mold of the molding die is allowed to cool down naturally. The die is demolded when the temperature drops below 60°C.

4. The manufacturing method of the arc-shaped carbon fiber foam sandwich CT bed plate according to claim 1, characterized in that, In step S2, placing the coated arc-shaped PMI foam core material in the lower mold of the molding mold for vacuum pre-compression includes: sequentially laying a non-porous isolation film and a breathable felt on the surface of the arc-shaped PMI foam core material, and then sealing the coated arc-shaped PMI foam core material between the lower mold of the molding mold and the vacuum bag for vacuum pre-compression.

5. The manufacturing method of the arc-shaped carbon fiber foam sandwich CT bed plate according to claim 1, characterized in that, In step S2, the carbon fiber prepreg is laid on the surface of the arc-shaped PMI foam core material according to the designed number of layers and angles in the lower mold of the molding mold. During the laying process, the lower mold of the molding mold is subjected to low-temperature auxiliary heating, and a vacuum pre-compression is performed once for each set number of layers of carbon fiber prepreg laid. Specifically, the lower mold of the molding mold is placed on the press platform, the heating system of the press is turned on, the lower mold of the molding mold is heated to 30-35°C and then kept warm, and the carbon fiber prepreg is laid on the upper and lower surfaces and four sides of the arc-shaped PMI foam core material. The lower layer of carbon fiber prepreg is laid in the lower mold of the molding mold, the arc-shaped PMI foam core material is laid on the lower layer of carbon fiber prepreg, and the upper layer of carbon fiber prepreg is laid on the arc-shaped PMI foam core material. A vacuum pre-compression is performed in the lower mold of the molding mold every three layers of carbon fiber prepreg laid.

6. The method for manufacturing the arc-shaped carbon fiber foam sandwich CT bed plate according to claim 5, characterized in that, The carbon fiber prepreg is applied to the top and bottom surfaces and four sides of the curved PMI foam core material using a 0° and 90° cross-layout method. The length direction of the curved PMI foam core material is defined as the 0° direction. Specifically, the 0° direction layout involves applying one layer of carbon fiber prepreg above and below the curved PMI foam core material along the 0° direction, and then joining or overlapping the two layers of carbon fiber prepreg at the four sides. The direction perpendicular to the 0° direction is defined as the 90° direction. Specifically, the 90° direction layout involves applying one layer of carbon fiber prepreg on the surface of the curved PMI foam core material along the 90° direction. One layer of carbon fiber prepreg is circumferentially wrapped around the entire curved PMI foam core material, and then joining or overlapping the sides along the length direction of the curved PMI foam core material. Furthermore, a vacuum pre-compression is performed on the lower mold of the molding die every three layers of carbon fiber prepreg applied cross-layout.

7. The manufacturing method of the arc-shaped carbon fiber foam sandwich CT bed plate according to claim 1, characterized in that, In step S2, the lower mold of the molding die is subjected to low-temperature auxiliary heating, and the preform is subjected to vacuum pre-compression on the lower mold of the molding die. This includes: sequentially laying a non-porous isolation film and a breathable felt on the surface of the preform, then sealing the preform with the film laid on between the lower mold of the molding die and the vacuum bag, placing the lower mold of the molding die on the press platform, turning on the heating system and vacuum system of the press, heating the lower mold of the molding die to 35°C, and starting the timer when the vacuum pressure is -0.1 MPa, and maintaining the temperature and pressure for 15 minutes.

8. The method for manufacturing the arc-shaped carbon fiber foam sandwich CT bed plate according to any one of claims 1-7, characterized in that, In step S2, before laying the carbon fiber prepreg, the shape and size of the carbon fiber prepreg sheet are designed according to the laying requirements, and an automatic fabric cutting machine is used to cut the material.

9. The method for manufacturing the arc-shaped carbon fiber foam sandwich CT bed plate according to any one of claims 1-7, characterized in that, Before step S1, the method further includes: step A1, preparing the upper mold and the lower mold of the molding mold, inspecting and wiping the surfaces of the upper mold and the lower mold of the molding mold, and attaching high-temperature sealing strips and the vacuum bag along the edge of the lower mold line; Following step S3, the following is also included: S4. Machining: Trimming, milling, and drilling of the arc-shaped carbon fiber foam sandwich CT bed board; S5. Spray painting: After cleaning the surface of the arc-shaped carbon fiber foam sandwich CT bed board, spray water-soluble ceramic paint evenly onto the surface.

10. An arc-shaped carbon fiber foam sandwich CT bed board, comprising an arc-shaped PMI foam core and a carbon fiber skin, characterized in that, The arc-shaped carbon fiber foam sandwich CT bed panel is manufactured using the manufacturing method of the arc-shaped carbon fiber foam sandwich CT bed panel as described in any one of claims 1-9.

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