Preparation method of structure and function integrated case

Abstract

The invention belongs to the technical field of aircrafts, and relates to a preparation method of a structure and function integrated case. The invention discloses a preparation method of a structure and function integrated case. The preparation method comprises the following steps: (1) preparing a main body outer side reinforcing layer by adopting a continuous fiber reinforced PEEK thermoplastic composite material; (2) after being preheated, the main body outer side reinforcing layer is combined with the insert, and an assembly is obtained through hot press molding; and (3) carrying out injection molding on a discontinuous fiber modified PEEK thermoplastic composite material in the assembly to obtain a main body inner side base material, and fixedly connecting the main body inner side base material with the assembly. The invention further discloses application of the structure and function integrated cartridge receiver in an aircraft transmission system. The continuous-discontinuous fiber reinforced thermoplastic composite material is adopted as the casing main body, the discontinuous fiber modified PEEK thermoplastic composite material is accurate in structure during injection molding, the continuous fiber reinforced PEEK thermoplastic composite material is high in hardness and has good impact resistance, the overall mechanical property of the casing is improved, and the service life of the casing is prolonged.

Description

Technical Field

[0001] The invention belongs to the technical field of aircraft, and relates to a method for preparing a casing with integrated structure and function. Background Art

[0002] The casing is one of the key components of the aircraft transmission system. During the operation of the aircraft, it not only needs to bear the meshing force generated by the rotation of the internal gears and the torque, shear and tensile loads transmitted from other components, but also needs to be isolated from the outside world to connect and protect the internal components. Due to its complex load-bearing and diverse shapes, a casing with sufficient strength and rigidity is the basis for improving the efficiency and reliability of the aircraft transmission system. At present, aviation casings are usually made of high-strength and lightweight metal materials (such as magnesium, aluminum alloy, etc.). The disadvantages of metal casings are large mass, easy corrosion, and difficulty in casting processing. Therefore, there is an urgent need for a lightweight, high-strength, corrosion-resistant and fatigue-resistant material to replace the existing cast aluminum casing to achieve lightweight while meeting performance requirements. Thermoplastic carbon fiber composites have the advantages of high specific modulus, high specific strength, and corrosion resistance, and have been widely used in various structural parts of aerospace aircraft. However, conventional thermoplastic carbon fiber composites still have the problem that the hardness cannot meet the mechanical performance requirements and the heat dissipation capacity is poor.

[0003] The casing is an important heat dissipation component. Its heat dissipation has a significant impact on the working performance, anti-bonding ability, thermal deformation and other transmission problems of the internal transmission system. However, the thermal conductivity of polyetheretherketone (PEEK) is poor, with a thermal conductivity of only 0.25W / (m·K) at room temperature, which limits its application. In the prior art, a single thermal conductive filler is usually added. Although it improves the thermal conductivity of the PEEK material to a certain extent, it still cannot meet the heat dissipation requirements of the casing. Summary of the invention

[0004] The purpose of the present invention is to address the above-mentioned problems existing in the prior art and to propose a method for preparing a casing with integrated structure and function. By adopting continuous-discontinuous fiber reinforced thermoplastic composite materials, not only can the casing be prepared in an integrated and rapid manner, but after being connected and assembled with alloy inserts, weight reduction can be achieved while maintaining the casing stiffness and strength, and still having a high heat dissipation efficiency.

[0005] The purpose of the present invention can be achieved by the following technical solutions:

[0006] A method for preparing a casing with integrated structure and function, comprising:

[0007] (1) The outer reinforcement layer of the main body is made of continuous fiber reinforced PEEK thermoplastic composite material;

[0008] (2) The outer reinforcement layer of the main body is preheated and combined with the insert to obtain an assembly by hot pressing;

[0009] (3) A non-continuous fiber-modified PEEK thermoplastic composite material is used in the assembly for injection molding to obtain a main body inner substrate, which is fixedly connected to the assembly to obtain a structural and functional integrated casing.

[0010] Preferably, the non-continuous fiber modified PEEK thermoplastic composite material has a flexural modulus of ≥37 GPa and a thermal conductivity of ≥2w / (mk).

[0011] Preferably, the continuous fiber reinforced PEEK thermoplastic composite material has a flexural modulus ≥ 70GP and a thermal conductivity ≥ 2.5w / (mk).

[0012] Preferably, the non-continuous fiber-modified PEEK thermoplastic composite material comprises 20 to 100 parts of a PEEK substrate and 20 to 70 parts of non-continuous fibers, wherein the length of the non-continuous fibers is 10 to 400 μm;

[0013] The continuous fiber reinforced PEEK thermoplastic composite material comprises 30 to 80 parts of a PEEK substrate and 20 to 80 parts of continuous fibers, and the length of the continuous fibers is ≥500 mm.

[0014] Preferably, the non-continuous fiber modified PEEK thermoplastic composite material further comprises 1 to 10 parts of nanoparticles, wherein the nanoparticles comprise hBN nanoparticles;

[0015] The continuous fiber reinforced PEEK thermoplastic composite material also includes 0 to 10 parts of nanoparticles, and the nanoparticles include hBN nanoparticles.

[0016] Further preferably, the amount of non-continuous fibers added to the non-continuous fiber-modified PEEK thermoplastic composite material is 30 to 60 wt %; and the amount of continuous fibers added to the continuous fiber-modified PEEK thermoplastic composite material is 30 to 60 wt %.

[0017] Preferably, the discontinuous fiber-modified PEEK thermoplastic composite material comprises 50 to 60 parts of PEEK substrate, 30 to 40 parts of discontinuous fibers, and 1 to 10 parts of hBN nanoparticles, and the length of the discontinuous reinforcing fibers is 30 to 300 μm;

[0018] The continuous fiber reinforced PEEK thermoplastic composite material comprises 35-45 parts of PEEK substrate, 55-65 parts of continuous fibers, and 0-10 parts of hBN nanoparticles, and the length of the continuous fibers is ≥1000 mm.

[0019] More preferably, the continuous fibers include one or more of carbon fibers, glass fibers, and aramid fibers; and the discontinuous fibers include one or more of carbon fibers, glass fibers, and aramid fibers.

[0020] Preferably, the thickness of the main body inner substrate is ≥2mm; the thickness of the main body outer reinforcement layer is ≥1mm; the thickness difference between the main body inner substrate and the main body outer reinforcement layer (the thickness of the main body inner substrate - the thickness of the main body outer reinforcement layer) is ≥1mm.

[0021] Further preferably, the thickness of the main body inner substrate is ≥5mm; the thickness of the main body outer reinforcement layer is ≥2mm; the thickness difference between the main body inner substrate and the main body outer reinforcement layer (the thickness of the main body inner substrate - the thickness of the main body outer reinforcement layer) is ≥3mm.

[0022] More preferably, the thickness of the main body inner substrate is 5-50 mm, and the thickness of the main body outer reinforcement layer is 2-10 mm; the thickness difference between the main body inner substrate and the main body outer reinforcement layer (the thickness of the main body inner substrate - the thickness of the main body outer reinforcement layer) is ≥10 mm.

[0023] Preferably, the structurally and functionally integrated casing comprises, from the inside to the outside, an insert, an inner substrate of the main body, and an outer reinforcement layer of the main body.

[0024] Preferably, the base material inside the main body and the reinforcement layer outside the main body form the main body.

[0025] Preferably, a first connecting structure is further provided between the insert and the inner substrate of the main body.

[0026] Preferably, the insert and the inner substrate of the main body are connected by a first connecting structure to control the relative positions of the two.

[0027] Further preferably, the first connection structure includes one or more of abutting connection, nesting connection, plug-in connection, clamping connection, and threaded connection.

[0028] Preferably, the insert is made of alloy material by machining.

[0029] Preferably, the insert is a hollow columnar structure, or a hollow columnar-like structure with one end open.

[0030] Further preferably, the alloy material includes one or more of aluminum alloy, titanium alloy, zinc alloy, magnesium alloy, and stainless steel.

[0031] Preferably, the area of ​​the insert surface not in contact with the main body and the inner sleeve accounts for 30-80% of the total surface area.

[0032] Preferably, an inner liner sleeve is provided inside the insert and is made of structural steel.

[0033] Further preferably, the insert and the inner sleeve are cooperatively connected via a second connecting structure to control the relative positions of the two.

[0034] More preferably, the second connection structure includes one or more of abutment connection, nested connection, plug-in connection, clamping connection, and threaded connection.

[0035] Preferably, the preheating temperature is 100-350°C.

[0036] Preferably, the heating temperature of the hot pressing molding is 300-800° C. and the pressure is 5-100 MPa.

[0037] More preferably, the heating temperature of the hot pressing molding is 320-500° C. and the pressure is 5-20 MPa.

[0038] Preferably, a gasket is provided on the outside of the main body, and the gasket is annular.

[0039] Further preferably, the gasket is made of structural steel.

[0040] Further preferably, the main body and the gasket are connected by a third connecting component to control the relative positions of the two.

[0041] More preferably, the third connection structure includes one or more of abutting connection, nesting connection, plug-in connection, clamping connection, and threaded connection.

[0042] Another object of the present invention is to provide a casing with integrated structure and function, which comprises a main body and an insert fixedly connected from the outside to the inside;

[0043] The main body includes a substrate inside the main body and a reinforcement layer outside the main body.

[0044] The inner substrate of the main body is made of a non-continuous fiber-modified PEEK thermoplastic composite material by injection molding; the outer reinforcing layer of the main body is made of a continuous fiber-reinforced PEEK thermoplastic composite material by hot pressing;

[0045] The outer reinforcement layer of the main body is combined with the insert to obtain a combined part by hot pressing, and the inner substrate of the main body is obtained by injection molding in the combined part and is fixedly connected to the combined part.

[0046] Preferably, a first connecting structure is provided between the insert and the inner substrate of the main body for cooperative connection.

[0047] Further preferably, the first connection structure includes one or more of abutting connection, nesting connection, plug-in connection, clamping connection, and threaded connection.

[0048] Preferably, the non-continuous fiber modified PEEK thermoplastic composite material has a flexural modulus of ≥37 GPa and a thermal conductivity of ≥2w / (mk).

[0049] Preferably, the continuous fiber reinforced PEEK thermoplastic composite material has a flexural modulus ≥ 70GP and a thermal conductivity ≥ 2.5w / (mk).

[0050] Preferably, the non-continuous fiber-modified PEEK thermoplastic composite material comprises 20 to 100 parts of a PEEK substrate and 20 to 70 parts of non-continuous fibers, wherein the length of the non-continuous fibers is 10 to 400 μm;

[0051] The continuous fiber reinforced PEEK thermoplastic composite material comprises 30 to 80 parts of a PEEK substrate and 20 to 80 parts of continuous fibers, and the length of the continuous fibers is ≥500 mm.

[0052] Preferably, the non-continuous fiber modified PEEK thermoplastic composite material further comprises 1 to 10 parts of nanoparticles, wherein the nanoparticles comprise hBN nanoparticles;

[0053] The continuous fiber reinforced PEEK thermoplastic composite material also includes 0 to 10 parts of nanoparticles, and the nanoparticles include hBN nanoparticles.

[0054] Preferably, the discontinuous fiber-modified PEEK thermoplastic composite material comprises 50 to 60 parts of PEEK substrate, 30 to 40 parts of discontinuous fibers, and 1 to 10 parts of hBN nanoparticles, and the length of the discontinuous reinforcing fibers is 30 to 300 μm;

[0055] The continuous fiber reinforced PEEK thermoplastic composite material comprises 35-45 parts of PEEK substrate, 55-65 parts of continuous fibers, and 0-10 parts of hBN nanoparticles, and the length of the continuous fibers is ≥1000 mm.

[0056] More preferably, the continuous fibers include one or more of carbon fibers, glass fibers, and aramid fibers; and the discontinuous fibers include one or more of carbon fibers, glass fibers, and aramid fibers.

[0057] Preferably, the thickness of the main body inner substrate is ≥2mm; the thickness of the main body outer reinforcement layer is ≥1mm; the thickness difference between the main body inner substrate and the main body outer reinforcement layer (the thickness of the main body inner substrate - the thickness of the main body outer reinforcement layer) is ≥1mm.

[0058] Further preferably, the thickness of the main body inner substrate is ≥5mm; the thickness of the main body outer reinforcement layer is ≥2mm; the thickness difference between the main body inner substrate and the main body outer reinforcement layer (the thickness of the main body inner substrate - the thickness of the main body outer reinforcement layer) is ≥3mm.

[0059] More preferably, the thickness of the main body inner substrate is 5-50 mm, and the thickness of the main body outer reinforcement layer is 2-10 mm; the thickness difference between the main body inner substrate and the main body outer reinforcement layer (the thickness of the main body inner substrate - the thickness of the main body outer reinforcement layer) is ≥10 mm.

[0060] Preferably, the insert is a hollow columnar structure, or a hollow columnar-like structure with one end open.

[0061] Preferably, the area of ​​the insert surface not in contact with the main body and the inner sleeve accounts for 30-80% of the total surface area.

[0062] Preferably, the heating temperature of the hot pressing molding is 300-800° C. and the pressure is 5-100 MPa.

[0063] More preferably, the heating temperature of the hot pressing molding is 320-500° C. and the pressure is 5-20 MPa.

[0064] Preferably, an inner liner sleeve is provided inside the insert and is made of structural steel.

[0065] Further preferably, the insert and the inner sleeve are cooperatively connected via a second connecting structure to control the relative positions of the two.

[0066] Preferably, a gasket is provided on the outer side of the main body, and the gasket is annular.

[0067] Further preferably, the gasket is made of structural steel.

[0068] Further preferably, the main body and the gasket are connected by a third connecting structure to control the relative positions of the two.

[0069] More preferably, the third connection structure includes one or more of abutting connection, nesting connection, plug-in connection, clamping connection, and threaded connection.

[0070] The present invention also provides a casing with integrated structure and function, which is composed of a main body, an insert, and an inner sleeve, which are connected in sequence from the outside to the inside;

[0071] The main body includes an inner substrate and an outer reinforcement layer.

[0072] The inner substrate of the main body is made of a non-continuous fiber-modified PEEK thermoplastic composite material by injection molding; the outer reinforcing layer of the main body is made of a continuous fiber-reinforced PEEK thermoplastic composite material by compression molding;

[0073] The outer reinforcement layer of the main body is combined with the insert to form an assembly by hot pressing, and the inner substrate of the main body is formed by injection molding in the assembly and fixedly connected to the assembly;

[0074] The insert and the inner sleeve are connected in cooperation via a second connecting structure.

[0075] Preferably, a first connecting structure is provided between the insert and the outer substrate of the main body for cooperative connection.

[0076] Preferably, the non-continuous fiber modified PEEK thermoplastic composite material has a flexural modulus of ≥37 GPa and a thermal conductivity of ≥2w / (mk).

[0077] Preferably, the continuous fiber reinforced PEEK thermoplastic composite material has a flexural modulus ≥ 70GP and a thermal conductivity ≥ 2.5w / (mk).

[0078] Preferably, the non-continuous fiber-modified PEEK thermoplastic composite material comprises 20 to 100 parts of a PEEK substrate and 20 to 70 parts of non-continuous fibers, wherein the length of the non-continuous fibers is 10 to 400 μm;

[0079] The continuous fiber reinforced PEEK thermoplastic composite material comprises 30 to 80 parts of a PEEK substrate and 20 to 80 parts of continuous fibers, and the length of the continuous fibers is ≥500 mm.

[0080] Preferably, the non-continuous fiber modified PEEK thermoplastic composite material further comprises 1 to 10 parts of nanoparticles, wherein the nanoparticles comprise hBN nanoparticles;

[0081] The continuous fiber reinforced PEEK thermoplastic composite material also includes 0 to 10 parts of nanoparticles, and the nanoparticles include hBN nanoparticles.

[0082] Preferably, the discontinuous fiber-modified PEEK thermoplastic composite material comprises 50 to 60 parts of PEEK substrate, 30 to 40 parts of discontinuous fibers, and 1 to 10 parts of hBN nanoparticles, and the length of the discontinuous reinforcing fibers is 30 to 300 μm;

[0083] The continuous fiber reinforced PEEK thermoplastic composite material comprises 35-45 parts of PEEK substrate, 55-65 parts of continuous fibers, and 0-10 parts of hBN nanoparticles, and the length of the continuous fibers is ≥1000 mm.

[0084] More preferably, the continuous fibers include one or more of carbon fibers, glass fibers, and aramid fibers; and the discontinuous fibers include one or more of carbon fibers, glass fibers, and aramid fibers.

[0085] Preferably, the thickness of the main body inner substrate is ≥2mm; the thickness of the main body outer reinforcement layer is ≥1mm; the thickness difference between the main body inner substrate and the main body outer reinforcement layer (the thickness of the main body inner substrate - the thickness of the main body outer reinforcement layer) is ≥1mm.

[0086] Further preferably, the thickness of the main body inner substrate is ≥5mm; the thickness of the main body outer reinforcement layer is ≥2mm; the thickness difference between the main body inner substrate and the main body outer reinforcement layer (the thickness of the main body inner substrate - the thickness of the main body outer reinforcement layer) is ≥3mm.

[0087] More preferably, the thickness of the main body inner substrate is 5-50 mm, and the thickness of the main body outer reinforcement layer is 2-10 mm; the thickness difference between the main body inner substrate and the main body outer reinforcement layer (the thickness of the main body inner substrate - the thickness of the main body outer reinforcement layer) is ≥10 mm.

[0088] Preferably, the area of ​​the insert surface not in contact with the main body and the inner sleeve accounts for 30-80% of the total surface area.

[0089] Preferably, the heating temperature of the hot pressing molding is 300-800° C. and the pressure is 5-100 MPa.

[0090] More preferably, the heating temperature of the hot pressing molding is 320-500° C. and the pressure is 5-20 MPa.

[0091] Preferably, the insert is a hollow columnar structure, or a hollow columnar-like structure with one end open.

[0092] Preferably, the first connection structure includes one or more of abutment connection, nested connection, plug-in connection, clamping connection, and threaded connection;

[0093] The second connection structure includes one or more of abutting connection, nesting connection, plug-in connection, clamping connection, and threaded connection.

[0094] Preferably, a gasket is provided on the outer side of the main body, and the gasket is annular.

[0095] Further preferably, the gasket is made of structural steel.

[0096] Further preferably, the main body and the gasket are connected by a third connecting structure to control the relative positions of the two.

[0097] More preferably, the third connection structure includes one or more of abutting connection, nesting connection, plug-in connection, clamping connection, and threaded connection.

[0098] The invention discloses an application of a casing with integrated structure and function in an aircraft transmission system.

[0099] Compared with the prior art, the present invention has the following beneficial effects:

[0100] 1. The present invention adopts continuous-discontinuous fiber reinforced thermoplastic composite material as the casing body. The PEEK thermoplastic composite material modified by discontinuous fibers has a precise structure during injection molding, and the PEEK thermoplastic composite material reinforced by continuous fibers has high hardness and good impact resistance, thereby improving the overall mechanical properties and service life of the casing.

[0101] 2. The casing main body material of the present invention adopts inorganic hBN nanoparticles to modify the PEEK matrix. The micron-level filler filling can greatly reduce the contact thermal resistance between the fillers, thereby better improving the thermal conductivity. In addition, carbon fiber (CF) is added to the main body material. The carbon fiber (CF) has the characteristics of low density, high modulus, small linear expansion coefficient and excellent thermal conductivity. The present invention adopts mixed fillers to modify the PEEK substrate, giving full play to the synergistic effect between the components, making up for or overcoming the shortcomings of a single filler, and further improving the thermal conductivity of PEEK.

[0102] 3. After the insert and the outer reinforcement layer of the main body are combined, the inner substrate of the main body is injection molded, and fixedly connected with the combination of the insert and the outer reinforcement layer of the main body. A first connection structure is also provided between the insert and the inner substrate of the main body to further ensure the effectiveness of the connection between the two.

[0103] 4. The present invention also provides an annular gasket on the outside of the main body to enhance the overall modulus of the casing and ensure the connection seal;

[0104] 5. The structural and functional integrated casing of the present invention has good mechanical properties, is lightweight and has excellent heat dissipation performance. When used in an aircraft, it can ensure its service life and improve system efficiency and reliability. BRIEF DESCRIPTION OF THE DRAWINGS

[0105] Figure 1 It is a structural schematic diagram of the casing with integrated structure and function in the present invention.

[0106] Figure 2 It is a cross-sectional view of the casing with integrated structure and function in the present invention.

[0107] Figure 3 It is a structural schematic diagram of the main body in the structural and functional integrated casing of the present invention.

[0108] Figure 4It is a structural schematic diagram of the main body of the structural and functional integrated casing of the present invention from another perspective.

[0109] Figure 5 It is a schematic diagram of the structure of the insert in the casing with integrated structure and function in the present invention.

[0110] In the figure, 10, main body; 11, first connecting hole; 12, arc-shaped strip; 13, cylindrical groove; 14, first annular reinforcing rib; 15, second annular reinforcing rib; 16, flange; 17, first reinforcing rib; 18, second reinforcing rib; 19, first concave cavity; 110, second concave cavity; 120, strip convex edge; 20, insert; 21, first limiting portion; 22, second limiting portion; 23, second connecting hole; 24, arc-shaped strip groove; 25, cylindrical protrusion; 26, strip concave cavity; 27, first positioning hole; 30, inner sleeve; 31, second positioning hole; 40, gasket; 41, third connecting hole. DETAILED DESCRIPTION

[0111] The following are specific embodiments of the present invention, which further describe the technical solutions of the present invention, but the present invention is not limited to these embodiments.

[0112] Unless otherwise specified, the materials used in the present invention are conventional commercial products, and the methods used are conventional technical means.

[0113] The method for preparing the structural and functional integrated casing of the present invention comprises:

[0114] (1) The outer reinforcement layer of the main body is made of continuous fiber reinforced PEEK thermoplastic composite material;

[0115] The continuous fiber reinforced PEEK thermoplastic composite material has a flexural modulus of ≥70GP and a thermal conductivity of ≥2.5w / (mk);

[0116] The continuous fiber reinforced PEEK thermoplastic composite material includes 30 to 80 parts of PEEK substrate and 20 to 80 parts of continuous fibers, wherein the length of the continuous fibers is ≥500 mm; the continuous fiber reinforced PEEK thermoplastic composite material also includes 0 to 10 parts of nanoparticles, wherein the nanoparticles include hBN nanoparticles; the continuous fibers include one or more of carbon fibers, glass fibers, and aramid fibers;

[0117] (2) The insert 20 is formed by machining an alloy material; the insert 20 is a hollow columnar structure, or a hollow columnar structure with one end open; the insert 20 has a diameter of 80 to 800 mm and a mass of 0.1 to 10 kg; the alloy material includes one or more of aluminum alloy, titanium alloy, zinc alloy, magnesium alloy, and stainless steel;

[0118] The outer reinforcement layer of the main body is preheated at 100-350°C and then combined with the insert, placed in an EASYMASTER injection molding machine (EM80-V), and hot-pressed to obtain a combined component; the hot-pressing molding temperature is 300-1000°C and the pressure is 5-100Mpa;

[0119] (3) In the assembly, a PEEK thermoplastic composite material modified with non-continuous fibers is injection molded to obtain an inner substrate of the main body, which is fixedly connected to the assembly;

[0120] The non-continuous fiber modified PEEK thermoplastic composite material comprises 20 to 100 parts of a PEEK substrate and 20 to 70 parts of non-continuous fibers, wherein the length of the non-continuous fibers is 10 to 400 μm; the non-continuous fiber modified PEEK thermoplastic composite material has a bending modulus of ≥37 GPa and a thermal conductivity of ≥2 w / (mk);

[0121] The main body 10 includes an inner substrate and an outer reinforcement layer of the main body. The diameter of the main body 10 is 100-1000 mm and the mass is 0.1-10 kg. The thickness of the inner substrate of the main body is ≥2 mm, the thickness of the outer reinforcement layer of the main body is ≥1 mm, and the difference in thickness between the inner substrate of the main body and the outer reinforcement layer of the main body (the thickness of the inner substrate of the main body-the thickness of the outer reinforcement layer of the main body) is ≥1 mm.

[0122] A first connection structure is also provided between the insert 20 and the inner substrate of the main body to further ensure the effectiveness of the connection between the two; the first connection structure includes one or more of abutment connection, nested connection, plug-in connection, clamping connection, and threaded connection;

[0123] An inner sleeve 30 is disposed in the insert 20, and the inner sleeve 30 is connected to the insert 20 via a second connection structure; the second connection structure includes one or more of abutting connection, nesting connection, plug-in connection, clamping connection, and threaded connection;

[0124] The surface area of ​​the insert 20 that is not in contact with the main body 10 and the inner sleeve 30 is 30 to 80% of its total surface area;

[0125] (4) An annular gasket 40 is also provided outside the main body 10, wherein the annular gasket 40 has a thickness of 1 to 5 mm, a diameter of 300 to 500 mm, and a mass of 0.1 to 5 kg;

[0126] The main body 10 and the annular gasket 40 are connected by a third connection structure to control the relative position of the two; the third connection structure includes one or more of abutting connection, nesting connection, plug-in connection, clamping connection, and threaded connection; a structural and functional integrated casing is obtained.

[0127] The structural and functional integrated casing of the present invention is as follows: Figures 1-2As shown, it includes a main body 10, an insert 20, and an inner sleeve 30 which are fixedly connected from the outside to the inside.

[0128] In one embodiment, the main body 10 and the insert 20 are connected via a first connection structure, and the first connection structure includes a first limiting portion 21, a first positioning portion, and a second positioning portion.

[0129] In one embodiment, a first limiting portion 21 and a second limiting portion 22 are provided on the insert 20, and the relative position between the main body 10 and the insert 20 is controlled by the first limiting portion 21, and the relative position between the insert 20 and the inner sleeve 30 is controlled by the second limiting portion 22, and the main body is provided with first connecting holes 11 distributed in an annular shape, and the insert 20 is provided with second connecting holes 23 distributed in an annular shape.

[0130] In one embodiment, if Figure 3 As shown, the structure of the main body 10 is as follows: a first annular reinforcing rib 14, a second annular reinforcing rib 15 and a flange 16 are formed radiating outward from the center of the main body 10, and a first reinforcing rib 17 is arranged between the first annular reinforcing rib 14 and the second recessed portion, and a second reinforcing rib 18 is arranged between the first annular reinforcing rib 14 and the second annular reinforcing rib 15, and a plurality of first connecting holes 11 are arranged on the flange 16, wherein a sunken first concave cavity 19 is formed between two adjacent first reinforcing ribs 17, and a sunken second concave cavity 110 is formed between two adjacent second reinforcing ribs 18.

[0131] In one embodiment, a first positioning portion is provided between one end surface of the main body 10 and the first limiting portion 21 on the insert 20 to limit the relative rotation of the two, and the first positioning portion includes a first convex portion provided on one end surface of the main body 10, and a first concave portion correspondingly provided on the first limiting portion 21, wherein the first convex portion and the first concave portion form a concave-convex nesting fit. The positions of the first convex portion and the first concave portion can be interchangeably provided.

[0132] In one embodiment, the first convex portion and the first concave portion are arranged in an arc shape, wherein the first convex portion includes a plurality of arc-shaped strips 12 , and the first concave portion includes a plurality of arc-shaped grooves 24 .

[0133] In one embodiment, a second positioning portion is further provided between the main body 10 and the insert 20 to limit the relative rotation of the two, and the second positioning portion includes a second convex portion provided on the outer wall of the insert 20, and a second concave portion correspondingly provided on the inner wall of the main body 10, wherein the second convex portion and the second concave portion form a concave-convex nesting fit. The positions of the second convex portion and the second concave portion can also be interchanged.

[0134] In one embodiment, the second convex portion and the second concave portion are arranged in a columnar shape, wherein the second convex portion includes a plurality of columnar convex columns 25, and the second concave portion includes a plurality of columnar grooves 13. A plurality of strip convex ridges 120 are arranged between two adjacent columnar grooves 13, and the plurality of strip convex ridges 120 are arranged up and down along the axis direction of the main body 10, wherein the strip convex ridges 120 are nested one by one with the strip concave cavities 26 on the outer side wall of the insert 20.

[0135] In one embodiment, the insert 20 and the inner sleeve 30 are connected via a second connection structure, which includes a first positioning hole 27 on the inner wall of the insert 20, a second positioning hole 31 on the inner sleeve 30, and a connector connecting the two positioning holes.

[0136] In one embodiment, if Figures 4-5 As shown, a first positioning hole 27 is provided on the inner wall of the insert 20, and a second positioning hole 31 is provided on the inner sleeve 30, wherein the position of the first positioning hole 27 corresponds to the position of the second positioning hole 31, and the connection and fixation between the insert 20 and the inner sleeve 30 are achieved through a connecting piece.

[0137] In one embodiment, the main body 10 and the gasket 40 are connected via a third connection structure, which includes a first connection hole 11 on the main body 10, a third connection hole 41 on the gasket 40, and a locking member connecting the two connection holes.

[0138] In one embodiment, a plurality of first connection holes 11 are provided on the flange 16 of the main body 10, and a third connection hole 41 corresponding to the position of the first connection hole is provided on the annular gasket 40, and the locking member fixes the relative position of the main body 10 and the annular gasket 40 through the first connection hole and the third connection hole.

[0139] Example 1

[0140] In the structural and functional integrated casing of the present embodiment, the main body 10, the insert 20 and the inner sleeve 30 are nested in pairs from the outside to the inside, and an annular gasket 40 is also provided on the outside of the main body 10; the main body 10 includes an inner substrate and an outer reinforcement layer of the main body, the thickness of the inner substrate of the main body is 34 mm, and the thickness of the outer reinforcement layer of the main body is 2 mm.

[0141] The method for preparing the structural and functional integrated casing in this embodiment includes:

[0142] (1) The outer reinforcement layer of the main body is made of continuous fiber reinforced PEEK thermoplastic composite material;

[0143] 40 parts of PEEK substrate and 60 parts of continuous fibers (carbon fibers with an average length of 700 mm) are made into a continuous fiber PEEK thermoplastic composite material, and the continuous fiber-modified PEEK thermoplastic composite material is injection molded to obtain a main body outer reinforcement layer;

[0144] (2) machining the aluminum alloy to obtain an insert 20, wherein the insert 20 is a hollow columnar structure with one end open, the diameter of the insert 20 is 200 mm, and the mass is 0.6 kg;

[0145] The outer reinforcement layer of the main body is preheated at 300°C and combined with the insert, and the assembly is placed in an EASYMASTER injection molding machine (EM80-V) and hot-pressed at 380°C and 7Mpa to obtain the assembly;

[0146] (3) 55 parts of PEEK substrate, 35 parts of discontinuous fibers (carbon fibers with an average length of 60 μm), and 2 parts of hBN nanoparticles were prepared into a discontinuous fiber-modified PEEK thermoplastic composite;

[0147] In the assembly, a PEEK thermoplastic composite material modified with non-continuous fibers is used for injection molding to obtain a main body inner substrate, which is fixedly connected to the assembly;

[0148] The main body 10 and the insert 20 are also provided with a first connection structure for cooperation and connection; then the insert 20 and the inner sleeve 30 are cooperatively connected through a second connection structure;

[0149] (4) The main body 10 is connected to the annular gasket 40 through the third connecting structure. The diameter of the gasket 40 is 360 mm and the mass is 0.4 kg. A structural and functional integrated casing is obtained.

[0150] Example 2

[0151] In the structural and functional integrated casing of the present embodiment, the main body 10, the insert 20 and the inner sleeve 30 are nested in pairs from the outside to the inside, and an annular gasket 40 is also provided on the outside of the main body 10; the main body 10 includes an inner substrate and an outer reinforcement layer of the main body, the diameter of the main body 10 is 350 mm, and the mass is 1.2 kg; the thickness of the inner substrate of the main body is 32 mm, and the thickness of the outer reinforcement layer of the main body is 5 mm.

[0152] The method for preparing the structural and functional integrated casing in this embodiment includes:

[0153] (1) The outer reinforcement layer of the main body is made of continuous fiber reinforced PEEK thermoplastic composite material;

[0154] 40 parts of PEEK substrate and 60 parts of continuous fibers (carbon fibers with an average length of 600 mm) are made into a continuous fiber PEEK thermoplastic composite material, and the continuous fiber-modified PEEK thermoplastic composite material is injection molded to obtain a main body outer reinforcement layer;

[0155] (2) machining an aluminum alloy to obtain an insert 20, wherein the insert 20 is a hollow columnar structure with one end open, the diameter of the insert 20 is 210 mm, and the mass is 0.7 kg;

[0156] The outer reinforcement layer of the main body is preheated at 320°C and then combined with the insert, and the assembly is placed in an EASYMASTER injection molding machine (EM80-V) and hot-pressed at 390°C and 8Mpa to obtain the assembly;

[0157] (3) a PEEK thermoplastic composite modified with discontinuous fibers was prepared by combining 55 parts of a PEEK matrix, 33 parts of discontinuous fibers (carbon fibers with an average length of 50 μm), and 1 part of hBN nanoparticles;

[0158] In the assembly, a PEEK thermoplastic composite material modified with non-continuous fibers is used for injection molding to obtain a main body inner substrate, which is fixedly connected to the assembly;

[0159] The main body 10 and the insert 20 are also provided with a first connection structure for cooperation and connection; then the insert 20 and the inner sleeve 30 are cooperatively connected through a second connection structure;

[0160] (4) The main body 10 is connected to the annular gasket 40 through the third connecting structure. The diameter of the gasket 40 is 360 mm and the mass is 0.4 kg. A structural and functional integrated casing is obtained.

[0161] Example 3

[0162] Compared with the first embodiment, the difference is that there is no annular gasket 40 outside the main body 10 .

[0163] The structural and functional integrated casings obtained in Examples 1 to 3 of the present invention all have good mechanical properties and high heat dissipation efficiency, and have excellent use effects when applied to aircraft transmission systems.

[0164] In summary, the present invention adopts continuous-discontinuous fiber reinforced thermoplastic composite materials, which can not only realize the integrated and rapid preparation of the casing, but also achieve weight reduction while maintaining the stiffness and strength of the casing after being connected and assembled with the alloy inserts, and still have a high heat dissipation efficiency.

[0165] The specific embodiments described herein are merely examples of the spirit of the present invention. Those skilled in the art may make various modifications or additions to the specific embodiments described or replace them in similar ways, but they will not deviate from the spirit of the present invention or exceed the scope defined by the appended claims.

Claims

1. A method for preparing a casing with integrated structure and function, It is characterized in that The preparation method comprises: (1) The outer reinforcement layer of the main body is made of continuous fiber reinforced PEEK thermoplastic composite material; (2) The outer reinforcement layer of the main body is preheated and combined with the insert to obtain an assembly by hot pressing; (3) A non-continuous fiber-modified PEEK thermoplastic composite material is used in the assembly for injection molding to obtain a main body inner substrate, which is fixedly connected to the assembly to obtain a structural and functional integrated casing.

2. The preparation method according to claim 1, It is characterized in that The flexural modulus of the non-continuous fiber modified PEEK thermoplastic composite material is ≥37GPa, and the thermal conductivity is ≥2w / (mk); the flexural modulus of the continuous fiber reinforced PEEK thermoplastic composite material is ≥70GP, and the thermal conductivity is ≥2.5w / (mk).

3. The preparation method according to claim 1, It is characterized in that The non-continuous fiber-modified PEEK thermoplastic composite material comprises 20 to 100 parts of a PEEK substrate and 20 to 70 parts of non-continuous fibers, wherein the length of the non-continuous fibers is 10 to 400 μm; The continuous fiber reinforced PEEK thermoplastic composite material comprises 30 to 80 parts of a PEEK base material and 20 to 80 parts of continuous fibers, and the length of the continuous fibers is ≥500 mm.

4. The preparation method according to claim 3, It is characterized in that The non-continuous fiber modified PEEK thermoplastic composite material also includes 1 to 10 parts of nanoparticles, and the nanoparticles include hBN nanoparticles; the continuous fiber reinforced PEEK thermoplastic composite material also includes 0 to 10 parts of nanoparticles, and the nanoparticles include hBN nanoparticles.

5. The preparation method according to claim 1, It is characterized in that A first connection structure is also provided between the insert and the inner substrate of the main body; the first connection structure includes one or more of abutting connection, nesting connection, plug-in connection, clamping connection and threaded connection.

6. The preparation method according to claim 1, It is characterized in that An inner sleeve is arranged inside the insert; the insert and the inner sleeve are connected through a second connection structure, and the second connection structure includes one or more of abutting connection, nesting connection, plug-in connection, clamping connection, and threaded connection.

7. The preparation method according to claim 1, It is characterized in that A gasket is arranged on the outside of the main body, and the gasket is annular; the main body and the gasket are connected by a third connecting component, and the third connecting structure includes one or more of abutting connection, nesting connection, plug-in connection, clamping connection, and threaded connection.

8. A casing with integrated structure and function as claimed in claim 1, It is characterized in that It includes a main body and an insert that are fixedly connected from outside to inside; The main body includes a substrate inside the main body and a reinforcement layer outside the main body. The inner substrate of the main body is made of a non-continuous fiber-modified PEEK thermoplastic composite material by injection molding; the outer reinforcing layer of the main body is made of a continuous fiber-reinforced PEEK thermoplastic composite material by hot pressing; The outer reinforcement layer of the main body is combined with the insert to obtain a combined part by hot pressing, and the inner substrate of the main body is obtained by injection molding in the combined part and is fixedly connected to the combined part.

9. A casing with integrated structure and function as claimed in claim 1, It is characterized in that It consists of a main body, an insert, and an inner sleeve which are connected in sequence from outside to inside; The main body comprises an inner substrate and an outer reinforcement layer, wherein the inner substrate of the main body is made of a non-continuous fiber-modified PEEK thermoplastic composite material by injection molding; and the outer reinforcement layer of the main body is made of a continuous fiber-reinforced PEEK thermoplastic composite material by compression molding; The outer reinforcement layer of the main body is combined with the insert to obtain an assembly by hot pressing, and the inner substrate of the main body is injection-molded in the assembly and fixedly connected to the assembly; the insert and the inner liner are connected by a second connecting structure.

10. Use of the structural and functional integrated casing prepared by the preparation method according to any one of claims 1 to 7, and / or the structural and functional integrated casing according to claim 8, and / or the structural and functional integrated casing according to claim 9 in an aircraft transmission system.

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