A method for manufacturing a structure-function integrated machine case

Abstract

The application belongs to the technical field of aircrafts, and relates to a preparation method of a structure-function integrated nacelle. The application discloses a preparation method of a structure-function integrated nacelle, which comprises the following steps: (1) a continuous fiber reinforced PEEK thermoplastic composite material is used to make a main body outer reinforcing layer; (2) the main body outer reinforcing layer is combined with an insert after preheating, and a combined part is obtained through hot press forming; and (3) a discontinuous fiber modified PEEK thermoplastic composite material is used to perform injection molding on the combined part to obtain a main body inner base material, and the main body inner base material is fixedly connected with the combined part. The application further discloses an application of the structure-function integrated nacelle in an aircraft transmission system. The application uses a continuous-discontinuous fiber reinforced thermoplastic composite material as the nacelle main body, the discontinuous fiber modified PEEK thermoplastic composite material has accurate structure during injection molding, the continuous fiber reinforced PEEK thermoplastic composite material has high hardness and good impact resistance, and the mechanical properties and service life of the nacelle as a whole are improved.

Description

Technical Field

[0001] This invention belongs to the field of aircraft technology and relates to a method for manufacturing a structurally and functionally integrated casing. Background Technology

[0002] The transmission casing is one of the key components of an aircraft's transmission system. During aircraft operation, it not only needs to withstand the meshing forces generated by the rotation of internal gears and the torque, shear, and tensile loads transmitted from other components, but also needs to isolate it from the outside world, connecting and protecting internal components. Due to its complex load-bearing capacity and diverse shapes, a transmission casing with sufficient strength and rigidity is fundamental to improving the efficiency and reliability of an aircraft's transmission system. Currently, aircraft transmission casings are typically made of high-strength, lightweight metal materials (such as magnesium and aluminum alloys). The disadvantages of metal casings are their large weight, susceptibility to corrosion, and difficulty in casting and machining. Therefore, there is an urgent need for a lightweight, high-strength, corrosion-resistant, and fatigue-resistant material to replace the currently used cast aluminum casings, achieving weight reduction while meeting performance requirements. Thermoplastic carbon fiber composites have advantages such as high specific modulus, high specific strength, and corrosion resistance, and have been widely used in various structural components of aerospace vehicles. However, conventional thermoplastic carbon fiber composites still have problems such as insufficient hardness to meet mechanical performance requirements and poor heat dissipation.

[0003] The casing is a crucial heat dissipation component, significantly impacting the performance of the internal transmission system, its resistance to adhesion, and its ability to prevent thermal deformation. However, polyetheretherketone (PEEK) material has poor thermal conductivity, with a thermal conductivity of only 0.25 W / (m·K) at room temperature, limiting its application. Current technologies typically incorporate a single thermally conductive filler, which improves the thermal conductivity of PEEK to some extent, but still fails to adequately meet the heat dissipation requirements of the casing. Summary of the Invention

[0004] The purpose of this invention is to address the aforementioned problems in the existing technology by proposing a method for manufacturing an integrated structural and functional casing. By using continuous-discontinuous fiber-reinforced thermoplastic composite materials, not only can the casing be manufactured in an integrated and rapid manner, but after being connected and assembled with alloy inserts, weight reduction can be achieved while maintaining the rigidity and strength of the casing, and high heat dissipation efficiency can still be maintained.

[0005] The objective of this invention can be achieved through the following technical solutions:

[0006] A method for manufacturing a structurally and functionally integrated casing, comprising:

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

[0008] (2) The outer reinforcing layer of the main body is preheated and combined with the insert, and the assembly is formed by hot pressing.

[0009] (3) The inner substrate of the main body is obtained by injection molding of PEEK thermoplastic composite material modified with discontinuous fiber in the assembly, and fixedly connected with the assembly to obtain the integrated structural and functional casing.

[0010] Preferably, the discontinuous fiber modified PEEK thermoplastic composite material has a flexural modulus ≥37GPa and a thermal conductivity ≥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 discontinuous fiber modified PEEK thermoplastic composite material comprises 20-100 parts of PEEK substrate and 20-70 parts of discontinuous fiber, wherein the length of the discontinuous fiber is 10-400 μm;

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

[0014] Preferably, the discontinuous fiber modified PEEK thermoplastic composite material further includes 1 to 10 parts of nanoparticles, including hBN nanoparticles.

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

[0016] More preferably, the amount of discontinuous fiber added in the discontinuous fiber modified PEEK thermoplastic composite is 30-60 wt%; and the amount of continuous fiber added in the continuous fiber modified PEEK thermoplastic composite is 30-60 wt%.

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

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

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

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

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

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

[0023] Preferably, the integrated structural and functional casing includes, from the inside out, an insert, an inner substrate, and an outer reinforcing layer.

[0024] Preferably, the inner substrate and the outer reinforcing layer of the main body constitute the main body.

[0025] Preferably, a first connection structure is 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 their relative positions.

[0027] Further preferred, the first connection structure includes one or more of the following: abutment connection, nested connection, plug-in connection, snap-fit ​​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 structure with one end open.

[0030] More 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 that is not in contact with the main body or the inner liner is 30% to 80% of its total surface area.

[0032] Preferably, the insert also has an inner liner made of structural steel.

[0033] In a further preferred embodiment, the insert and the inner bushing are connected by a second connecting structure to control their relative positions.

[0034] More preferably, the second connection structure includes one or more of the following: abutment connection, nested connection, plug-in connection, snap-fit ​​connection, and threaded connection.

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

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

[0037] Further preferably, the heating temperature for hot pressing is 320–500°C, and the pressure is 5–20 MPa.

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

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

[0040] In a further preferred embodiment, the main body and the gasket are connected by a third connecting component to control their relative positions.

[0041] More preferably, the third connection structure includes one or more of the following: abutment connection, nested connection, plug-in connection, snap-fit ​​connection, and threaded connection.

[0042] Another object of the present invention is to provide a structurally and functionally integrated casing, which includes a main body and inserts fixedly connected from the outside to the inside;

[0043] The main body includes an inner substrate and an outer reinforcing layer.

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

[0045] The outer reinforcing layer of the main body and the insert are combined and hot-pressed to form an assembly. The inner substrate of the main body is then injection molded in the assembly and fixedly connected to the assembly.

[0046] Preferably, the insert and the inner substrate of the main body are connected by a first connecting structure.

[0047] Further preferred, the first connection structure includes one or more of the following: abutment connection, nested connection, plug-in connection, snap-fit ​​connection, and threaded connection.

[0048] Preferably, the discontinuous fiber modified PEEK thermoplastic composite material has a flexural modulus ≥37GPa and a thermal conductivity ≥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 discontinuous fiber modified PEEK thermoplastic composite material comprises 20-100 parts of PEEK substrate and 20-70 parts of discontinuous fiber, wherein the length of the discontinuous fiber is 10-400 μm;

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

[0052] Preferably, the discontinuous fiber modified PEEK thermoplastic composite material further includes 1 to 10 parts of nanoparticles, including hBN nanoparticles.

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

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

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

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

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

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

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

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

[0061] Preferably, the area of ​​the insert surface that is not in contact with the main body or the inner liner is 30% to 80% of its total surface area.

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

[0063] Further preferably, the heating temperature for hot pressing is 320–500°C, and the pressure is 5–20 MPa.

[0064] Preferably, the insert also has an inner liner made of structural steel.

[0065] In a further preferred embodiment, the insert and the inner bushing are connected by a second connecting structure to control their relative positions.

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

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

[0068] In a further preferred embodiment, the main body and the gasket are connected by a third connecting structure to control their relative positions.

[0069] More preferably, the third connection structure includes one or more of the following: abutment connection, nested connection, plug-in connection, snap-fit ​​connection, and threaded connection.

[0070] The present invention also provides a structural and functional integrated casing, which consists of a main body, inserts, and inner bushing connected in sequence from the outside to the inside;

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

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

[0073] The outer reinforcing layer of the main body and the insert are combined and hot-pressed to form an assembly. The inner substrate of the main body is then injection molded in the assembly and fixedly connected to the assembly.

[0074] The insert and inner sleeve are connected by a second connecting structure.

[0075] Preferably, the insert and the outer substrate of the main body are connected by a first connecting structure.

[0076] Preferably, the discontinuous fiber modified PEEK thermoplastic composite material has a flexural modulus ≥37GPa and a thermal conductivity ≥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 discontinuous fiber modified PEEK thermoplastic composite material comprises 20-100 parts of PEEK substrate and 20-70 parts of discontinuous fiber, wherein the length of the discontinuous fiber is 10-400 μm;

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

[0080] Preferably, the discontinuous fiber modified PEEK thermoplastic composite material further includes 1 to 10 parts of nanoparticles, including hBN nanoparticles.

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

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

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

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

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

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

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

[0088] Preferably, the area of ​​the insert surface that is not in contact with the main body or the inner liner is 30% to 80% of its total surface area.

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

[0090] Further preferably, the heating temperature for hot pressing is 320–500°C, and the pressure is 5–20 MPa.

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

[0092] As a preferred embodiment, the first connection structure includes one or more of the following: abutment connection, nested connection, plug-in connection, snap-fit ​​connection, and threaded connection;

[0093] The second connection structure includes one or more of the following: abutment connection, nested connection, plug-in connection, snap-fit ​​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] In a further preferred embodiment, the main body and the gasket are connected by a third connecting structure to control their relative positions.

[0097] More preferably, the third connection structure includes one or more of the following: abutment connection, nested connection, plug-in connection, snap-fit ​​connection, and threaded connection.

[0098] Application of a structurally and functionally integrated casing in an aircraft transmission system.

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

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

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

[0102] 3. In this invention, after combining the insert and the outer reinforcing layer of the main body, the inner substrate of the main body is injection molded and fixedly connected to the combination of the insert and the outer reinforcing 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 connection effectiveness 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 a sealed connection;

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

[0105] Figure 1 This is a structural schematic diagram of the integrated structural and functional casing of the present invention.

[0106] Figure 2 This is a cross-sectional view of the integrated structural and functional casing of the present invention.

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

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

[0109] Figure 5 This is a schematic diagram of the structure of the insert in the integrated structural and functional casing of the present invention.

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

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

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

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

[0114] (1) The outer reinforcing 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 ≥70GP and a thermal conductivity ≥2.5w / (mk).

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

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

[0118] The outer reinforcing layer of the main body is preheated to 100-350℃ and then combined with the insert. The assembly is placed in an EASYMASTER injection molding machine (EM80-V) and hot-pressed to obtain the assembly. The hot-pressing temperature is 300-1000℃ and the pressure is 5-100Mpa.

[0119] (3) The inner substrate of the main body is obtained by injection molding of discontinuous fiber modified PEEK thermoplastic composite material in the assembly, and is fixedly connected to the assembly.

[0120] The discontinuous fiber modified PEEK thermoplastic composite material comprises 20-100 parts of PEEK substrate and 20-70 parts of discontinuous fiber, wherein the length of the discontinuous fiber is 10-400 μm; the flexural modulus of the discontinuous fiber modified PEEK thermoplastic composite material is ≥37 GPa and the thermal conductivity is ≥2 W / (mK).

[0121] The main body 10 includes an inner substrate and an outer reinforcing layer. 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 is ≥2 mm, the thickness of the outer reinforcing layer is ≥1 mm, and the thickness difference between the inner substrate and the outer reinforcing layer (thickness of the inner substrate - thickness of the outer reinforcing layer) 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 the following: abutment connection, nested connection, plug-in connection, snap-fit ​​connection, and threaded connection;

[0123] An inner sleeve 30 is provided inside the insert 20, and the inner sleeve 30 is connected to the insert 20 through a second connecting structure; the second connecting structure includes one or more of the following: abutment connection, nested connection, plug-in connection, snap-fit ​​connection, and threaded connection.

[0124] The area of ​​the surface of 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. 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 connecting structure to control their relative positions; the third connecting structure includes one or more of the following: abutment connection, nested connection, plug-in connection, clamping connection, and threaded connection; thus forming a structurally and functionally integrated housing.

[0127] The structurally and functionally integrated casing of the present invention, such as Figures 1-2As shown, it includes a main body 10, an insert 20, and an inner sleeve 30 that are fixedly connected from the outside to the inside.

[0128] In one embodiment, the main body 10 and the insert 20 are connected by a first connecting structure, which includes a first limiting part 21, a first positioning part, and a second positioning part.

[0129] In one embodiment, the insert 20 is provided with a first limiting part 21 and a second limiting part 22. The first limiting part 21 controls the relative position between the main body 10 and the insert 20, and the second limiting part 22 controls the relative position between the insert 20 and the inner liner 30. The main body is provided with a first connecting hole 11 arranged in a ring, and the insert 20 is provided with a second connecting hole 23 arranged in a ring.

[0130] In one embodiment, such as 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. A first reinforcing rib plate 17 is provided between the first annular reinforcing rib 14 and the second recess, and a second reinforcing rib plate 18 is provided between the first annular reinforcing rib 14 and the second annular reinforcing rib 15. A plurality of first connecting holes 11 are provided on the flange 16. A recessed first cavity 19 is formed between two adjacent first reinforcing rib plates 17, and a recessed second cavity 110 is formed between two adjacent second reinforcing rib plates 18.

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

[0132] In one embodiment, the first protrusion and the first concave portion are arranged in an arc shape, wherein the first protrusion 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 their relative rotation. The second positioning portion includes a second protrusion disposed on the outer sidewall of the insert 20 and a corresponding second recess disposed on the inner sidewall of the main body 10, wherein the second protrusion and the second recess form a concave-convex nested fit. The positions of the second protrusion and the second recess can also be interchanged.

[0134] In one embodiment, the second protrusion and the second recess are columnar, wherein the second protrusion includes a plurality of columnar protrusions 25, and the second recess includes a plurality of columnar grooves 13. A plurality of strip-shaped protrusions 120 are provided between two adjacent columnar grooves 13, and the plurality of strip-shaped protrusions 120 are arranged vertically along the axial direction of the main body 10, wherein the strip-shaped protrusions 120 are nested and fitted with the strip-shaped 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 by a second connecting structure. The second connecting structure includes a first positioning hole 27 on the inner sidewall 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, such as Figures 4-5 As shown, the insert 20 has a first positioning hole 27 on its inner sidewall and the inner bushing 30 has a second positioning hole 31. The positions of the first positioning hole 27 and the second positioning hole 31 correspond to each other, and the insert 20 and the inner bushing 30 are connected and fixed by a connector.

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

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

[0139] Example 1

[0140] In this embodiment, the main body 10, insert 20 and inner bushing 30 of the integrated structural and functional casing are nested together in pairs from the outside to the inside. 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 reinforcing layer. The thickness of the inner substrate is 34mm and the thickness of the outer reinforcing layer is 2mm.

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

[0142] (1) The outer reinforcing 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 fiber (carbon fiber with an average length of 700 mm) were used to make a continuous fiber PEEK thermoplastic composite material. The continuous fiber modified PEEK thermoplastic composite material was injection molded to obtain the outer reinforcing layer of the main body.

[0144] (2) The aluminum alloy is machined into insert 20. Insert 20 is a hollow columnar structure with one end open. The diameter of insert 20 is 200mm and the mass is 0.6kg.

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

[0146] (3) 55 parts of PEEK substrate, 35 parts of discontinuous fiber (carbon fiber with an average length of 60 μm) and 2 parts of hBN nanoparticles were used to make a discontinuous fiber modified PEEK thermoplastic composite material.

[0147] The inner substrate of the main body is obtained by injection molding of discontinuous fiber modified PEEK thermoplastic composite material in the assembly, and is fixedly connected to the assembly.

[0148] A first connecting structure is provided between the main body 10 and the insert 20 for cooperation and connection; then the insert 20 and the inner bushing 30 are connected by a second connecting structure;

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

[0150] Example 2

[0151] In this embodiment, the main body 10, insert 20 and inner bushing 30 of the integrated structural and functional casing are nested together in pairs from the outside to the inside. 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 reinforcing layer. The diameter of the main body 10 is 350 mm and the weight is 1.2 kg. The thickness of the inner substrate is 32 mm and the thickness of the outer reinforcing layer is 5 mm.

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

[0153] (1) The outer reinforcing 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 fiber (carbon fiber with an average length of 600 mm) were used to make a continuous fiber PEEK thermoplastic composite material. The continuous fiber modified PEEK thermoplastic composite material was injection molded to obtain the outer reinforcing layer of the main body.

[0155] (2) The aluminum alloy is machined into insert 20. Insert 20 is a hollow columnar structure with one end open. The diameter of insert 20 is 210mm and the mass is 0.7kg.

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

[0157] (3) 55 parts of PEEK substrate, 33 parts of discontinuous fiber (carbon fiber with an average length of 50 μm) and 1 part of hBN nanoparticles were used to make a discontinuous fiber modified PEEK thermoplastic composite material.

[0158] The inner substrate of the main body is obtained by injection molding of discontinuous fiber modified PEEK thermoplastic composite material in the assembly, and is fixedly connected to the assembly.

[0159] A first connecting structure is provided between the main body 10 and the insert 20 for cooperation and connection; then the insert 20 and the inner bushing 30 are connected by a second connecting structure;

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

[0161] Example 3

[0162] Compared with Example 1, the difference is that there is no annular gasket 40 on the outside of the main body 10.

[0163] The integrated structural and functional casings prepared in Embodiments 1 to 3 of this invention all have good mechanical properties and high heat dissipation efficiency, and have excellent performance when applied to aircraft transmission systems.

[0164] In summary, the present invention uses continuous-discontinuous fiber-reinforced thermoplastic composite materials, which not only enables the integral and rapid fabrication of the casing, but also achieves weight reduction while maintaining the rigidity and strength of the casing after being connected and assembled with alloy inserts, and still has high heat dissipation efficiency.

[0165] The specific embodiments described herein are merely illustrative of the spirit of the invention. Those skilled in the art to which this invention pertains may make various modifications or additions to the described specific embodiments or use similar methods to substitute them, without departing from the spirit of the invention or exceeding the scope defined by the appended claims.

Claims

1. A structurally and functionally integrated casing, characterized in that, It includes a main body and inserts that are fixedly connected from the outside in; The main body includes an inner substrate and an outer reinforcing layer. The inner substrate of the main body is made of discontinuous fiber modified PEEK thermoplastic composite material by injection molding; the outer reinforcing layer of the main body is made of continuous fiber reinforced PEEK thermoplastic composite material by hot pressing. The outer reinforcing layer of the main body and the insert are combined and hot-pressed to form an assembly. The inner substrate of the main body is then injection molded in the assembly and fixedly connected to the assembly. The discontinuous fiber modified PEEK thermoplastic composite material comprises 50-60 parts of PEEK matrix, 30-40 parts of discontinuous fiber, and 1-10 parts of hBN nanoparticles, wherein the length of the discontinuous fiber is 30-300 μm; The continuous fiber reinforced PEEK thermoplastic composite material comprises 35-45 parts of PEEK matrix, 55-65 parts of continuous fiber, and 0-10 parts of hBN nanoparticles, wherein the length of the continuous fiber is ≥1000 mm. The insert and the inner substrate of the main body are connected by a first connecting structure. The first connection structure includes a first limiting part, a first positioning part, and a second positioning part; A first positioning part is provided between one end face of the main body and the first limiting part on the insert to limit the relative rotation of the two. The first positioning part includes a first protrusion provided on one end face of the main body and a first recess provided on the first limiting part. The first protrusion and the first recess form a concave-convex nested fit. The positions of the first protrusion and the first recess can be interchanged. A second positioning part is also provided between the main body and the insert to limit the relative rotation of the two. The second positioning part includes a second protrusion provided on the outer wall of the insert and a second recess provided on the inner wall of the main body. The second protrusion and the second recess form a concave-convex nested fit. The positions of the second protrusion and the second recess can also be interchanged.

2. A structurally and functionally integrated casing, characterized in that, It includes a main body, inserts, and inner bushing that are fixedly connected from the outside in; The main body includes an inner substrate and an outer reinforcing layer. The inner substrate of the main body is made of discontinuous fiber modified PEEK thermoplastic composite material by injection molding; the outer reinforcing layer of the main body is made of continuous fiber reinforced PEEK thermoplastic composite material by hot pressing. The discontinuous fiber modified PEEK thermoplastic composite material comprises 50-60 parts of PEEK matrix, 30-40 parts of discontinuous fiber, and 1-10 parts of hBN nanoparticles, wherein the length of the discontinuous fiber is 30-300 μm; The continuous fiber reinforced PEEK thermoplastic composite material comprises 35-45 parts of PEEK matrix, 55-65 parts of continuous fiber, and 0-10 parts of hBN nanoparticles, wherein the length of the continuous fiber is ≥1000 mm. The outer reinforcing layer of the main body and the insert are combined and hot-pressed to form an assembly. The inner substrate of the main body is then injection molded in the assembly and fixedly connected to the assembly. The insert and the inner substrate of the main body are connected by a first connecting structure, and the insert and the inner liner are connected by a second connecting structure. A first positioning part is provided between one end face of the main body and the first limiting part on the insert to limit the relative rotation of the two. The first positioning part includes a first protrusion provided on one end face of the main body and a first recess provided on the first limiting part. The first protrusion and the first recess form a concave-convex nested fit. The positions of the first protrusion and the first recess can be interchanged. A second positioning part is also provided between the main body and the insert to limit the relative rotation of the two. The second positioning part includes a second protrusion provided on the outer wall of the insert and a second recess provided on the inner wall of the main body. The second protrusion and the second recess form a concave-convex nested fit. The positions of the second protrusion and the second recess can also be interchanged.

3. The integrated structural and functional casing according to claim 1 or 2, characterized in that, The discontinuous fiber-modified PEEK thermoplastic composite material has a flexural modulus ≥37 GPa and a thermal conductivity ≥2 W / (mK); the continuous fiber-reinforced PEEK thermoplastic composite material has a flexural modulus ≥70 GPa and a thermal conductivity ≥2.5 W / (mK).

4. The structurally and functionally integrated casing according to claim 1 or 2, characterized in that, The structure of the main body includes: a first annular reinforcing rib, a second annular reinforcing rib, and a flange radiating outward from the center of the main body; a first reinforcing rib is provided between the first annular reinforcing rib and the second recess; a second reinforcing rib is provided between the first annular reinforcing rib and the second annular reinforcing rib; and a plurality of first connecting holes are provided on the flange. A recessed first cavity is formed between two adjacent first reinforcing ribs, and a recessed second cavity is formed between two adjacent second reinforcing ribs.

5. The structurally and functionally integrated casing according to claim 1 or 2, characterized in that, The insert is a hollow columnar structure, or a hollow columnar structure with one end open.

6. The structurally and functionally integrated casing according to claim 1 or 2, characterized in that, A gasket, which is ring-shaped, is also provided on the outer side of the main body; The main body and the gasket are connected by a third connecting structure; The third connection structure includes a first connection hole on the main body, a third connection hole on the gasket, and a locking element connecting the two connection holes.

7. The integrated structural and functional casing according to claim 1 or 2, characterized in that, The second protrusion and the second concave are columnar. The second protrusion includes multiple columnar protrusions, and the second concave includes multiple columnar grooves. Multiple strip-shaped protrusions are provided between two adjacent columnar grooves, and the multiple strip-shaped protrusions are arranged up and down along the axis of the main body. The strip-shaped protrusions are nested and fitted with the strip-shaped cavities on the outer wall of the insert.

8. The integrated structural and functional casing according to claim 2, characterized in that, The insert is provided with a first limiting part and a second limiting part. The first limiting part controls the relative position between the main body and the insert, and the second limiting part controls the relative position between the insert and the inner bushing. The main body is provided with a first connecting hole distributed in a ring, and the insert is provided with a second connecting hole distributed in a ring.

9. A method for manufacturing a structurally and functionally integrated casing as described in claim 1 or 2, characterized in that, The preparation method includes: (1) The outer reinforcing layer of the main body is made of continuous fiber-reinforced PEEK thermoplastic composite material; (2) The outer reinforcing layer of the main body is preheated and combined with the insert, and the assembly is formed by hot pressing; (3) The inner substrate of the main body is obtained by injection molding of PEEK thermoplastic composite material modified with discontinuous fiber in the assembly, and fixedly connected with the assembly to obtain the integrated structural and functional casing.

10. The application of a structurally and functionally integrated casing as described in any one of claims 1 to 8 in an aircraft transmission system.

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