Method for manufacturing a large structural and functional integrated composite mast

Abstract

The application discloses a large-scale structural and functional integrated composite material comprehensive mast in the technical field of composite material products, which comprises a base made of metal material and used for fixing an outer wall to the use environment of the mast, an outer wall made of composite material and fixed at the top of the base, an equipment cavity formed in the inner part of the outer wall and used for accommodating equipment, and a plurality of equipment hatches formed on the surface of the outer wall, and a floor made of composite material and fixed in the inner part of the outer wall, which divides the space in the inner part of the outer wall into multiple layers. The application simultaneously satisfies the functions of frequency selection and wave transmission and can bear mechanical performance. The application solves the size change problem caused by the inconsistent thermal expansion coefficients of the composite material and the metal material after installation.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of composite material products, in particular to a preparation method of a mast. BACKGROUND

[0002] The mast, the earliest is used to hang the high column on the ship and the flag, install the antenna, support the observation platform, the early mast is all made of wood, after the development of the steel ship, a large number of steel masts are used. The mast has developed to today except the ship, and the top of the signal transmitting tower, such as power signal transmitting tower, broadcast television signal transmitting tower, mobile phone signal transmitting tower and the like, all use the mast device.

[0003] At present, the mast has developed into a multifunctional device with bearing, installing antenna, various radars and the like, so the mast has the increasingly obvious demand for installing multi-frequency radar equipment, wind and rain prevention function, and even frequency selection and wave transmission function. At present, the metal mast can bear, prevent wind and rain, but cannot realize the overall frequency selection and wave transmission function. Therefore, it is necessary to select new materials and new processes to realize the structure function integration of the comprehensive mast which can bear load, prevent wind and rain, realize frequency selection and wave transmission and electromagnetic stealth. SUMMARY

[0004] In view of the deficiencies in the prior art, the present application provides a preparation method of a large-scale structure function integrated composite material comprehensive mast, which is built by using composite materials to solve the construction process of the large-size mast of the metal material at present, is built by using the heat pressing tank integral forming process to ensure the integrity and structural strength of the mast, so that the structural mechanical properties are better, the functional materials and the structural materials are jointly laid, the materials are selected according to the required radar wave band to be transmitted or shielded, the frequency selection and wave transmission function are met at the same time, and the mechanical properties can be borne, and the size change problem caused by the inconsistent thermal expansion coefficients of the composite material and the metal material after installation is solved.

[0005] The purpose of the present application is achieved by a preparation method of a large-scale structure function integrated composite material comprehensive mast, comprising the following steps:

[0006] Step 1) outer wall forming, a plurality of layers of materials are laid on a metal negative mold, the outermost layer is a wave transmission material, quartz fiber reinforced cyanate ester prepreg is laid, PMI foam, resistance film, PMI foam plate, resistance film, PMI foam plate, resistance film, PMI foam plate are sequentially laid, the above 8 layers form a wave absorption material, finally, carbon fiber reinforced cyanate ester prepreg is laid, which can realize electromagnetic shielding, then a vacuum bag is made and is put into a heat pressing tank for high temperature and high pressure curing and forming, and the outer wall is obtained after demolding;

[0007] Step 2) floor forming, adopting a sandwich structure, including an upper skin, an intermediate layer, and a lower skin, the upper skin and the lower skin adopt the same carbon fiber reinforced cyanate ester prepreg as the outer wall, the intermediate layer adopts PMI foam, then a vacuum bag is prepared and high-temperature and high-pressure curing is performed in a heat press tank to form a floor;

[0008] Step 3) base forming, first fixing the inner ring, the bottom ring, the reinforcing rib, and the fixing piece to obtain a partial base;

[0009] Step 4) assembly of the outer wall and the floor, placing the floor into the inner cavity of the outer wall, and placing the outer periphery of the floor close to the inner wall of the outer wall, using hand lay-up process to lay the same series of carbon fiber cloth and liquid cyanate ester resin to the connection between the outer wall and the floor, and laying up from top to bottom, and waiting for the resin to cure under room temperature conditions after the hand lay-up process is completed;

[0010] Step 5) assembly of the outer wall and the base, first, the bottom of the outer wall is sleeved on the outer periphery of the inner ring and supported on the bottom ring, finally, the outer ring and the bottom ring are fixed, and the outer wall is clamped, finally, the inner ring, the outer wall, and the outer ring are fixed by using fasteners to complete the assembly of the entire mast.

[0011] Further, the large-scale structure and function integrated composite mast comprises:

[0012] The base is made of metal material and is used to fix the outer wall to the use environment of the mast, the base adopts a frame structure and comprises an inner ring, a bottom ring, and an outer ring, the inner ring and the outer ring are fixed on the inner side and the outer side of the bottom ring respectively, and a groove for inserting the bottom of the outer wall is formed between the inner ring and the outer ring, the inner ring and the bottom ring are provided with reinforcing ribs and fixing pieces, and corresponding waist-shaped holes are formed in the bottom of the outer wall and the base, and fasteners for fixing the outer wall and the base are arranged in the waist-shaped holes;

[0013] The outer wall is made of composite material and is fixed on the top of the base, an equipment cavity for accommodating equipment is formed in the inner part of the outer wall, and a plurality of equipment hatches are formed on the surface of the outer wall, the outer wall is made of carbon fiber prepreg, PMI foam, resistance film, quartz fiber prepreg, and structural adhesive film, and the floor is made of carbon fiber prepreg and PMI foam;

[0014] The floor is made of composite material and is fixed in the inner part of the outer wall to divide the space in the inner part of the outer wall into multiple layers, and the carbon fiber cloth is laid and fixed at the connection between the floor and the outer wall.

[0015] Further, step 1) specifically comprises:

[0016] 1-1) after the metal negative mold is prepared in place, the quartz fiber reinforced cyanate ester prepreg and the carbon fiber prepreg are cut to the size required for the layer laying process by using an automatic cutting machine;

[0017] 1-2) First, lay the outermost layer of the outer wall material, the outermost layer is 0.6mm quartz fiber reinforced cyanate ester prepreg, the thickness of the single layer of the sheet is 0.2mm, a total of 3 layers are needed to be laid, and a vacuum pre-exhaust bag is made after laying to precompact the sheet;

[0018] 1-3) Lay a layer of cyanate ester structural adhesive film on the surface of the pre-compacted quartz fiber prepreg, then lay the first layer of 2.5mm PMI foam board, and make a vacuum pre-exhaust bag to precompact the sheet and foam board;

[0019] 1-4) After laying the first layer of PMI foam board, continue to lay cyanate ester structural adhesive film on its surface, then lay the first layer of resistance film, the thickness of the first layer of electronic film is 0.1mm, after laying, continue to make a vacuum pre-exhaust bag to precompact the resistance film and foam board;

[0020] 1-5) Continue to lay cyanate ester structural adhesive film on the surface of the first layer of resistance film, then lay the second layer of PMI foam board, the thickness of the second layer of PMI foam board is 5mm, after laying, continue to make a vacuum pre-exhaust bag to precompact the foam board and resistance film;

[0021] 1-6) Lay a layer of ester structural adhesive film on the surface of the second layer of foam board, then continue to lay the second layer of resistance film, the thickness of the second layer of resistance film is 0.1mm, and a vacuum pre-exhaust bag is made after laying;

[0022] 1-7) Continue to lay a layer of cyanate ester structural adhesive film on the surface of the second layer of resistance film, then lay the third layer of PMI foam board, the thickness of the third layer of PMI foam board is 5mm, and a vacuum pre-exhaust bag is made after laying;

[0023] 1-8) Lay a layer of cyanate ester structural adhesive film on the surface of the third layer of PMI foam board, then lay the third layer of resistance film, the thickness of the resistance film is 0.1mm, and a vacuum pre-exhaust bag is made after laying;

[0024] 1-9) Lay cyanate ester structural adhesive film on the surface of the third layer of resistance film, then continue to lay the fourth layer of PMI foam, the thickness of which is 5mm, and a vacuum pre-exhaust bag is made after laying;

[0025] 1-10) After laying the fourth layer of PMI foam board, continue to lay a layer of cyanate ester structural adhesive film on its surface, then lay the last carbon fiber prepreg, the thickness of which is 2mm, the thickness of the single layer of the carbon fiber reinforced cyanate ester plain weave prepreg is 0.2mm, a total of 10 layers are needed to be laid, and a vacuum pre-exhaust bag is needed to be made according to the design requirements to precompact the sheet;

[0026] 1-11) After all the patches are completely laid, a final vacuum bag is made to enter a heat press tank for high-temperature and high-pressure curing and forming, and the curing system is 130 DEG C, 0.6Mpa for 1 hour, and then the temperature is raised to 180 DEG C, 0.6Mpa for 3 hours; after the outer wall is cured and formed, the outer wall is separated from the mold, and the excess area is cut by a cutting machine to obtain the net size of the outer wall product.

[0027] Further, the resistive film and the PMI foam plate are both treated by carbon black and graphene to meet the requirements of frequency selection and wave transmission in the specified frequency band.

[0028] Further, step 2) specifically comprises:

[0029] 2-1) A flat plate mold is used for laying, the upper skin and the lower skin of the floor are both 2mm thick, the single layer thickness is 0.2mm, the lower skin is laid first, and the lower skin is carbon fiber cyanate ester prepreg; every 4 layers of prepreg are laid to make a vacuum pre-exhaust bag to pre-compact the material;

[0030] 2-2) After the lower skin is laid, a layer of cyanate ester structural adhesive film is laid on the surface of the lower skin, and then a 30mm ordinary PMI foam plate is laid, and a layer of structural adhesive film is continuously laid on the surface of the foam plate; after the adhesive film is laid, a vacuum pre-exhaust bag is made for pre-compaction;

[0031] 2-3) Finally, the upper skin is laid, and the upper skin is also 2mm carbon fiber cyanate ester prepreg, and the laying design angle is consistent with that of the lower skin, and every 4 layers of prepreg are laid to pre-compact once, and all the patches are laid in a technical groove, and a final vacuum bag is made to enter a heat press tank for high-temperature and high-pressure curing and forming, and the curing system is consistent with that of the mast outer wall.

[0032] Further, the metal material of the base is consistent with the material of the base in the use environment.

[0033] Compared with the prior art, the beneficial effects of the present application are:

[0034] (1) The large comprehensive mast is changed to a composite material in the present application, and the density is only 1 / 5 of that of steel, which greatly reduces the self-weight of the mast, saves a large amount of load space of the ship body for installing other equipment and articles, and also reduces the bearing of the launching tower, thereby reducing the construction cost of the parent platform to a certain extent.

[0035] (2) The mast manufactured by using the composite material laying and heat press tank integral forming technology is convenient to install, the time of high-altitude operation is reduced, the risk of high-altitude operation is reduced, and the safety protection of the operating personnel is further improved.

[0036] (3) The successful development of large composite structure and function integrated mast solves the problem of easy peeling of the traditional spray, paste and invisible function layer material outside the metal structure layer, reduces the maintenance cost and guarantees the service life. BRIEF DESCRIPTION OF DRAWINGS

[0037] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the drawings needed to be used in the embodiments or the prior art description will be briefly introduced. Obviously, the drawings in the following description are only a part of the embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative labor on the basis of the provided drawings.

[0038] Figure 1 It is a schematic diagram of the mast structure in the present application.

[0039] Figure 2 It is a schematic diagram of the base structure of the mast in the present application.

[0040] Figure 3 It is a sectional view of the base of the mast in the present application.

[0041] Figure 4 It is a schematic diagram of the internal structure of the mast in the present application.

[0042] Figure 5 It is a schematic diagram of the floor structure of the mast in the present application.

[0043] Figure 6 It is a schematic diagram of the connection between the outer wall and the floor of the mast in the present application.

[0044] Figure 7 It is a schematic diagram of the outer wall layer of the mast in the present application.

[0045] Among them, 100 is the base, 101 is the inner ring, 102 is the bottom ring, 103 is the outer ring, 104 is the reinforcing rib, 105 is the fixing piece, 200 is the outer wall, 201 is the equipment cabin door, 300 is the floor, 301 is the upper skin, 302 is the middle layer, and 303 is the lower skin. DETAILED DESCRIPTION

[0046] The technical solutions in the embodiments of the present application will be described clearly and completely in combination with the drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0047] Embodiment 1

[0048] As Figures 1-7The large-scale structural and functional integrated composite comprehensive mast shown comprises:

[0049] The base 100 is made of metal material and is used to fix the outer wall 200 to the environment of the mast;

[0050] The outer wall 200 is made of composite material and is composed of four sides and a top, is fixed on the top of the base 100, and forms a device cavity inside to accommodate devices, and a plurality of device hatches 201 are arranged on the surface;

[0051] The floor 300 is made of composite material and is fixed inside the outer wall 200 to divide the space inside the outer wall 200 into multiple layers.

[0052] Further, the base 100 adopts a frame structure, including an inner ring 101, a bottom ring 102, and an outer ring 103, the inner ring 101 and the outer ring 103 are fixed on the inner side and the outer side of the bottom ring 102 respectively, and a groove is formed between the inner ring 101 and the outer ring 103 for the bottom of the outer wall 200 to be inserted, the inner ring 101 and the bottom ring 102 are provided with reinforcing ribs 104 and fixing pieces 105, and corresponding waist-shaped holes are arranged on the bottom of the outer wall 200 and the base 100, and fasteners are arranged in the waist-shaped holes to fix the outer wall 200 and the base 100.

[0053] It should be noted that the inner ring 101, the bottom ring 102, and the outer ring 103 are in a square structure as a whole to form a square frame, which facilitates the formation of the groove for the outer wall 200 to be inserted; the reinforcing ribs 104 enhance the structural strength of the frame; and the fixing pieces 105 facilitate the welding of the base 100 with the deck or the launching tower.

[0054] Further, the outer wall 200 is made of carbon fiber prepreg, PMI foam, resistance film, quartz fiber prepreg, and structural adhesive film, and the floor 300 is made of carbon fiber prepreg and PMI foam, including an upper skin 301, an intermediate layer 302, and a lower skin 303, the upper skin 301 and the lower skin 303 are made of the same carbon fiber reinforced cyanate ester prepreg as the outer wall 200, and the intermediate layer 302 is made of PMI foam.

[0055] Further, the connection between the floor 300 and the outer wall 200 is fixed by laying and pasting carbon fiber cloth.

[0056] The mast body structure in the embodiment has a height of 8.5 m, a bottom size of 7.8 m x 5.3 m, and a top size of 5.75 m x 3.2 m, and is a tower structure, and the space structure is divided into three layers, which are separated by the floor 300. Four device hatches 201 are arranged on each layer of the mast, which are used for installing radar and other signal emitting devices in the later stage. The metal base 100 is arranged at the bottom of the mast, and the metal base 100 can be welded with the metal ship deck and the launching tower.

[0057] Specifically, the mast, in addition to the bottom connection metal adapter plate according to the desired welding matrix material to select the same material, the rest of the material is made of composite materials.

[0058] Specifically, the composite parts of the mast mainly include the mast outer wall 200 and the floor 300. Since the floor 300 does not involve the requirement of frequency selective wave transmission, it is only made of ordinary carbon fiber composite material.

[0059] Specifically, the electromagnetic shielding performance of the mast outer wall 200 selected for frequency selective wave transmission and stealth requirements: the average isolation of the 3MHz-29MHz frequency band is less than 20dB; the isolation of the 30MHz-3GHz frequency band is less than 25dB; the average isolation of the 5GHz-18GHz frequency band is not less than 40dB.

[0060] Specifically, the wave absorption performance of the mast outer wall 200 selected for frequency selective wave transmission and stealth requirements: the vertical incidence of the outer wall 200 is 2GHz-8GHz≤-10dB, 8GHz-18GHz≤-15dB; the 45° oblique incidence of the outer wall 200 is 2GHz-8GHz≤-8dB, 8GHz-18GHz≤-12dB.

[0061] The following is a list of material compositions of the main parts of the mast:

[0062] Serial number Part name Material composition Remark 1 Mast outer wall Carbon fiber prepreg + PMI foam + resistance film + quartz fiber prepreg + structural adhesive film With electromagnetic shielding and frequency selective wave transmission function + bearing structure strength function 2 First floor Carbon fiber prepreg + PMI foam Bearing structure strength function 3 Second floor Carbon fiber prepreg + PMI foam Bearing structure strength function 4 Bottom metal connecting adapter plate According to the parent material (ship deck material, launch tower material, etc.) to select the same brand metal material Bearing structure strength function + connection function

[0063] Example 2

[0064] A preparation method of a large-scale structure and function integrated composite comprehensive mast, comprising the following steps:

[0065] Step 1) Forming and manufacturing of mast outer wall 200

[0066] The mast outer wall 200 is formed by laying and pasting a metal negative mold. It is made of ordinary Q235 steel welding processing. In order to ensure the size of the outer wall 200, the actual size of the mold at room temperature needs to be reduced according to the expansion coefficient of the mast outer wall 200 during the curing process at high temperature when designing the steel mold; Because the size of the mold is large, it is used in a spliced manner to realize the processing of the size and precision of the inner surface of the negative mold; The mast outer wall 200 involves two kinds of prepreg, one resistive film, two specifications of PMI foam board, and the use of cyanate structure adhesive film between each material for simultaneous laying and pasting to increase the interlayer strength.

[0067] 1-1) After the mold is prepared, the quartz fiber prepreg and the carbon fiber prepreg are cut to the size required for the layer laying process by using an automatic cutting machine;

[0068] 1-2) First, the outermost layer of the mast outer wall 200 is laid, which is 0.6mm quartz fiber reinforced cyanate ester plain preform, the thickness of the sheet is 0.2mm, a total of 3 layers are needed, according to the design layer angle is (0°, 90°, 0°), the mast height direction is 0°, after laying, a vacuum pre-exhaust bag is made to precompact the sheet;

[0069] 1-3) A layer of cyanate ester structural adhesive film is laid on the surface of the pre-compacted quartz fiber preform, which increases the adhesion between the preform and other material layers, then a 2.5mm PMI foam board is laid, to ensure that the foam board is laid tightly with the adhesive film and the preform, a vacuum pre-exhaust bag is made to precompact the foam board;

[0070] 1-4) After the first layer of foam board is laid, a cyanate ester structural adhesive film is laid on its surface, then a first layer of resistance film is laid, the thickness of the electronic film is 0.1mm, after laying, a vacuum pre-exhaust bag is made to precompact the resistance film and the foam board;

[0071] 1-5) A cyanate ester structural adhesive film is laid on the surface of the first layer of resistance film, then a second layer of PMI foam board is laid, the thickness of the second layer of foam board is 5mm, after laying, a vacuum pre-exhaust bag is made to precompact the foam board and the resistance film;

[0072] 1-6) A layer of cyanate ester structural adhesive film is laid on the surface of the second layer of foam board, then a second layer of resistance film is laid, the thickness of the second layer of resistance film is also 0.1mm, after laying, a vacuum pre-exhaust bag is made to precompact;

[0073] 1-7) A layer of cyanate ester structural adhesive film is laid on the surface of the second layer of resistance film, then a third layer of PMI foam board is laid, the thickness of the third layer of foam board is 5mm, after laying, a vacuum pre-exhaust bag is made to precompact;

[0074] 1-8) A layer of cyanate ester structural adhesive film is laid on the surface of the third layer of PMI foam board, then a third layer of resistance film is laid, the thickness of the resistance film is still 0.1mm, which is the last layer of resistance film, after laying, a vacuum pre-exhaust bag is made to precompact;

[0075] 1-9) A layer of cyanate ester structural adhesive film is laid on the surface of the third layer of resistance film, then a fourth layer of PMI foam is laid, which is also the last layer of foam board, the thickness is also 5mm, after laying, a vacuum pre-exhaust bag is made to precompact;

[0076] 1-10) After the last layer of foam board is laid, a layer of cyanate structural adhesive film is laid on its surface, and then the last carbon fiber prepreg is laid, with a thickness of 2 mm. The single layer thickness of the carbon fiber reinforced cyanate plain weave prepreg is 0.2 mm, and a total of 10 layers are needed to be laid. According to the design requirements, the thickness of each laid piece must not exceed 4 layers, and a vacuum pre-exhaust bag must be made to pre-compact the piece to ensure that there are no bubbles, pores, wrinkles, etc. between the layers. The carbon fiber prepreg laying process needs to be pre-compacted 3 times, and the laying design angle is (0°, 45°, 90°, -45°, 0°, 0°, -45°, 90°, 45°, 0°);

[0077] 1-11) After all the pieces are laid, the final vacuum bag is made and put into the autoclave for high temperature and high pressure curing and forming, with a curing system of 130°C, 0.6Mpa for 1 hour, and then the temperature is raised to 180°C, 0.6Mpa for 3 hours. After curing and forming, the mast outer wall 200 is separated from the mold, and the excess area is cut off with a cutting machine to obtain the net size of the mast outer wall 200 finished product.

[0078] Step 2) Floor 300 forming

[0079] The mast floor 300 mainly includes a first floor 300 and a second floor 300, wherein the size of the first floor 300 is 5.67m×3.67m, and the size of the second floor 300 is 5.34m×3.23m. The thickness of the two floors 300 is the upper and lower skin 303 plus the foam sandwich structure, with a thickness of 34mm.

[0080] The floor 300 is a flat plate structure, which can be laid with a steel flat plate mold. According to the size of the two floors 300, the corresponding size of the cutting diagram is made, and the pieces are cut by an automatic cutting machine. The thickness of the upper and lower skin 303 of the floor 300 is 2mm. The lower skin 303 is laid first, and the laying design angle is (0°, 45°, 90°, -45°, 0°, 0°, -45°, 90°, 45°, 0°). Similarly, the vacuum pre-exhaust bag is made to pre-compact the pieces every 4 layers of prepreg.

[0081] After the lower skin 303 is laid, a layer of cyanate structural adhesive film is laid on its surface, and then 30mm ordinary PMI foam board is laid. A layer of structural adhesive film is laid on the surface of the foam board. After the adhesive film is laid, the vacuum pre-exhaust bag is made to pre-compact.

[0082] The last layer of the upper skin 301 is laid, and the upper skin 301 is also 2mm of carbon fiber cyanate prepreg. The laying design angle is consistent with that of the lower skin 303, and it is also pre-compacted once every 4 layers of prepreg. All the pieces are laid in a technical groove, and the final vacuum bag is made and put into the autoclave for high temperature and high pressure curing and forming, with the same curing system as the mast outer wall 200.

[0083] Step 3) Bottom metal connection adapter plate

[0084] The bottom metal connection adapter plate is mainly used for the connection of the composite mast and the parent platform, and its material is consistent with the parent platform, which can ensure the welding with the parent platform. The outer wall 200 of the mast is made of composite material. To solve the problem of different thermal expansion coefficients between the composite material and the metal adapter plate, a waist-shaped hole connection is adopted to realize small position sliding.

[0085] The metal adapter plate is mainly made of metal plate and profile through laser cutting, and then welded. Finally, according to the installation accuracy, the size can be finished by gantry numerical control machining center and the waist-shaped hole can be punched.

[0086] Step 4) Hand lay-up connection

[0087] The floor 300 and the outer wall 200 of the mast are both made of composite material. In order to make them more integrated, the hand lay-up process is used to connect the floor 300 and the outer wall 200 of the mast. According to the design, the same series of carbon fiber cloth and liquid cyanate ester resin are used for the mast, the hand lay-up thickness is 2mm on the ground surface and 2mm below the floor 300, and the hand lay-up connection single side width is 150mm. Since the hand lay-up single layer thickness is 0.25mm, the number of hand lay-up material pieces is 8 layers. After hand lay-up, the resin is cured for more than 8 hours at room temperature.

[0088] In this embodiment, according to the design, the outer wall 2005 of the mast is made of full composite material integrated construction process. After the foam core material, frequency selection wave-transparent, electromagnetic shielding, and bearing structure pre-impregnated material are mixed and laid, they are put into a heat press tank for one-time high temperature and high pressure curing and forming. One floor 300 and two floors 300 are mixed and laid with bearing structure pre-impregnated material and foam core material, and then put into a heat press tank for high temperature and high pressure curing and forming. The bottom connection adapter plate is made of metal material.

[0089] The mast wall plate has a main size of 8.5m in height, 7.8m x 5.3m in bottom size, and 5.75m x 3.2m in top size, which is a five-faced tower structure. According to the design requirements, in order to make the structural strength more integrated, the five faces are laid integrally. In order to ensure the smoothness of the shape of the mast, a metal negative mold is used for laying.

[0090] The outer wall 200 of the mast is the outermost wave-transparent material, which is selected from 0.6 mm quartz fiber reinforced cyanate ester prepreg (single layer thickness 0.2 mm, laid 3 layers), laid in turn 2.5 mm thick PMI foam, 0.1 mm thick resistance film, 5 mm thick PMI foam board, 0.1 mm thick resistance film, 5 mm thick PMI foam board, 0.1 mm thick resistance film, 5 mm thick PMI foam board, the above 8 layers of materials are composed of wave-absorbing power, and finally 2 mm of carbon fiber reinforced cyanate ester prepreg (single layer thickness 0.2 mm, laid 10 layers) can realize electromagnetic shielding material, 9 kinds of layer materials are combined into mast outer wall 200 material which can realize frequency selective wave transmission and load structure strength. The resistance film and PMI foam board are treated with carbon black and graphene, which are unconventional materials, so that the frequency selective wave transmission requirements of the specified frequency band can be met by selecting materials and designing layer laying.

[0091] The specific processing process is as follows:

[0092] a) Preparation of impregnating solution: select appropriate carbon black and graphene materials according to needs, and disperse them in appropriate solvents to prepare impregnating solution. Ultrasonic treatment or mechanical stirring is used to promote the dispersion of carbon black and graphene. According to needs, other additives such as surfactants, adhesives, etc. can be added to the impregnating solution to improve the dispersibility and adhesion of carbon black and graphene in the foam.

[0093] b) Soaking foam: soak the resistance film and PMI foam board in the impregnating solution to ensure that the foam fully absorbs the impregnating solution. The impregnation effect can be controlled by adjusting the soaking time, temperature and concentration of the impregnating solution. Vacuum impregnation or pressure impregnation methods can be used to improve the impregnation effect.

[0094] c) Drying treatment: take out the impregnated resistance film and PMI foam board from the impregnating solution, and use filter paper or other water-absorbing materials to absorb the excess impregnating solution on the surface. Place the foam in a well-ventilated environment and dry naturally or use a low-temperature oven to dry. The drying temperature and time should be adjusted according to the characteristics of the foam material and the composition of the impregnating solution to avoid deformation or damage to the foam material.

[0095] It should be noted that the multi-layer structure is used as the outer plate material (outer quartz glass fiber layer, inner carbon fiber layer, and middle foam + resistance film layer), the quartz fiber layer transmits waves, the foam + resistance film layer absorbs waves, and the carbon fiber layer shields. From the functional point of view, after the electromagnetic wave transmits through the quartz fiber layer, it is absorbed by the required frequency band (4 layers of wave-absorbing foam and 4 layers of resistance film) for multiple times, and finally reflected by the carbon fiber layer and then absorbed again. This back-and-forth absorption ensures that the specific wave band electromagnetic wave can be completely shielded. From the structural strength point of view, the quartz fiber layer serves as the structural strength, the foam + resistance film layer serves as the internal filling to increase the structural modulus, and the carbon fiber layer serves as the structural strength. The combined outer plate can meet the structural strength and rigidity of the entire mast. It is summarized that the raw materials and layer design used by the mast are complementary to each other in terms of function and structure, and multiple simulation calculations are required to obtain the final layer design.

[0096] In this embodiment, the floor 300 is designed with two layers, and both the first floor 300 and the second floor 300 are load-bearing structural components that do not require frequency-selective wave transmission and stealth functions. To ensure that the same material system is used as the outer wall 200, the upper and lower skins 303 are made of carbon fiber reinforced cyanate ester prepreg (single layer thickness 0.2 mm, 10 layers laid), and the middle layer 302 is made of PMI regular foam board with a thickness of 30 mm (not treated with carbon black and graphene).

[0097] Since the floor 300 is a flat plate structure, it can be laid with a common steel flat plate mold. After laying, a vacuum bag is made and high-temperature and high-pressure co-curing is performed in a heat press tank.

[0098] In this embodiment, the purpose of the metal adapter plate at the bottom of the mast is to connect with the ship body, launch tower and other platforms. Since most ships and launch towers are made of steel, and the mast is made of composite material, the two materials cannot be directly welded. Therefore, the metal adapter plate is made of metal material and welded with the ship body or launch tower, and the adapter plate and the composite material mast are connected by metal bolts.

[0099] Due to the large difference in the thermal expansion coefficient between metal materials and organic composite materials, in different environments (large temperature difference between the equator and the north and south poles), if metal and composite materials are directly connected by ordinary holes, the composite material is easily cracked under multiple thermal expansion and contraction, resulting in damage to the connection between the mast and the parent body. To solve this problem, according to the temperature difference in different environments, the size change of the mast and the bottom connecting adapter plate is calculated and a special length of waist hole is designed and made. The composite mast and the adapter plate are both provided with corresponding size waist holes. After the bolt connection, the composite material and the metal material can slide accordingly to avoid damage between the composite material and the metal material.

[0100] In this embodiment, the floor 300 and the outer wall 200 are constructed by using organic composite materials, and the properties of the two are the same, and the thermal expansion coefficients are consistent. In order to ensure the structural strength of the whole mast, carbon fiber cloth is used to connect the liquid cyanate ester resin (room temperature curing resin) here, so as to ensure the consistency of the material, and the strength of the hand lay-up connection tends to be more integrated.

[0101] The above description of the embodiments is only used to help understand the method of the present application and its core idea. It should be pointed out that for those skilled in the art, without departing from the principles of the present application, some improvements and modifications can be made to the present application, and these improvements and modifications also fall within the protection scope of the claims of the present application.

Claims

1. A method for manufacturing a large-scale integrated composite material comprehensive mast, characterized in that, Comprising the following steps: Step 1) outer wall forming, using multi-layer material to lay on the metal negative mold, the outermost layer is a wave-transparent material, using quartz fiber reinforced cyanate ester prepreg to lay, laying PMI foam, resistance film, PMI foam board, resistance film, PMI foam board, resistance film, PMI foam board in turn, the above 8 layers form a wave-absorbing material, finally laying carbon fiber reinforced cyanate ester prepreg, which can realize electromagnetic shielding material, then making a vacuum bag and entering a heat press tank for high temperature and high pressure curing forming, after demolding, the outer wall is obtained, step 1) specifically comprising: 1-1) after the metal negative mold is prepared in place, the quartz fiber reinforced cyanate ester prepreg and the carbon fiber prepreg are cut to the size required in the layer laying process by using an automatic cutting machine; 1-2) first, lay the outermost layer of the outer wall, the outermost layer is 0.6mm quartz fiber reinforced cyanate ester prepreg, the thickness of the single layer of the material sheet is 0.2mm, a total of 3 layers are needed to lay, after laying, a vacuum pre-exhaust bag is made to pre-compact the material sheet; 1-3) lay a layer of cyanate ester structural adhesive film on the surface of the pre-compact quartz fiber prepreg, then lay the first layer of 2.5mm PMI foam board, make a vacuum pre-exhaust bag to pre-compact the material sheet and the foam board; 1-4) after laying the first layer of PMI foam board, lay the cyanate ester structural adhesive film on its surface, then lay the first layer of resistance film, the thickness of the first layer of electronic film is 0.1mm, after laying, continue to make a vacuum pre-exhaust bag to pre-compact the resistance film and the foam board; 1-5) continue to lay the cyanate ester structural adhesive film on the surface of the first layer of resistance film, then lay the second layer of PMI foam board, the thickness of the second layer of PMI foam board is 5mm, after laying, continue to make a vacuum pre-exhaust bag to pre-compact the foam board and the resistance film; 1-6) lay a layer of cyanate ester structural adhesive film on the surface of the second layer of foam board, then continue to lay the second layer of resistance film, the thickness of the second layer of resistance film is 0.1mm, after laying, make a vacuum pre-exhaust bag for pre-compact; 1-7) continue to lay a layer of cyanate ester structural adhesive film on the surface of the second layer of resistance film, then lay the third layer of PMI foam board, the thickness of the third layer of PMI foam board is 5mm, after laying, make a vacuum pre-exhaust bag for pre-compact; 1-8) lay a layer of cyanate ester structural adhesive film on the surface of the third layer of PMI foam board, then lay the third layer of resistance film, the thickness of the resistance film is 0.1mm, after laying, make a vacuum pre-exhaust bag for pre-compact; 1-9) lay the cyanate ester structural adhesive film on the surface of the third layer of resistance film, then continue to lay the fourth layer of PMI foam, the thickness is 5mm, after laying, make a vacuum pre-exhaust bag for pre-compact; 1-10) after laying the fourth layer of PMI foam board, continue to lay a layer of cyanate ester structural adhesive film on its surface, then lay the last carbon fiber prepreg, the thickness is 2mm, the thickness of the single layer of carbon fiber reinforced cyanate ester plain weave prepreg is 0.2mm, a total of 10 layers are needed to lay, according to the design requirements, the thickness of each laid material sheet cannot exceed 4 layers, a vacuum pre-exhaust bag needs to be made for pre-compact; 1-11) After all the patches are completely laid, the final vacuum bag is made and the high-temperature and high-pressure curing is carried out in the autoclave, the curing temperature is 130℃, 0.6Mpa for 1 hour, and then the temperature is raised to 180℃, 0.6Mpa for 3 hours; the outer wall is separated from the mold after curing, and the excess area is cut off by a cutting machine to obtain the net size of the outer wall product; Step 2) Floor forming, using a sandwich structure, including upper skin, middle layer, lower skin, upper skin and lower skin using the same carbon fiber reinforced cyanate ester prepreg as the outer wall, the middle layer uses PMI foam, then make a vacuum bag and autoclave high-temperature and high-pressure curing, and get the floor after demolding; Step 3) Base forming, first fix the inner ring, bottom ring, reinforcing rib and fixing piece to get part of the base; Step 4) Assembly of outer wall and floor, place the floor into the inner cavity of the outer wall, and the outer periphery of the floor is close to the inner wall of the outer wall, use hand lay-up process to lay the same series of carbon fiber cloth and liquid cyanate ester resin on the connection between the outer wall and the floor, and lay up from top to bottom, and wait for the resin to cure under room temperature conditions after hand lay-up is completed; Step 5) Assembly of outer wall and base, first, the bottom of the outer wall is sleeved on the outer periphery of the inner ring and supported on the bottom ring, then the outer ring and the bottom ring are fixed, and the outer wall is clamped, finally, the inner ring, the outer wall and the outer ring are fixed by using fasteners, and the assembly of the whole mast is completed.

2. The method for preparing a large-scale structural and functional integrated composite mast according to claim 1, characterized in that, The large-scale structural and functional integrated composite mast comprises: a base made of metal material, used to fix the outer wall to the use environment of the mast, the base adopts a frame structure, including an inner ring, a bottom ring and an outer ring, the inner ring and the outer ring are fixed on the inner side and the outer side of the bottom ring respectively, and a groove for inserting the bottom of the outer wall is formed between the inner ring and the outer ring, the inner ring and the bottom ring are provided with reinforcing ribs and fixing pieces on the inner side, and corresponding waist-shaped holes are formed on the bottom of the outer wall and the base, and fasteners for fixing the outer wall and the base are arranged in the waist-shaped holes; an outer wall made of composite material, fixed on the top of the base, and forming an equipment cavity for accommodating equipment inside, and a plurality of equipment hatches are formed on the surface, the outer wall is made of carbon fiber prepreg, PMI foam, resistance film, quartz fiber prepreg and structural adhesive film, and the floor is made of carbon fiber prepreg and PMI foam; a floor made of composite material, fixed inside the outer wall, and separating the space inside the outer wall into multiple layers, and the connection between the floor and the outer wall is fixed by laying carbon fiber cloth.

3. The method of claim 1 or 2, wherein the method is characterized by, The resistance film and the PMI foam board are treated by carbon black and graphene to meet the requirements of frequency selection and wave transmission in the specified frequency band.

4. The method of claim 1 or 2, wherein the large-scale integrated composite mast is prepared by the steps of: (a) preparing a plurality of large-scale integrated composite mast units; (b) combining the plurality of large-scale integrated composite mast units to form the large-scale integrated composite mast. Step 2) specifically includes: 2-1) flat plate mold laying can be used, the upper skin and the lower skin of the floor are both 2mm thick, and the single layer thickness is 0.2mm, the lower skin is first laid, which is carbon fiber cyanate ester prepreg, and a vacuum pre-exhaust bag is made every 4 layers of prepreg to pre-compact the material; 2-2) after the lower skin is laid, a layer of cyanate ester structural adhesive film is laid on the surface of the lower skin, then a 30mm ordinary PMI foam board is laid, and a layer of structural adhesive film is continuously laid on the surface of the foam board, and a vacuum pre-exhaust bag is made after the adhesive film is laid. 2-3) Finally, the skin is laid, which is also 2mm carbon fiber cyanate ester prepreg, and the layup design angle is consistent with the lower skin, which is also 4 layers of prepreg per layup, pre-compacted once, all the pieces are laid in the technical groove, and the final vacuum bag is made into a hot press tank for high temperature and high pressure curing, and the curing temperature is consistent with the mast outer wall.

5. The method of claim 1 or 2, wherein the large-scale integrated composite mast is prepared by the steps of: (a) preparing a plurality of large-scale integrated composite mast units; (b) combining the plurality of large-scale integrated composite mast units to form the large-scale integrated composite mast. The metal material of the base is consistent with the material of the base in the use environment.

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