Molding method of composite material deck

Abstract

The invention discloses a forming method of a composite material deck, which comprises the following steps: 1, preparing raw materials; 2, preparing a mold; 3, bottom plate paving is conducted on the male mold according to the paving layer design, and after paving is completed, a vacuum leading-in system is arranged, glue is injected, and curing is conducted in sequence; 4, a plurality of positioning longitudinal foam is installed on the bottom plate, whole-surface laying is conducted according to the laying design, and after laying is finished, a vacuum leading-in system is arranged, glue is injected, and curing is conducted in sequence; 5, longitudinal girder foams and middle strong cross beam foams are installed according to the designed positions; 6, paving various longitudinal girder foams and middle strong cross beam foams according to the paving layer design, and sequentially arranging a vacuum introduction system, injecting glue and curing; 7, longitudinal foams are installed on the bottom plate between every two adjacent transverse foams, laying is conducted on the longitudinal foams according to the laying layer design, and a vacuum leading-in system, glue injection and curing are sequentially arranged; 8, demolding; the clamping plate prepared through the method is lighter in mass, and deck forming can be completed without the help of large equipment.

Description

Technical Field

[0001] The invention relates to the technical field of deck molding, in particular to a molding method of a composite material deck. Background Art

[0002] The deck is one of the key components of the hull. With the development of composite materials, composite materials are widely used in the molding of decks. In the prior art, the deck is usually prepared by autoclave molding, but the size of the deck is large, and large autoclave equipment is required for autoclave molding. Large autoclave equipment is expensive and has a long construction period. In addition, as thick-walled parts need to be cured in sections, it is difficult to move large parts in and out of the autoclave. Summary of the invention

[0003] The purpose of this section is to summarize some aspects of embodiments of the present invention and briefly introduce some preferred embodiments. Some simplifications or omissions may be made in this section and the specification abstract and the invention title of this application to avoid blurring the purpose of this section, the specification abstract and the invention title, and such simplifications or omissions cannot be used to limit the scope of the present invention.

[0004] In view of the above-mentioned and / or existing problems in the preparation of existing decks, the present invention is proposed.

[0005] Therefore, the object of the present invention is to provide a molding method for a composite material deck, which does not require the use of large-scale equipment for hot pressing molding, has a simple molding process, and reduces the preparation cost.

[0006] In order to solve the above technical problems, the present invention provides the following technical solutions: a method for forming a composite material deck, comprising the following steps: 1. Raw materials preparation; 2. Mold preparation; 3. Lay the base plate on the male mold according to the layer design. After paving, arrange the vacuum introduction system, vacuum glue injection, and cure at room temperature after glue injection; 4. Install several positioning longitudinal foams on the cured bottom plate. After the positioning longitudinal foams are fixed, perform full-surface ply laying on the bottom plate and the positioning longitudinal foams according to the ply design. After the ply laying is completed, arrange the vacuum introduction system, and after the completion, perform vacuum glue injection. After the glue injection is completed, it will be cured at room temperature. 5. Install the longitudinal girders according to the designed positions. Install several middle strong transverse beam foams at intervals in the front-to-back direction at the center of the bottom plate. Install middle longitudinal girders foams on the upper sides of the bottom plates on the left and right sides of several middle strong transverse beam foams. Install side longitudinal girders foams on the bottom plate to the left of the middle longitudinal girders foam on the left and on the right of the middle longitudinal girders foam on the right. Install transverse foams on the left side of the middle longitudinal girders foam on the left, on the right side of the middle longitudinal girders foam on the right, and on the bottom plates on the left and right sides of the side longitudinal girders foams. 6. According to the ply design, the foam is laid on the middle longitudinal girders, the middle strong cross beams and the side longitudinal girders respectively, and the vacuum introduction system is arranged. After completion, vacuum glue injection is performed, and the glue is cured at room temperature; 7. Install the longitudinal foam on the bottom plate between two adjacent transverse foams, lay the tiles on the longitudinal foam according to the ply design, arrange the vacuum introduction system, and perform vacuum glue injection after completion. After the glue injection is completed, it will be cured at room temperature; 8. Demoulding.

[0007] As a preferred embodiment of the forming method of the composite material deck in the present invention, step 2 specifically comprises: cleaning the deck steel positive mold surface and the flat mold with acetone, and laying a single-sided adhesive release cloth within the excess line after the acetone on the mold surface evaporates and dries, and ensuring that there are no bubbles and wrinkles on the surface during the laying process.

[0008] As a preferred embodiment of the forming method of the composite material deck of the present invention, in step 3, during paving, the first layer of felt is first paved on the upper side of the male mold, and three cycles of full-surface paving are first performed on the first layer of felt, and the full-surface paving sequence of each cycle is to use a layer of biaxial cloth [45°, -45°], a layer of biaxial cloth [0°, 90°], a layer of unidirectional cloth 0°, a layer of biaxial cloth [90°, 0°], a layer of [-45°, 45 °] biaxial cloth and a layer of [0°, 90°] biaxial cloth, then lay the second layer of felt, and perform 2 cycles of whole-surface laying on the second layer of felt. The laying order of each cycle is a layer of [45°, -45°] biaxial cloth, a layer of [0°, 90°] biaxial cloth, a layer of 0° unidirectional cloth, a layer of [90°, 0°] biaxial cloth and a layer of [-45°, 45°] biaxial cloth. The thickness of the above paving is 12mm.

[0009] As a preferred embodiment of the forming method of the composite deck in the present invention, when paving in step 4, three cycles of full-surface paving are performed on the basis of step 3, and the paving sequence of each cycle is one layer of biaxial cloth [45°, -45°], one layer of biaxial cloth [0°, 90°], one layer of unidirectional cloth at 0°, one layer of biaxial cloth [90°, 0°] and one layer of biaxial cloth [-45°, 45°], and the paving thickness is 7 mm.

[0010] As a preferred embodiment of the forming method of the composite deck of the present invention, in step 6, layers are laid respectively on the connected middle strong cross beam foam, middle longitudinal girder foam and side longitudinal girder foam, and the laying method is the same, and the layers are laid in an interlaced and overlapped manner, and the overlap interface position needs to be staggered and overlapped.

[0011] As a preferred embodiment of the forming method of the composite material deck in the present invention, the entire surface of the composite material deck is respectively layered on the connected intermediate strong transverse beam foam and the intermediate longitudinal girder foam, and the layering sequence is successively a layer of biaxial cloth of [45°, -45°], a layer of biaxial cloth of [0°, 90°], a layer of unidirectional cloth of 0°, a layer of biaxial cloth of [90°, 0°] and a layer of biaxial cloth of [-45°, 45°]; the entire surface of the intermediate strong transverse beam foam and the intermediate longitudinal girder foam is layered, and the layering sequence is successively a layer of biaxial cloth of [45°, -45°], a layer of biaxial cloth of [0°, 90°], a layer of unidirectional cloth of 0°, a layer of biaxial cloth of [90°, 0°], axial cloth and a layer of [-45°, 45°] biaxial cloth, and then the entire surface is laid on the connected middle strong crossbeam foam and middle longitudinal girder foam, the laying order is one layer of [45°, -45°] biaxial cloth, one layer of [0°, 90°] biaxial cloth, one layer of 0° unidirectional cloth, one layer of [90°, 0°] biaxial cloth and one layer of [-45°, 45°] biaxial cloth, and then a layer of felt is laid, and the above laying steps are repeated twice on the basis of this layer of felt, and the laying is completed. After the laying is completed, the facades on the front and rear sides of the middle strong crossbeam foam, the facades on the left and right sides of the middle longitudinal girder foam, and the facades on the left and right sides of the side longitudinal girder foam are called webs, and the thickness of the web is 15mm. After the laying is completed, the upper surface of the middle strong crossbeam foam, the upper surface of the middle longitudinal girder foam and the upper surface of the side longitudinal girder foam are called panels, and the thickness of the panel is 22mm.

[0012] As a preferred embodiment of the forming method of the composite material deck in the present invention, the plying step in step 7 is to perform full-surface plying on the longitudinal foam, first plying a layer of biaxial cloth of [45°, -45°], and then performing 2 cycles of full-surface plying on this basis, and the plying sequence of each cycle is, in turn, a layer of 0° unidirectional cloth, a layer of [90°, 0°] biaxial cloth, a layer of [-45°, 45°] biaxial cloth, a layer of [45°, -45°] biaxial cloth and a layer of [0°, 90°] biaxial cloth, and then plying a layer of [90°, 0°] biaxial cloth, a layer of [-45°, 45°] biaxial cloth, a layer of [45°, -45°] biaxial cloth and a layer of [0°, 90°] biaxial cloth in turn. A layer of biaxial cloth [-45°, 45°] and a layer of felt are laid, and the entire surface is laid on the basis of the felt. The laying order is: a layer of biaxial cloth [45°, -45°], a layer of biaxial cloth [0°, 90°], a layer of unidirectional cloth [0°], a layer of biaxial cloth [90°, 0°], a layer of biaxial cloth [-45°, 45°], a layer of biaxial cloth [45°, -45°], a layer of biaxial cloth [0°, 90°], a layer of unidirectional cloth [0°] and a layer of biaxial cloth [-45°, 45°], and finally a layer of felt is laid. The total laying thickness is 11mm.

[0013] As a preferred scheme of the forming method of the composite material deck in the present invention, when the vacuum introduction system is arranged in step S6, the vacuum introduction guide net and guide tube are arranged in a top-down glue injection manner, the first glue injection port is placed in the center of the panel, the second glue injection port is placed in the middle of the web, a circle of glue outlet guide tubes is arranged around the bottom of the web, and vacuum double bag film is produced in each area after being fixed with masking tape.

[0014] Compared with the prior art, the present invention has the following technical effects: the present invention directly performs vacuum introduction molding on a steel mold, first prepares 2 / 3 of the bottom plate skin, and then installs positioning longitudinal bones on 2 / 3 of the bottom plate skin after the preparation is completed, divides the area, and layers the entire surface to prepare the skin of the remaining 1 / 3 of the bottom plate, and fixes and installs the corresponding longitudinal girders foams according to the divided areas, and then layers are laid, vacuum introduction bags are arranged, vacuumized and cured in turn on this basis, and the longitudinal foam is fixedly installed on the bottom plate between two adjacent transverse foams, and layers are laid, vacuum introduction bags are arranged, vacuumized and cured in turn, and the layers are positioned and laid and molded by dividing the area, without the need for large-scale equipment for molding, and the operation is simple, and the molding cost is reduced. While meeting the strength requirements, the dimensional accuracy and appearance requirements are also guaranteed, and the parts are completed with high quality and high efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for describing the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative labor. Among them: Figure 1 It is a three-dimensional structural diagram of the flat plate mold in the present invention.

[0016] Figure 2 This is a three-dimensional structural diagram after the positioning longitudinal bone foam is installed on the upper side of the 2 / 3 skin.

[0017] Figure 3 This is a three-dimensional structural diagram of the deck before the longitudinal foam is installed.

[0018] Figure 4 The three-dimensional structural diagram of the deck processed by the present invention (a hatch door for installing a small hatch door and a hatch cover opening for installing a hatch cover are opened later).

[0019] Figure 5 for Figure 4 A partial enlarged view of point A in the middle.

[0020] Figure 6 for Figure 4 A partial enlarged view of point B in the middle.

[0021] Figure 7 Schematic diagram of vacuum introduction.

[0022] In the figure: 1 flat mold, 2 bottom plate, 201 2 / 3 skin, 202 1 / 3 skin, 3 positioning longitudinal bone foam, 4 positioning transverse bone foam, 5 prefabricated plate, 6 middle longitudinal girder foam, 7 middle longitudinal girder, 8 side longitudinal girder foam, 9 side longitudinal girder, 10 second side transverse reinforcement rib, 11 first side transverse reinforcement rib, 14 second side transverse reinforcement foam, 15 first middle transverse reinforcement rib, 16 second middle transverse reinforcement rib, 17 third middle transverse reinforcement rib, 18 longitudinal foam, 19 longitudinal reinforcement rib, 20 positioning longitudinal rib, 21 positioning transverse rib. DETAILED DESCRIPTION

[0023] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the specific implementation methods of the present invention are described in detail below in conjunction with the accompanying drawings.

[0024] In the following description, many specific details are set forth to facilitate a full understanding of the present invention, but the present invention may also be implemented in other ways different from those described herein, and those skilled in the art may make similar generalizations without violating the connotation of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0025] Secondly, the term "one embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The term "in one embodiment" that appears in different places in this specification does not necessarily refer to the same embodiment, nor does it refer to a separate or selective embodiment that is mutually exclusive with other embodiments.

[0026] Example 1 Reference Figure 1 to Figure 6 , which is the first embodiment of the present invention, provides a method for forming a composite material deck, which can realize the molding of the deck without the aid of large-scale equipment and is easy to operate.

[0027] A method for forming a composite material deck comprises the following steps: S1 Raw material preparation, including paving cloth, vinyl resin, curing agent, inhibitor, PVC foam, hardwood embedded parts, steel plate embedded parts; S2 mold preparation: clean the deck steel male mold surface and the flat mold with acetone. After the acetone on the mold surface evaporates and dries, lay a single-sided adhesive release cloth within the excess line. Ensure that there are no bubbles and wrinkles on the surface during the laying process; S3 lays the bottom plate on the positive mold according to the layup design and completes 2 / 3 of the skin layer. During the layup process, the dry cloth interface overlaps 30mm and the overlap interface positions need to be staggered. The layup surface must be flat and wrinkle-free. The dry cloth in the flange area needs to be fixed with 3M spray glue to facilitate the subsequent vacuum system layout. After the laying is completed, the bottom plate skin vacuum introduction system is arranged, and vacuum glue injection is carried out after completion. After the glue injection is completed, it is cured at room temperature; S4 uses a tape measure, laser level and ink fountain to locate the laying position of the longitudinal foam. After passing the test, the longitudinal foam is classified and pre-laid at the location. At the same time, the prefabricated panels are placed at the bulkhead assembly position (the position where two adjacent longitudinal foams need to be combined in the longitudinal direction). The prefabricated panels are fiberglass panels. To prevent the foam from moving, vinyl resin is added with 5% curing agent and stirred evenly and applied to the bonding surface. Iron plates are used for compaction and waiting for the resin to solidify. To facilitate subsequent laying and injection of glue, viscous resin is prepared during bonding. A scraper is used to scrape out an arc shape at the R corner. After the foam is fixed, the entire surface is laid according to the laying design to complete the remaining 1 / 3 of the skin. When laying, wood is used to support the R corner and a wooden hammer is used to knock Ensure that the dry cloth at the R corner is rolled solid without overhead. During the laying process, the dry cloth interface is overlapped 30mm and the overlap position needs to be staggered. The surface of the laying is guaranteed to be flat and wrinkle-free. After the laying is completed, the edge trimming and guide hole trimming work are carried out. After the laying is completed, the vacuum bag system is made according to the same glue injection principle as the bottom plate skin. Before bagging, the reserved flow water needs to be filled with a silicone rod. The subsequent vacuum bag system needs to put all the hat-shaped rib R area (the junction of the positioning longitudinal rib and the bottom plate, which is called the positioning longitudinal rib after the positioning longitudinal bone foam is laid and solidified) in place to ensure the smooth implementation of vacuum glue injection. After the vacuum bag system is completed, vacuum glue injection can be carried out. After the glue injection is completed, it will be cured at room temperature. After it is basically hardened and left to stand for 12 hours, the bag can be removed; S5 installs longitudinal girders in three designed areas. Several middle strong cross beam foams are installed at intervals in the front and rear directions on the upper end of the center of the bottom plate. Middle longitudinal girders are installed on the upper sides of the bottom plate on the left and right sides of the middle strong cross beam foams. In the height direction, two middle longitudinal girders are stacked together at the corresponding positions. In the longitudinal direction, hardwood embedded parts are placed at the position where two adjacent middle longitudinal girders need to be combined. In the height direction, prefabricated panels are placed between the two stacked middle longitudinal girders. The skin on the left side of the middle longitudinal girders and the skin on the right side of the middle longitudinal girders are placed on the left side of the middle longitudinal girders. The side longitudinal girder foam is installed on the upper end of the skin on the right side of the foam. In the longitudinal direction, hardwood embedded parts are placed at the position where two adjacent side longitudinal girder foams need to be combined together. The first side transverse reinforcement foam is installed on the bottom plate on the left side of the hardwood embedded parts on the left side of the left side longitudinal girder foam and on the right side of the hardwood embedded parts on the right side of the right side longitudinal girder foam. Steel plate embedded parts are placed on the side longitudinal girder foam and the middle longitudinal girder foam respectively at the positions corresponding to the hatch openings to be opened. Resin is applied to the bonding surface for installation and fixation, and then two layers of felt cloth are hand-pasted on the surface for reinforcement and fixation so that the steel plate will not tip over to ensure the safety of the operator; S6: According to the ply design, the middle longitudinal girders, the middle strong transverse beams, the side longitudinal girders and the first side transverse reinforcement foam are paved respectively. After the regional plying is completed, the vacuum introduction system is arranged in each region. After the completion, vacuum glue injection is performed. After the glue injection is completed, it is cured at room temperature. After it is basically hardened, a heating blanket is used to fully spread the temperature to ensure that it is completely cured. After the curing is completed, the bag is unpacked, and visual inspection, small hammer tapping test, thickness measurement, longitudinal and transverse spacing measurement and hardness test (the above tests are all existing technologies and will not be repeated) are performed, and records are recorded. After all the tests are qualified, the process goes to step S7; The first intermediate transverse reinforcement foam is installed on the bottom plate between the middle longitudinal girder and the corresponding side longitudinal girder on the front and rear sides of the S7 hatch cover opening. The first intermediate transverse reinforcement foam is placed on the side of the hatch cover opening with a steel plate embedded part, and is installed and fixed by applying resin on the bonding surface. Then, two layers of felt cloth are hand-pasted on the surface to reinforce and fix the steel plate so that the steel plate will not tip over, ensuring the safety of the operator. A number of second side transverse reinforcement foams are installed on the bottom plate on the left side of the front and rear side longitudinal girder of the left first side transverse reinforcement rib (the part after the first side transverse reinforcement foam is laid and cured is called the first side transverse reinforcement rib), and a number of second side transverse reinforcement foams are also installed on the bottom plate on the right side of the side longitudinal girder on the right first side transverse reinforcement rib. The second intermediate transverse reinforcement foam and the third intermediate transverse reinforcement foam are installed on the bottom plate on the right side of the left side longitudinal girder and the left side of the left intermediate girder, respectively. The second intermediate transverse reinforcement foam and the third intermediate transverse reinforcement foam are also installed on the bottom plate on the right side of the right intermediate girder and the left side of the right side longitudinal girder, respectively. There is a gap between the second intermediate transverse reinforcement foam and the corresponding third intermediate transverse reinforcement foam. S8 completes paving on the second side transverse reinforcement foam, the first middle transverse reinforcement foam, the second middle transverse reinforcement foam and the third middle transverse reinforcement foam according to the ply design, arranges the vacuum introduction system in each area after the regional plying is completed, performs vacuum glue injection after completion, cures at room temperature after the glue injection is completed, and uses a heating blanket to fully spread and heat up after it is basically hardened to ensure that it is completely cured. After the curing is completed, the bag is unpacked, visual inspection, hammer tapping test, thickness measurement, vertical and horizontal spacing measurement and hardness test (the above tests are all existing technologies and will not be repeated), and records are made. After all the tests are qualified, enter step S9; S9 installs longitudinal foam on the bottom plate between the second middle transverse reinforcement rib and the corresponding third middle transverse reinforcement rib, one side of the longitudinal foam in the front-to-back direction is connected with the corresponding third transverse reinforcement foam, and the other side of the longitudinal foam in the front-to-back direction is flush with the front side of the bottom plate, and the longitudinal foam is laid on the longitudinal foam according to the laying design, and the vacuum introduction system is arranged, and vacuum glue injection is performed after completion, and the glue is cured at room temperature after the injection is completed; S10 demoulding.

[0028] During paving in step S3, firstly lay the first layer of felt on the upper side of the male mold, and then perform 3 cycles of full-surface paving on the first layer of felt, and the order of full-surface paving in each cycle is to use a layer of biaxial cloth of [45°, -45°], a layer of biaxial cloth of [0°, 90°], a layer of unidirectional cloth of 0°, a layer of biaxial cloth of [90°, 0°], a layer of biaxial cloth of [-45°, 45°] and a layer of biaxial cloth of [0°, 90°], and then lay the second layer of felt, and perform 2 cycles of full-surface paving on the second layer of felt, and the order of plying in each cycle is to use a layer of biaxial cloth of [45°, -45°], a layer of biaxial cloth of [0°, 90°], a layer of unidirectional cloth of 0°, a layer of biaxial cloth of [90°, 0°] and a layer of biaxial cloth of [-45°, 45°], and the thickness after paving is 12 mm.

[0029] During paving in step S4, two cycles of full-surface paving are performed on the basis of step S3. The paving sequence of each cycle is one layer of biaxial cloth [45°, -45°], one layer of biaxial cloth [0°, 90°], one layer of unidirectional cloth 0°, one layer of biaxial cloth [90°, 0°] and one layer of biaxial cloth [-45°, 45°]. The paving thickness is 7 mm.

[0030] In step S6, plying is performed on the connected middle strong cross beam foam and middle longitudinal girder foam, the side longitudinal girder foam and the first side transverse reinforcement foam respectively, and the plying method is the same, according to the mutual interlacing and overlapping plying, and the overlap position needs to be staggered overlapped. The specific plying process is to perform full-surface plying on the connected middle strong cross beam foam and middle longitudinal girder foam respectively, and the plying sequence is one layer of [45°, -45°] biaxial cloth, one layer of [0°, 90°] biaxial cloth, one layer of 0° unidirectional cloth, one layer of [90°, 0°] biaxial cloth and one layer of [-45°, 45°] biaxial cloth, and then the upper surface of the middle strong cross beam foam and the middle longitudinal girder foam is plyed as a whole, and the plying sequence is one layer of [45°, -45°] biaxial cloth, one layer of [0°, 90°] unidirectional cloth, one layer of [90°, 0°] biaxial cloth and one layer of [-45°, 45°] biaxial cloth. °] biaxial cloth, a layer of 0° unidirectional cloth, a layer of [90°, 0°] biaxial cloth and a layer of [-45°, 45°] biaxial cloth, and then the entire surface is laid on the connected middle strong crossbeam foam and middle longitudinal girders foam. The laying order is one layer of [45°, -45°] biaxial cloth, a layer of [0°, 90°] biaxial cloth, a layer of 0° unidirectional cloth, a layer of [90°, 0°] biaxial cloth and a layer of [-45°, 45°] biaxial cloth, and then a layer of felt is laid. On the basis of this layer of felt, the above laying steps are repeated twice. After the laying is completed, a layer of felt is laid. After the laying is completed, the facades on the front and rear sides of the middle strong crossbeam foam, the facades on the left and right sides of the middle longitudinal girders foam, and the facades on the left and right sides of the side longitudinal girders foam are called webs. The thickness of the web is 15mm. After paving, the upper side of the foam of the middle strong cross beam, the upper side of the foam of the middle longitudinal girders and the upper side of the foam of the side longitudinal girders are called panels, and the thickness of the panels is 22mm. When arranging the vacuum introduction system, the vacuum introduction guide net and guide pipe are arranged according to the glue injection method from top to bottom. The first glue injection port is placed in the center of the panel, and the second glue injection port is placed in the middle of the web. A circle of glue outlet guide pipes is arranged around the bottom of the web. After fixing with masking tape, vacuum double bag film is produced in each area.

[0031] The layering steps in step S8 are: S801 performs full-surface laying on several second-side transverse reinforcement foams on the left and right sides respectively, first laying a layer of [45°, -45°] biaxial cloth, and then performing 2 cycles of full-surface laying on this basis. The order of full-surface laying in each cycle is a layer of 0° unidirectional cloth, a layer of [90°, 0°] biaxial cloth, a layer of [-45°, 45°] biaxial cloth, a layer of [45°, -45°] biaxial cloth and a layer of [0°, 90°] biaxial cloth, followed by laying a layer of 0° unidirectional cloth, a layer of [90°, 0°] biaxial cloth, a layer of [-45°, 45°] biaxial cloth, a layer of felt, a layer of [45°, -45°] biaxial cloth, a layer of [0°, 90°] biaxial cloth, a layer of 0° unidirectional cloth, a layer of [0°, 90°] biaxial cloth, a layer of [-45°, 45°] biaxial cloth, a layer of [45°, -45°] biaxial cloth, a layer of [90°, 0°] biaxial cloth, a layer of 0° unidirectional cloth, a layer of [-45°, 45°] biaxial cloth, a layer of felt, a layer of [45°, -45°] biaxial cloth, a layer of [0°, 90°] biaxial cloth, a layer of 0° unidirectional cloth, a layer of [-45°, 45°] biaxial cloth and a layer of felt, with a total paving thickness of 11mm and a flange of 200mm; S802: 2 cycles of full-surface paving are performed on the first middle transverse reinforcement foam with steel plate embedded parts installed. The full-surface paving sequence of each cycle is one layer of biaxial fabric [45°, -45°], one layer of biaxial fabric [90°, 0°], one layer of unidirectional fabric 0°, one layer of biaxial fabric [90°, 0°] and one layer of biaxial fabric [-45°, 45°]. After 2 cycles of full-surface paving, a layer of felt is laid, and 2 cycles of full-surface paving are performed on the felt. Finally, another layer of felt is laid. The total paving thickness is 9 mm, and the flange is 60 mm. S803 performs full-surface laying on the second intermediate transverse reinforced foam and the third intermediate transverse reinforced foam respectively. The laying method is the same. The first intermediate transverse reinforced foam is taken as an example for laying. Two cycles of full-surface laying are performed on the first intermediate transverse reinforced foam. The order of full-surface laying in each cycle is one layer of [45°, -45°] biaxial cloth, one layer of [0°, 90°] biaxial cloth, one layer of 0° unidirectional cloth, one layer of [90°, 0°] biaxial cloth and one layer of [-45°, 45°] biaxial cloth. After two cycles of full-surface laying, the first layer of felt is laid, and two cycles of full-surface laying are performed on the first layer of felt, and the second layer of felt is laid, and two cycles of full-surface laying are performed on the second layer of felt, and finally one layer of felt is laid. The total laying thickness is 15mm, and the flange is 150mm.

[0032] The laying step in step S9 is to perform full-surface laying on the longitudinal foam, first lay a layer of [45°, -45°] biaxial fabric, and then perform 2 cycles of full-surface laying on this basis. The laying order of each cycle is a layer of 0° unidirectional fabric, a layer of [90°, 0°] biaxial fabric, a layer of [-45°, 45°] biaxial fabric, a layer of [45°, -45°] biaxial fabric and a layer of [0°, 90°] biaxial fabric, and then lay a layer of [90°, 0°] biaxial fabric, a layer of [-45°, 45°] biaxial fabric, and a layer of [0°, 90°] biaxial fabric. 5°] biaxial cloth and a layer of felt, and then continue to lay the entire surface on the basis of the felt. The laying order is: a layer of biaxial cloth [45°, -45°], a layer of biaxial cloth [0°, 90°], a layer of unidirectional cloth [0°], a layer of biaxial cloth [90°, 0°], a layer of biaxial cloth [-45°, 45°], a layer of biaxial cloth [45°, -45°], a layer of biaxial cloth [0°, 90°], a layer of unidirectional cloth [0°] and a layer of biaxial cloth [-45°, 45°], and finally a layer of felt. The total laying thickness is 11mm.

[0033] After being laid and cured on the first middle transverse reinforcing foam, the second middle transverse reinforcing foam and the third middle transverse reinforcing foam, they are respectively called the first middle transverse reinforcing rib, the second middle transverse reinforcing rib and the third middle transverse reinforcing rib.

[0034] The flame retardant vinyl resin, curing agent and polymerization inhibitor in the present application are all materials commonly used in the composite molding process and are prior art.

[0035] During the above laying process, a right-hand coordinate system is specified, with the length direction of the longitudinal foam stringer as 0° and the horizontal direction perpendicular to the length direction of the longitudinal foam stringer as 90°.

[0036] Example 2 Reference Figure 7 , which is the second embodiment of the present invention, and this embodiment provides a molding method for a composite material deck, which further ensures the glue injection effect.

[0037] Specifically, in step S3, the arrangement of the bottom plate skin vacuum introduction system is as follows: after the bottom plate skin is laid, the peeling cloth, guide net, guide pipe, injection port base and breathable felt are laid on the dry cloth according to the glue injection method from the middle to both sides (the parts laid on the dry cloth are conventional technology). The peeling cloth needs to cover and exceed the skin area, the guide net needs to be trimmed and laid 5cm shorter than the edge of the skin, and the guide pipe needs to be laid parallel to the glue injection direction at intervals of 400mm, and the length must be the same as the width of the guide net. The glue ports are also arranged at intervals of about 2 meters and the base of the glue port is placed. After laying the vacuum introduction auxiliary materials, the first layer of vacuum bags is spliced ​​and produced. After the inner bag is sealed, it is connected to the vacuum pump system to ensure that the vacuum degree reaches above -0.09MPa within 1 hour. After the vacuum degree of the first layer of bag film is qualified, the glue port and the glue outlet are inserted and sealed with putty strips. Each glue injection port is checked to ensure that there is no air leakage. After the vacuum test meets the requirements, the second layer of outer bag is produced. After the vacuum degree is qualified, the glue injection pipe is connected and combined and placed in the glue injection bucket.

[0038] The schematic diagram of vacuum introduction is as follows Figure 7 As shown, in order to prevent the resin from flowing into the vacuum pump, a buffer tank is connected between the glue outlet and the vacuum pump.

[0039] The bottom panel skin is vacuum-introduced and cured. The specific steps are: according to the design requirements, flame-retardant vinyl resin (hereinafter referred to as 627 resin) must be used, and a resin gel time test must be carried out before injection. The proportions of three different curing agents and inhibitors are adjusted according to the real-time temperature and humidity. The mass ratio of 627 resin, curing agent and inhibitor is 100:1.5:0.4, which ensures that the resin can be smoothly connected during the injection process without the risk of faults.

[0040] In order to speed up the injection process, two rows of injection ports are used to alternately replace each other, and an auxiliary air extraction port is connected near the injection port. After the injection is completed, it is cured at room temperature. After it heats up and hardens, the vacuum is removed and it is left to stand for 12 hours to allow it to be completely cured.

[0041] After curing, the auxiliary materials are peeled off and the surface of the bottom plate skin is cleaned with acetone; Use calipers to perform multi-point thickness inspection, use A-scan instruments to perform internal quality inspection, and use a Barcol hardness tester for multi-point inspection. Visually check whether there are obvious defects on the skin surface. The inspection results are recorded in the on-site process card. If qualified, proceed to step S4.

[0042] In step S6, the vacuum system is arranged specifically as follows: after the regional plying is completed, the vacuum introduction auxiliary materials are laid out in the regions, and the vacuum introduction guide net, guide pipe and inlet and outlet bases are arranged according to the glue injection method from top to bottom. The first glue injection port is placed in the center of the panel in the length direction of the hat-shaped rib (all kinds of foams after paving are collectively referred to as hat-shaped ribs), and the second glue injection port is placed in the middle of the web. A circle of glue outlet guide pipes is arranged around the bottom of the hat-shaped rib, and the vacuum double bag film of each region is produced after being fixed with masking tape.

[0043] After the vacuum system is manufactured, appropriate amounts of 627 resin, LPT curing agent and inhibitor are mixed in proportion according to the site temperature and site tests for injection. After the injection is completed, room temperature curing is also used. After it is basically hardened, a heating blanket is used to fully increase the temperature to ensure complete curing.

[0044] The arrangement of the vacuum system in step S8 is similar to that in step S6, and will not be described in detail here.

[0045] Example 3 Reference Figure 2 and Figure 3 , which is the third embodiment of the present invention, and this embodiment provides a molding method for a composite material deck, which can further facilitate the connection and positioning of small hatches in subsequent processes.

[0046] For the convenience of description, in the left and right directions, the longitudinal foam on the left is named the left longitudinal foam, and the longitudinal foam on the right is named the right longitudinal foam. A number of positioning transverse bone foams spaced apart in the front-to-back direction are provided on the right side of the positioning longitudinal bone foam to the left of the left longitudinal foam (the positioning transverse bone foams are installed in step S4). When placing the longitudinal foams, the left side of the left longitudinal foam is attached to the right side of the positioning transverse bone foam on the left, and the right side of the right longitudinal foam is attached to the left side of the positioning transverse bone foam on the right.

[0047] The parts where the positioning longitudinal bone foam, positioning transverse bone foam and longitudinal foam are located after laying and curing are respectively called positioning longitudinal ribs, positioning transverse ribs and longitudinal reinforcing ribs. The joint setting of the positioning longitudinal ribs, positioning transverse ribs and corresponding longitudinal reinforcing ribs forms a space for accommodating the small cabin door, which facilitates the connection and positioning of the small cabin door.

[0048] Through the three embodiments in this application, while meeting the strength requirements, the dimensional accuracy and appearance requirements are also guaranteed, and the deck can be prepared with high quality and high efficiency. It does not require the use of large-scale equipment for molding, is simple to operate, and has low preparation costs.

[0049] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. A method for forming a composite material deck, characterized in that: The following steps are included:

1. Raw materials preparation; 2. Mold preparation; 3. Lay the base plate on the male mold according to the layer design. After paving, arrange the vacuum introduction system, vacuum glue injection, and cure at room temperature after glue injection; 4. Install several positioning longitudinal foams on the cured bottom plate. After the positioning longitudinal foams are fixed, perform full-surface ply laying on the bottom plate and the positioning longitudinal foams according to the ply design. After the ply laying is completed, arrange the vacuum introduction system, and after the completion, perform vacuum glue injection. After the glue injection is completed, it will be cured at room temperature.

5. Install the longitudinal girders according to the designed positions. Install several middle strong transverse beam foams at intervals in the front-to-back direction at the center of the bottom plate. Install middle longitudinal girders foams on the upper sides of the bottom plates on the left and right sides of several middle strong transverse beam foams. Install side longitudinal girders foams on the bottom plate to the left of the middle longitudinal girders foam on the left and on the right of the middle longitudinal girders foam on the right. Install transverse foams on the left side of the middle longitudinal girders foam on the left, on the right side of the middle longitudinal girders foam on the right, and on the bottom plates on the left and right sides of the side longitudinal girders foams.

6. According to the ply design, the foam is laid on the middle longitudinal girders, the middle strong cross beams and the side longitudinal girders respectively, and the vacuum introduction system is arranged. After completion, vacuum glue injection is performed, and the glue is cured at room temperature; 7. Install the longitudinal foam on the bottom plate between two adjacent transverse foams, lay the tiles on the longitudinal foam according to the ply design, arrange the vacuum introduction system, and perform vacuum glue injection after completion. After the glue injection is completed, it will be cured at room temperature; 8. Demoulding.

2. The method for forming a composite material deck according to claim 1, characterized in that: Step 2 is to clean the deck steel positive mold surface and the flat mold with acetone, and after the acetone on the mold surface evaporates and dries, lay a single-sided adhesive release cloth within the excess line, and ensure that there are no bubbles and wrinkles on the surface during the laying process.

3. The method for forming a composite material deck according to claim 1, characterized in that: During paving in step 3, first lay the first layer of felt on the upper side of the male mold, and perform three cycles of full-surface paving on the first layer of felt. The order of full-surface paving in each cycle is to use a layer of biaxial cloth [45°, -45°], a layer of biaxial cloth [0°, 90°], a layer of unidirectional cloth at 0°, a layer of biaxial cloth [90°, 0°], a layer of biaxial cloth [-45°, 45°] and a layer of biaxial cloth [0°, 90°]. Then lay the second layer of felt, and perform two cycles of full-surface paving on the second layer of felt. The order of paving in each cycle is to use a layer of biaxial cloth [45°, -45°], a layer of biaxial cloth [0°, 90°], a layer of unidirectional cloth at 0°, a layer of biaxial cloth [90°, 0°] and a layer of biaxial cloth [-45°, 45°]. The thickness after paving is 12 mm.

4. The method for forming a composite material deck according to claim 3, characterized in that: During paving in step 4, three cycles of full-surface paving are performed on the basis of step 3. The paving order of each cycle is one layer of biaxial cloth [45°, -45°], one layer of biaxial cloth [0°, 90°], one layer of unidirectional cloth 0°, one layer of biaxial cloth [90°, 0°] and one layer of biaxial cloth [-45°, 45°]. The paving thickness is 7 mm.

5. The method for forming a composite material deck according to any one of claims 1 to 4, characterized in that: In step 6, the layers are laid on the connected middle strong cross beam foam, middle longitudinal girder foam and side longitudinal girder foam respectively. The laying method is the same, and the layers are laid in an interlaced and overlapping manner. The overlap positions need to be staggered and overlapped.

6. The method for forming a composite material deck according to claim 5, characterized in that: The entire surface of the middle strong cross beam foam and the middle longitudinal girder foam are respectively laid in the order of one layer of biaxial cloth [45°, -45°], one layer of biaxial cloth [0°, 90°], one layer of unidirectional cloth 0°, one layer of biaxial cloth [90°, 0°] and one layer of biaxial cloth [-45°, 45°]. The entire surface of the middle strong cross beam foam and the middle longitudinal girder foam are laid in the order of one layer of biaxial cloth [45°, -45°], one layer of biaxial cloth [0°, 90°], one layer of unidirectional cloth 0°, one layer of biaxial cloth [90°, 0°] and one layer of biaxial cloth [-45°, 45°]. °] biaxial cloth, and then the entire surface is laid on the connected middle strong crossbeam foam and middle longitudinal girder foam, the laying order is one layer of [45°, -45°] biaxial cloth, one layer of [0°, 90°] biaxial cloth, one layer of 0° unidirectional cloth, one layer of [90°, 0°] biaxial cloth and one layer of [-45°, 45°] biaxial cloth, and then a layer of felt is laid, and the above laying steps are repeated twice on the basis of this layer of felt, and the laying is completed. The vertical surfaces on the front and rear sides of the middle strong crossbeam foam, the vertical surfaces on the left and right sides of the middle longitudinal girder foam, and the vertical surfaces on the left and right sides of the side longitudinal girder foam after the laying are called webs, and the thickness of the webs is 15mm. The upper surfaces of the middle strong crossbeam foam, the upper surfaces of the middle longitudinal girder foam, and the upper surfaces of the side longitudinal girder foam after the laying are called panels, and the thickness of the panels is 22mm.

7. The method for forming a composite material deck according to claim 6, characterized in that: The plying step in step 7 is to perform full-surface plying on the longitudinal foam, first plying a layer of biaxial cloth of [45°, -45°], and then performing 2 cycles of full-surface plying on this basis, and the plying order of each cycle is a layer of 0° unidirectional cloth, a layer of biaxial cloth of [90°, 0°], a layer of biaxial cloth of [-45°, 45°], a layer of biaxial cloth of [45°, -45°] and a layer of biaxial cloth of [0°, 90°], and then plying a layer of biaxial cloth of [90°, 0°], a layer of biaxial cloth of [-45°, 45°], and a layer of biaxial cloth of [0°, 90°] in sequence. unidirectional cloth and a layer of felt, and then continue to lay the entire surface on the basis of the felt. The laying order is: a layer of bi-axial cloth [45°, -45°], a layer of bi-axial cloth [0°, 90°], a layer of uni-directional cloth [0°], a layer of bi-axial cloth [90°, 0°], a layer of bi-axial cloth [-45°, 45°], a layer of bi-axial cloth [45°, -45°], a layer of bi-axial cloth [0°, 90°], a layer of uni-directional cloth [0°] and a layer of bi-axial cloth [-45°, 45°], and finally a layer of felt. The total laying thickness is 11mm.

8. The method for forming a composite material deck according to claim 6, characterized in that: When arranging the vacuum introduction system in step 6, arrange the vacuum introduction guide net and guide tube according to the glue injection method from top to bottom. The first glue injection port is placed in the center of the panel, and the second glue injection port is placed in the middle of the web. A circle of glue outlet guide tubes is arranged around the bottom of the web. After fixing with masking tape, vacuum double bag film is produced in each area.

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