Forming method of composite material cabin outer plate

Abstract

The invention discloses a forming method of a composite cabin outer plate, which comprises the following steps of: paving an outer plate skin in a female die according to a paving layer design, and sequentially performing vacuum introduction, glue injection and curing after paving; longitudinal bones are formed on the ship bottom and the ship side of the solidified outer plate skin respectively; various longitudinal ribs are sequentially formed on the bulkhead of the outer plate skin according to the designed positions; forming of longitudinal girders, a plurality of side ribs and ship bottom strong cross beams is completed on the ship bottom in sequence; forming of a broadside strong cross beam and forming of a broadside longitudinal girder are sequentially completed on the broadside; demolding is conducted; the cabin outer plate prepared by the method is lighter in weight, and the cabin outer plate can be formed without large equipment.

Description

Technical Field

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

[0002] The cabin outer plate is one of the key components of the hull. With the development of composite materials, composite materials are widely used in the molding of cabin outer plates. In the prior art, the cabin outer plate is usually prepared by autoclave molding, but the size of the cabin outer plate 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 and / or existing problems in the preparation of existing ship cabin outer plates, the present invention is proposed.

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

[0006] In order to solve the above technical problems, the present invention provides the following technical solutions: a molding method of a composite material cabin outer plate, comprising the following steps: 1. Raw materials preparation; 2. Mold preparation; 3. Lay the outer panel skin in the female mold according to the layer design. After the laying is completed, arrange the vacuum introduction system, vacuum inject glue after completion, and cure at room temperature after the injection of glue; 4. Install several longitudinal foams on the bottom and side of the cured outer skin, and lay the entire side and bottom of the ship according to the laying design on the positioning longitudinal foam. During the laying process, the fabric interfaces need to be overlapped and the overlap positions need to be staggered. After laying, arrange the vacuum introduction system, and after completion, vacuum glue injection is carried out. After the glue injection is completed, it is cured at room temperature; 5. Install the vertically arranged first longitudinal foam on the bulkhead of the outer skin according to the designed position, complete the individual paving on each first 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; 6. Install the second longitudinal foam, the third longitudinal foam and the horizontal transverse foam which are vertically arranged and thicker than the first longitudinal foam on the bulkhead between the longitudinal foams at the set position. The thickness of the second longitudinal foam, the third longitudinal foam and the transverse foam are the same. The width of the second longitudinal foam is greater than that of the third longitudinal foam. The transverse foam and various longitudinal foams are crossed. The second longitudinal foam, the third longitudinal foam and the transverse foam are laid as a whole according to the laying design. When laying, the transverse and longitudinal fibers need to be laid alternately and continuously with dry cloth. After the laying is completed, the vacuum introduction system is arranged, and vacuum glue injection is carried out. After the glue injection is completed, it is cured at room temperature; 7. Install several longitudinal foams on the bottom of the ship at the set position, and complete the individual paving on each longitudinal foam according to the ply design. After the plying is completed, arrange the vacuum introduction system, and after the completion, vacuum glue injection is carried out, and the glue is cured at room temperature; 8. Install a middle hardwood embedded part on the bottom between two bottom longitudinal foams, install several middle crossbeam foams spaced apart in the front-to-back direction on the bottom outward from the front and rear sides of the middle hardwood embedded part, install two first side keel foams spaced apart in the left-right direction and stacked together in the height direction on the bottom on the front and rear sides of the middle hardwood embedded part, install side hardwood embedded parts between the two first side keel foams spaced apart in the left-to-right direction, install two side keel foams on the bottom of the two bottom longitudinal foams away from each other in the left-to-right direction, connect the two second side keel foams stacked together in the height direction connected to the bottom of the ship on the front and rear sides of the side hardwood embedded part, and connect metal embedded parts at the set positions of the first side keel foam and the second side keel foam; 9. According to the ply design, complete the whole surface paving on the connected middle beam foam, the first side keel foam and the middle hardwood embedded parts, the connected side hardwood embedded parts and the second side keel foam respectively. After the plying is completed, arrange the vacuum introduction system, and after the completion, vacuum glue injection is carried out, and the glue is cured at room temperature after the injection is completed; 10. Install several side strong transverse beam foams spaced in the front-rear direction on the bottom of the ship on the side away from the two side ribs. The side strong transverse beam foam is installed on the side at one end away from the corresponding side rib in the left-right direction. Lay on each side strong transverse beam foam according to the laying design. After the laying is completed, arrange the vacuum introduction system, perform vacuum glue injection, and cure at room temperature after the glue injection is completed. 11. Install the side longitudinal girder foam on the side between two adjacent side transverse beams according to the designed position, and perform hand lay-up on each side longitudinal girder foam according to the lay-up design; 12. Demoulding; Among them, when installing each longitudinal foam, use structural adhesive to bond and fix them in sections from bottom to top. When installing the transverse foam, first use the preset lifting wooden blocks to support the transverse foam and then use structural adhesive to bond and fix them.

[0007] As a preferred embodiment of the molding method of the composite material cabin outer plate in the present invention, step 1 and step 2 are in no particular order. In step 2, the mold surface of the steel female mold of the cabin outer plate is cleaned with acetone, and after the acetone on the mold surface evaporates and dries, 770NC mold release agent is applied on the mold surface with wiping paper. At least 8 layers of mold release agent are applied to the new mold, and the time interval between each layer of mold release agent is more than 15 minutes to ensure that the mold release agent is completely cured.

[0008] As a preferred embodiment of the forming method of the composite material cabin outer plate in the present invention, wherein: in step 3, during paving, the area where the upper parts of the inner walls at the left and right ends of the female mold are located is zone I, the central concave area at the bottom of the female mold is zone III, the area where the inner wall of the female mold between zones I and III is located is zone II, and the area where the inner walls at the front and rear ends of the female mold are located corresponds to the bulkhead of the outer plate. First, two cycles of paving are performed in the female mold. The paving process of each cycle of paving is to first lay the first layer of felt as a whole, and then perform the first full-surface paving on the first layer of felt. The order of the first full-surface paving is to use 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 first single paving is performed at the position of zone III, and the order of the first single paving is to use 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, a layer of [-45°, 45°] biaxial cloth and a layer of felt; on the basis of 2 cycles of laying, the first single laying is carried out at the bulkhead, zone II and zone III. The laying order of the first single laying is one layer of [45°, -45°] biaxial cloth, one layer of [0°, 90°] biaxial cloth, a layer of 0° unidirectional cloth, a layer of [90°, 0°] biaxial cloth and one layer of [-45°, 45°] biaxial cloth. Continue to lay the layers at the bulkhead and zone III. The laying order is to use one layer of biaxial fabric [45°, -45°], one layer of biaxial fabric [0°, 90°], one layer of unidirectional fabric 0°, one layer of biaxial fabric [90°, 0°] and one layer of biaxial fabric [-45°, 45°], and then carry out the second whole-surface laying. On the basis of the second whole-surface laying, lay a layer of felt. Carry out the second single laying at the position of the bulkhead, zone II and zone III. The laying order of the second single laying is the same as that of the first single laying. Carry out the third whole-surface laying. The order of each whole-surface laying is the same. On the basis of the third whole-surface laying, carry out the fourth The fourth full-surface laying includes two cycles of laying, and the laying order of each cycle of laying 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°], one layer of biaxial cloth [-45°, 45°], 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°], and a layer of felt is laid between the two cycles of laying; laying is interspersed at four positions and the laying is completed at the same time;After the layers are laid, the skin thickness of zone III is 28mm, the skin thickness of zone II is 18mm, the skin thickness of zone I is 13mm, and the thickness of the bottom plate at the bulkhead is 22mm. ;

[0009] As a preferred embodiment of the forming method of the composite material cabin outer plate in the present invention, wherein: during paving in step 4, the entire surface is paved on the basis of step 3, specifically, 2 cycles of entire surface paving are performed, and the order of the entire surface paving in each cycle is a layer of biaxial cloth [45°, -45°], a layer of biaxial cloth [90°, 0°], a layer of unidirectional cloth 0°, a layer of biaxial cloth [90°, 0°] and a layer of biaxial cloth [-45°, 45°]; after 2 cycles of entire surface paving are completed, a layer of felt is paved, and 2 cycles of entire surface paving are performed on the felt, and finally another layer of felt is paved; the skin thickness after the paving is completed is 9 mm.

[0010] As a preferred embodiment of the forming method of the composite material cabin outer plate in the present invention, wherein: in step 5, separate layers are respectively laid on each first longitudinal foam of the bulkhead bottom plate, and the laying sequence is 2 cycles of full-surface laying, and the full-surface laying sequence of each cycle is a layer of [45°, -45°] biaxial cloth, a layer of [90°, 0°] biaxial cloth, a layer of 0° unidirectional cloth, a layer of [90°, 0°] biaxial cloth and a layer of [-45°, 45°] biaxial cloth; after 2 cycles of full-surface laying, a layer of felt is laid, and 2 cycles of full-surface laying are performed on the felt, and finally another layer of felt is laid; the skin thickness after the laying is 9 mm, and the flange is 100 mm.

[0011] As a preferred embodiment of the forming method of the composite material cabin outer plate in the present invention, wherein: in step 6, plying is performed on various types of foams, and when plying, the horizontal and vertical fibers are alternately and continuously cross-laid on the dry cloth, specifically, first a layer of [45°, -45°] biaxial cloth is laid, and on this basis, 2 cycles of full-surface plying are performed, and the plying order of 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, and then a layer of [90°, 0°] is laid in sequence. A layer of biaxial cloth, a layer of [-45°, 45°] biaxial cloth and a layer of felt, 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 at 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 at 0° and a layer of biaxial cloth [-45°, 45°], and finally a layer of felt is laid; the layer thickness is 11mm.

[0012] As a preferred embodiment of the forming method of the composite material cabin outer plate in the present invention, the laminating step in step 7 is to perform separate whole-surface laminating on each bottom longitudinal girder foam of the bottom of the ship, specifically, first perform 2 cycles of separate whole-surface laminating, and the order of separate whole-surface laminating 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 2 cycles of separate whole-surface laminating, lay the first layer of felt, perform 2 cycles of whole-surface laminating on the first layer of felt, lay the second layer of felt, perform 2 cycles of whole-surface laminating on the second layer of felt, and finally lay another layer of felt, with a total laying thickness of 15 mm and a flange of 200 mm.

[0013] As a preferred embodiment of the forming method of the composite material cabin outer plate in the present invention, the lamination step in step 10 is to perform separate full-surface lamination on each side strong transverse beam foam of the ship side, specifically, first perform 2 cycles of separate full-surface lamination, and the order of separate full-surface lamination 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 2 cycles of separate full-surface lamination, lay the first layer of felt, and perform 2 cycles of full-surface lamination on the first layer of felt, lay the second layer of felt, and perform 2 cycles of full-surface lamination on the second layer of felt, and finally lay another layer of felt, with a total laying thickness of 15 mm and a flange of 200 mm.

[0014] Compared with the prior art, the present invention has the following technical effects: the present invention directly performs vacuum introduction molding in the female mold, and for the bottom and the cabin side, skins of different thicknesses are prepared first by dividing the area, and after the preparation is completed, the positioning longitudinal bones are respectively installed on the skins of the bottom and the cabin side, and the entire surface is laid to achieve the preparation of the remaining 9 mm of skin, and the corresponding longitudinal and transverse foams are respectively fixedly installed on the skins of the bulkhead, the bottom and the cabin side, and on this basis, the laying, vacuum introduction bags are arranged, vacuuming and curing are carried out in sequence; the preparation of the outer plate skin is completed by dividing the area for positioning, laying and molding, and then the installation and laying of various types of foams are completed in sequence on the outer plate skin according to the steps, without the need for molding with the help of large equipment, simple operation, and reduced molding cost. While meeting the strength requirements, the dimensional accuracy and appearance requirements are also guaranteed, and the molding operation of the cabin outer plate is 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 The figure is a three-dimensional structural diagram of a cabin outer plate prepared using the present invention.

[0016] Figure 2 for Figure 1 A partial enlarged view of point A in the middle.

[0017] Figure 3 This is a three-dimensional structural diagram of the ship's bottom and cabin side connected together (after the cabin outer plate hides the bulkhead).

[0018] Figure 4 for Figure 3 A partial enlarged view of point B in the middle.

[0019] Figure 5 for Figure 3 A partial enlarged view of point C in the middle.

[0020] Figure 6 It is a three-dimensional structural diagram of the negative mold in the present invention.

[0021] Figure 7 Schematic diagram of four thickness regions of the outer panel skin in the present invention.

[0022] Figure 8 This is a schematic diagram of the placement of the glue injection pipelines in the outer panel skin section.

[0023] Fig. 9 Schematic diagram of the sewing and fixing of the vertical supporting wall material fabric.

[0024] In the figure: 1 second longitudinal foam, 2 first longitudinal foam, 3 third longitudinal foam, 4 transverse foam, 5 first side keel foam, 6 bottom longitudinal girder foam, 7 bottom strong transverse beam, 8 side keel prefabricated plate, 9 middle transverse beam foam, 10 second side keel foam, 11 side strong transverse beam foam, 12 side longitudinal girder foam, 13 negative mold, 14 bulkhead. DETAILED DESCRIPTION

[0025] 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.

[0026] 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.

[0027] 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.

[0028] Example 1 Reference Figure 1 to Figure 6 , which is the first embodiment of the present invention, provides a molding method for a composite material cabin outer plate, which can realize the molding of the cabin outer plate without the aid of large-scale equipment and is easy to operate.

[0029] A method for forming a composite material cabin outer plate comprises the following steps: 1. Collect the raw materials required for the outer panels from the warehouse, including 0 / 90 biaxial cloth, 45 / -45 biaxial cloth, unidirectional cloth, chopped strand mat, vinyl resin, LTP curing agent, PVC foam, hardwood embedded parts, and metal embedded parts. They must be placed in a clean and dust-free area for standby use; 2. Clean the mold surface of the steel female mold 13 of the cabin outer plate with acetone. After the acetone on the mold surface evaporates and dries, apply 770NC mold release agent on the mold surface with a cleaning paper. Apply at least 8 layers of mold release agent to the new mold. The interval between each layer of mold release agent is more than 15 minutes to ensure that the mold release agent is completely cured. 3. Lay the outer panel skin in the female mold 13 according to the layer laying design. After the laying is completed, arrange the vacuum introduction system, vacuum glue injection is completed, and the glue is cured at room temperature after the injection is completed; 4. Install several longitudinal foams on the bottom and side of the cured outer skin, and lay the entire side and bottom of the ship according to the laying design on the positioning longitudinal foam. During the laying process, the fabric interfaces need to be overlapped and the overlap positions need to be staggered. After laying, arrange the vacuum introduction system, and after completion, vacuum glue injection is carried out. After the glue injection is completed, it is cured at room temperature; 5. Install the vertically arranged first longitudinal foam 2 on the bulkhead 14 of the outer panel skin according to the designed position, complete the individual paving on each first longitudinal foam 2 according to the ply design, arrange the vacuum introduction system, perform vacuum glue injection after completion, and cure at room temperature after glue injection; 6. Install the second longitudinal foam 1, the third longitudinal foam 3 and the horizontal transverse foam 4 which are arranged vertically and have a thickness greater than the first longitudinal foam 2 on the bulkhead 14 between the longitudinal foams at the set position. The thickness of the second longitudinal foam 1, the third longitudinal foam 3 and the transverse foam 4 are the same. The width of the second longitudinal foam 1 is greater than the width of the third longitudinal foam 3. The transverse foam 4 and various longitudinal foams are crossed. The second longitudinal foam 1, the third longitudinal foam 3 and the transverse foam 4 are integrally paved according to the ply design. When paving, the horizontal and vertical fibers need to be alternately and continuously cross-laid with dry cloth. After the plying is completed, the vacuum introduction system is arranged, and vacuum glue injection is performed after completion. After the glue injection is completed, it is cured at room temperature; 7. Install a number of ship bottom longitudinal girder foams 6 at set positions on the ship bottom, and complete individual paving on each ship bottom longitudinal girder foam 6 according to the ply design. After the plying is completed, a vacuum introduction system is arranged, and vacuum glue injection is performed after completion. After the glue injection is completed, it is cured at room temperature; 8. Install a middle hardwood embedded part on the bottom between two bottom longitudinal girder foams 6, install several middle crossbeam foams 9 spaced apart in the front-to-back direction on the bottom outward from the front and rear sides of the middle hardwood embedded part, install two first side keel foams 5 spaced apart in the left-right direction and stacked together in the height direction on the bottom on the front and rear sides of the middle hardwood embedded part, install side hardwood embedded parts between the two first side keel foams 5 spaced apart in the left-to-right direction, install two side keel foams 10 stacked together in the height direction on the bottom of the two bottom longitudinal girder foams 6 away from each other in the left-to-right direction, connect the front and rear sides of the side hardwood embedded part with two second side keel foams 10 connected to the bottom and stacked together in the height direction, and connect metal embedded parts at the set positions of the first side keel foam 5 and the second side keel foam 10; 9. Complete the whole surface paving on the connected middle beam foam 9, the first side keel foam 5 and the middle hardwood embedded parts, the connected side hardwood embedded parts and the second side keel foam 10 according to the ply design. After the plying is completed, arrange the vacuum introduction system, and perform vacuum glue injection. After the glue injection is completed, cure at room temperature; 10. Install a plurality of side strong transverse beam foams 11 spaced apart in the front-rear direction on the bottom of the ship on the side away from each other of the two side keels (the second side keel foam 10 after being laid and formed is referred to as the side keel here). The side strong transverse beam foams 11 are installed on the side at one end away from the corresponding side keel in the left-right direction. Lay the foam on each side strong transverse beam foam 11 according to the laying design. After the laying is completed, arrange the vacuum introduction system, perform vacuum glue injection, and cure at room temperature after the glue injection is completed. 11. Install the side longitudinal girder foam 12 on the side between two adjacent side strong transverse beams according to the designed position, and perform hand lay-up on each side longitudinal girder foam 12 according to the lay-up design; 12. Demoulding: After all the cabin outer panels are cured, they are unpacked and cleaned. After assembly, the molds around them are disassembled. Subsequently, the outer panels are lifted out of the house using special demoulding lifting points using a crane and placed on the outer panel transfer bracket.

[0030] When installing each longitudinal foam, the structural adhesive is used to bond and fix them in sections from bottom to top. When installing the transverse foam 4, the transverse foam 4 is first supported by a preset supporting wooden block and then bonded and fixed by the structural adhesive.

[0031] The biaxial cloth and the unidirectional cloth are both glass fiber cloth, and the flame retardant vinyl resin, LTP curing agent and polymerization inhibitor are all materials commonly used in the composite molding process, which are existing technologies.

[0032] Example 2 This is the second embodiment of the present invention, which provides a molding method for composite material cabin outer panels, which further realizes the layering in each process of the outer panels to ensure reliable molding of the outer panels.

[0033] Specifically, during paving in step 3, the area where the upper parts of the inner walls at the left and right ends of the female mold 13 are located is area I, the central concave area at the bottom of the female mold 13 is area III, the area where the inner walls of the female mold 13 between areas I and III are located is area II, the length of the transition area from area III to area II and from area II to area I is about 100 mm, the area where the inner walls at the front and rear ends of the female mold 13 are located corresponds to the bulkhead 14 of the outer plate, and two cycles of paving are first performed in the female mold 13. The paving process of each cycle of paving is to firstly lay the first layer of felt as a whole, and then perform the first full-surface paving on the first layer of felt. The order of the first full-surface paving is to use 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, at the position of area III The first single layer laying is carried out, and the order of the first single layer laying 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 biaxial cloth [-45°, 45°] and a layer of felt; on the basis of 2 cycles of laying, the first single layer laying is carried out at the positions of bulkhead 14, zone II and zone III, and the order of the first single layer laying 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°] and a layer of biaxial cloth [-45°, 45°]. Axial fabric, continue to lay at the position of bulkhead 14 and zone III, the laying order is to use one layer of [45°, -45°] biaxial fabric, one layer of [0°, 90°] biaxial fabric, one layer of 0° unidirectional fabric, one layer of [90°, 0°] biaxial fabric and one layer of [-45°, 45°] biaxial fabric, carry out the second whole-surface laying, lay a layer of felt on the basis of the second whole-surface laying, carry out the second single laying at the position of bulkhead 14, zone II and zone III, the laying order of the second single laying is the same as the first single laying, carry out the third whole-surface laying; the order of each whole-surface laying is the same; on the basis of the third whole-surface laying, lay a layer of felt on the basis of the second whole-surface laying, carry out the third whole-surface laying at zone I, zone II and zone III, the laying order of the second single laying is the same as the first single laying, carry out the third whole-surface laying; the order of each whole-surface laying is the same; on the basis of the third whole-surface laying, The fourth whole-surface laying is carried out at the position of zone III. The fourth whole-surface laying includes 2 cycles of laying. The laying order of each cycle 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°, a layer of biaxial cloth [90°, 0°] and a layer of biaxial cloth [-45°, 45°]. A layer of felt is laid between the 2 cycles of laying. The laying is interspersed at the four positions and the laying is completed at the same time.After the layers are laid, the skin thickness of zone III is 28mm, the skin thickness of zone II is 18mm, the skin thickness of zone I is 13mm, and the bottom plate thickness at bulkhead 14 is 22mm. ;

[0034] As the height of the outer panel is 5mm, the dry fiber fabric laid on the large facade is prone to falling off and slipping. When laying the whole layer, the dry cloth needs to be extended to the back of the mold, and the tension of the dry cloth itself is used to offset its gravity. When operating, it is necessary to spray more 3M setting agent on the facade. When using it, it is necessary to spray a large area at a distance of 1 meter from the product. It is not allowed to spray the same area back and forth repeatedly. In this way, the surface quality can be guaranteed.

[0035] When laying the layers, when laying the layers in the transition area from zone II to zone I, place strong hook magnets at multiple points in the transition area to assist in fixation. When laying the layers subsequently, remove the magnets one by one and lay the dry cloth.

[0036] During the laying process, overlap is adopted and the overlap is staggered to ensure the strength of the product. Rolling boards are used to compact the layers to ensure that the fabric is flat and has no obvious wrinkles.

[0037] The specific process of arranging the vacuum system is as follows: Lay the peeling cloth, guide net, glue injection pipeline, and breathable felt on the outer skin in sequence. According to the experience of vacuum introduction, the peeling cloth should cover the entire surface of the product, and the surface should be flat and wrinkle-free. Lay the guide net and guide spiral pipe according to the designed glue injection direction. Set a speed bump on the skin surface of one of the bulkheads 14 to ensure that all glue injections are completed at the same time to prevent the situation where glue has been injected on the lower surface but not on the higher surface; Lay out vacuum introduction auxiliary materials according to the above requirements and fix them with masking tape to complete the vacuum bag making. To prevent air leakage in the vacuum bag, make a double-layer sealed vacuum bag. After the first layer of vacuum bag is sealed, check the vacuum degree. The vacuum degree is required to exceed -0.09MPa during vacuuming, and the pressure drop should not exceed 0.01MPa for 10 minutes. After the vacuum degree meets the requirements, the second layer of vacuum bag packaging is carried out. When connected to the vacuum pump system, the vacuum degree must be guaranteed to reach -0.09MPa or above for 1 hour before preparing for vacuum introduction and injection. To prevent resin from flowing into the vacuum pump, a buffer tank must be connected between the glue outlet and the vacuum pump. When injecting glue, start from the middle of the bottom of the ship and guide it toward both sides. When reaching the side chord, open the injection ports of the bow and stern panels at the same time to inject glue in an upward climbing manner.

[0038] After the glue is injected, it is cured at room temperature. After it is basically hardened, it is fully heated with a heating blanket to make it finally completely cured or left to stand for 48 hours before subsequent demoulding.

[0039] After unpacking and demolding, use a caliper or height gauge to perform multi-point thickness inspection and record it. Visually check whether there are obvious defects on the surface of the skin, and use a Barcol hardness tester to perform multi-point inspection. If the Barcol hardness is above 40, the next procedure can be carried out.

[0040] During paving in step 4, the entire surface is paved on the basis of step 3, specifically, 2 cycles of entire surface paving are performed, and the order of the entire surface paving in each cycle is one layer of biaxial cloth [45°, -45°], one layer of biaxial cloth [90°, 0°], one layer of unidirectional cloth 0°, one layer of biaxial cloth [90°, 0°] and one layer of biaxial cloth [-45°, 45°]; after 2 cycles of entire surface paving are completed, a layer of felt is paved, and 2 cycles of entire surface paving are performed on the felt, and finally another layer of felt is paved; the skin thickness after paving is completed is 9 mm.

[0041] In step 5, separate layers are laid on each first longitudinal foam 2 of the bottom plate of the bulkhead 14, and the laying sequence is 2 cycles of full-surface laying, and the full-surface laying sequence of each cycle is a layer of [45°, -45°] biaxial cloth, a layer of [90°, 0°] biaxial cloth, a layer of 0° unidirectional cloth, a layer of [90°, 0°] biaxial cloth and a layer of [-45°, 45°] biaxial cloth; after 2 cycles of full-surface laying, a layer of felt is laid, and 2 cycles of full-surface laying are carried out on the felt, and finally another layer of felt is laid; the skin thickness after the laying is 9 mm, and the flange is 100 mm; the arrangement of the vacuum system is similar to that in step 3, and is not repeated here.

[0042] In step 6, plying is performed on various types of foams. When plying, the horizontal and vertical fibers are alternately and continuously cross-laid on the dry cloth. Specifically, a layer of [45°, -45°] biaxial cloth is first laid, and then two cycles of full-surface plying are performed on this basis. The plying order of 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, and then a layer of [90°, 0°] biaxial cloth, a layer of [-45°, 45°] biaxial cloth, and a layer of [0°, 90°] biaxial cloth are laid in sequence. 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 layer thickness is 11mm.

[0043] In step 5 and step 6, each layer of fabric needs to be fixed during vertical laying to ensure that the fabric does not slide down. Use a 5mm long drill bit to make wiring holes at the top, middle, and tail of the supporting wall material. After laying one layer, prepare a silver needle to insert a single fiber, wrap the wiring holes, sew the fabric to the foam, and fix the flange with 3M spray glue. Repeat this step to lay the fabric of all the supporting wall material cap-shaped ribs (each longitudinal foam is a supporting wall material).

[0044] Specifically, the laying step in step 7 is to carry out separate whole-surface laying on each of the bottom longitudinal girder foams 6 of the ship, specifically, first carry out 2 cycles of separate whole-surface laying, and the order of the separate whole-surface laying in 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°]; after 2 cycles of separate whole-surface laying, lay the first layer of felt, carry out 2 cycles of whole-surface laying on the first layer of felt, lay the second layer of felt, carry out 2 cycles of whole-surface laying on the second layer of felt, and finally lay another layer of felt, with a total laying thickness of 15 mm and a flange of 200 mm.

[0045] The following steps are also included between step 9 and step 10: in the left and right directions, a plurality of foams of the ship's bottom strong transverse beams 7 are installed on the ship's bottom between the first side keel and the corresponding longitudinal girder, the second side keel and the adjacent longitudinal girder; paving is performed on the foams of the ship's bottom strong transverse beams 7 according to the ply design; the plying sequence is the same as the plying sequence of the plying of the ship's bottom longitudinal girder foams 6; the total plying thickness is 15 mm, the flange is 200 mm, and after the plying is completed, a vacuum introduction system is arranged; after the completion, vacuum glue injection is performed; and after the glue injection is completed, the glue is cured at room temperature.

[0046] The laying step in step 10 is to carry out separate whole-surface laying on each side strong transverse beam foam 11 of the ship side, specifically, first carry out 2 cycles of separate whole-surface laying, and the order of separate whole-surface laying in 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°]; after 2 cycles of separate whole-surface laying, lay the first layer of felt, carry out 2 cycles of whole-surface laying on the first layer of felt, lay the second layer of felt, carry out 2 cycles of whole-surface laying on the second layer of felt, and finally lay another layer of felt, with a total laying thickness of 15 mm and a flange of 200 mm.

[0047] In the above laying steps, the R corners of all foams must be rolled solid without any gaps, and the edges must be gradually lost; a right-hand coordinate system is specified, with the length direction of the longitudinal bone foam as 0° and the horizontal direction perpendicular to the length direction of the longitudinal bone foam as 90°.

[0048] 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 cabin outer plate, which can further improve the structural strength of the side keel.

[0049] In step 8, the first side keel foam 5 stacked together is connected with the side keel prefabricated board 8, and the surface of the side keel foam of the lower part is used as the mold surface for hand lay-up. First, the side keel foam of the lower part is positioned, installed and fixed. First, a blanking template of the size that just covers the shape is cut according to the shape. According to the template, 4 layers of four-axis cloth are cut. The hand lay-up resin and curing agent are mixed at a ratio of 1000: (3~5) for 2kg each time. When hand lay-up, a wool roller is used to dip the resin to soak the dry cloth and apply it evenly. If bubbles or wrinkles appear between layers, a threaded roller is used to compact them. After the hand lay-up is completed, the surface quality is checked, and if there is a lack of glue, appropriate glue is added. After the hand lay-up is cured, the excess fabric is cut and polished along the edge of the foam, and the raised parts of the surface are polished flat to facilitate the subsequent foam installation.

[0050] Through the three embodiments in the present application, while meeting the strength requirements, the dimensional accuracy and appearance requirements are also guaranteed, and the preparation of the cabin outer plate is completed 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.

[0051] 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 cabin outer plate, characterized in that: The following steps are included:

1. Raw materials preparation; 2. Mold preparation; 3. Lay the outer panel skin in the female mold (13) according to the layer laying design. After the laying is completed, arrange the vacuum introduction system, vacuum glue injection is completed, and the glue is cured at room temperature after the injection is completed; 4. Install several longitudinal foams on the bottom and side of the cured outer skin, and lay the entire side and bottom of the ship according to the laying design on the positioning longitudinal foam. During the laying process, the fabric interfaces need to be overlapped and the overlap positions need to be staggered. After laying, arrange the vacuum introduction system, and after completion, vacuum glue injection is carried out. After the glue injection is completed, it is cured at room temperature; 5. Install the vertically arranged first longitudinal foam (2) on the bulkhead (14) of the outer panel skin according to the designed position, complete the individual paving on each first longitudinal foam (2) according to the ply design, arrange the vacuum introduction system, perform vacuum glue injection after completion, and cure at room temperature after the glue injection is completed; 6. A second longitudinal foam (1) and a third longitudinal foam (3) which are arranged vertically and have a thickness greater than that of the first longitudinal foam (2) and a horizontally arranged transverse foam (4) are installed on the bulkhead (14) between the longitudinal foams at the set position. The thickness of the second longitudinal foam (1), the third longitudinal foam (3) and the transverse foam (4) are the same. The width of the second longitudinal foam (1) is greater than that of the third longitudinal foam (3). The transverse foam (4) and various longitudinal foams are crossed. The second longitudinal foam (1), the third longitudinal foam (3) and the transverse foam (4) are integrally paved according to the ply design. When paving, the transverse and longitudinal fibers need to be alternately and continuously laid crosswise on the dry cloth. After the plying is completed, a vacuum introduction system is arranged. After the completion, vacuum glue injection is performed. After the glue injection is completed, the glue is cured at room temperature.

7. Install a number of ship bottom longitudinal girder foams (6) at set positions on the ship bottom, and complete individual paving on each ship bottom longitudinal girder foam (6) according to the paving design. After the paving is completed, a vacuum introduction system is arranged, and vacuum glue injection is performed after the completion. After the glue injection is completed, it is cured at room temperature; 8. An intermediate hardwood embedded part is installed on the bottom between two bottom longitudinal girder foams (6), and a plurality of intermediate crossbeam foams (9) are installed on the bottom outside the front and rear sides of the intermediate hardwood embedded part at intervals in the front and rear directions. Two first side keel foams (5) are installed on the bottom at intervals in the left and right directions and stacked together in the height direction. The intermediate crossbeam foam (9) is installed between the two first side keel foams (5) installed at intervals in the left and right directions. Side hardwood embedded parts are installed on the bottom of the two bottom longitudinal girder foams (6) at one end away from each other in the left and right directions. The front and rear sides of the side hardwood embedded parts are respectively connected to two second side keel foams (10) connected to the bottom and stacked together in the height direction. Metal embedded parts are connected to the set positions of the first side keel foams (5) and the second side keel foams (10).

9. Complete the whole surface paving on the connected middle beam foam (9), the first side keel foam (5) and the middle hardwood embedded parts, the connected side hardwood embedded parts and the second side keel foam (10) according to the ply design. After the ply is completed, arrange the vacuum introduction system, perform vacuum glue injection, and cure at room temperature after the glue injection is completed; 10. A plurality of side strong transverse beam foams (11) are respectively installed on the bottom of the ship at a side away from the two side ribs, and are arranged at intervals in the front-rear direction. The side strong transverse beam foams (11) are installed on the side at one end away from the corresponding side ribs in the left-right direction. The side strong transverse beam foams (11) are paved according to the ply design. After the ply is completed, a vacuum introduction system is arranged. After the completion, vacuum glue injection is performed. After the glue injection is completed, the glue is cured at room temperature.

11. Install the side longitudinal girder foam (12) on the side between two adjacent side transverse beams according to the designed position, and perform hand lay-up molding on each side longitudinal girder foam (12) according to the lay-up design; 12. Demoulding; When installing each longitudinal foam, the structural adhesive is used to bond and fix the foam in sections from bottom to top. When installing the transverse foam (4), the transverse foam (4) is first supported by a preset supporting wooden block and then bonded and fixed by the structural adhesive.

2. The method for forming a composite material ship cabin outer plate according to claim 1, characterized in that: Step 1 and step 2 are in no particular order. In step 2, the mold surface of the cabin outer plate steel female mold (13) is cleaned with acetone. After the acetone on the mold surface evaporates and dries, 770NC mold release agent is applied to the mold surface using a cleaning paper. At least 8 layers of mold release agent are applied to the new mold, and the time interval between each layer of mold release agent is more than 15 minutes to ensure that the mold release agent is completely cured.

3. The method for forming a composite material ship cabin outer plate according to claim 1, characterized in that: During paving in step 3, the area where the upper parts of the inner walls of the left and right ends of the female mold (13) are located is area I, the central concave area at the bottom of the female mold (13) is area III, the area where the inner wall of the female mold (13) between areas I and III is located is area II, and the area where the inner walls of the front and rear ends of the female mold (13) are located corresponds to the bulkhead (14) of the outer plate. First, two cycles of paving are performed in the female mold (13). The paving process of each cycle of paving is to first lay the first layer of felt as a whole, and then perform the first full-surface paving on the first layer of felt. The first full-surface paving sequence is to use 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 [- The first single layer is laid at the position of zone III, and the order of the first single layer is as follows: one layer of biaxial fabric [45°, -45°], one layer of biaxial fabric [0°, 90°], one layer of unidirectional fabric [0°], one layer of biaxial fabric [90°, 0°], one layer of biaxial fabric [-45°, 45°] and one layer of felt; on the basis of the two cycles of laying, the first single layer is laid at the position of bulkhead (14), zone II and zone III, and the order of the first single layer is as follows: one layer of biaxial fabric [45°, -45°], one layer of biaxial fabric [0°, 90°], one layer of unidirectional fabric [0°], one layer of biaxial fabric [90°, 0°] and a layer of biaxial fabric of [-45°, 45°], continue to lay at the bulkhead (14) and zone III, the laying order is to use a layer of biaxial fabric of [45°, -45°], a layer of biaxial fabric of [0°, 90°], a layer of unidirectional fabric of 0°, a layer of biaxial fabric of [90°, 0°] and a layer of biaxial fabric of [-45°, 45°], carry out the second whole-surface laying, lay a layer of felt on the basis of the second whole-surface laying, carry out the second single laying at the bulkhead (14), zone II and zone III, the laying order of the second single laying is the same as the first single laying, carry out the third whole-surface laying; the order of each whole-surface laying is the same; on the basis of the third whole-surface laying On the top, the fourth whole-surface laying is carried out at the positions of zone I, zone II and zone III. The fourth whole-surface laying includes 2 cycles of laying. The laying order of each cycle of laying 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°], one layer of biaxial cloth [-45°, 45°], 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 a layer of felt is laid between the 2 cycles of laying. Laying is interspersed at the four positions and the laying is completed at the same time.After the layers are laid, the skin thickness of zone III is 28 mm, the skin thickness of zone II is 18 mm, the skin thickness of zone I is 13 mm, and the thickness of the bottom plate at the bulkhead (14) is 22 mm. ; 4. The method for forming a composite material ship cabin outer plate according to claim 3, characterized in that: During paving in step 4, the entire surface is paved on the basis of step 3, specifically, 2 cycles of entire surface paving are performed, and the order of the entire surface paving in each cycle is one layer of biaxial cloth [45°, -45°], one layer of biaxial cloth [90°, 0°], one layer of unidirectional cloth 0°, one layer of biaxial cloth [90°, 0°] and one layer of biaxial cloth [-45°, 45°]; after 2 cycles of entire surface paving are completed, a layer of felt is paved, and 2 cycles of entire surface paving are performed on the felt, and finally another layer of felt is paved; the skin thickness after paving is completed is 9 mm.

5. The method for forming a composite material ship cabin outer plate according to claim 1, characterized in that: In step 5, separate layers are laid on each first longitudinal foam (2) of the bottom plate of the bulkhead (14), and the laying sequence is 2 cycles of full-surface laying, and the full-surface laying sequence of each cycle is 1 layer of biaxial cloth [45°, -45°], 1 layer of biaxial cloth [90°, 0°], 1 layer of unidirectional cloth 0°, 1 layer of biaxial cloth [90°, 0°] and 1 layer of biaxial cloth [-45°, 45°]; after 2 cycles of full-surface laying, a layer of felt is laid, and 2 cycles of full-surface laying are carried out on the felt, and finally another layer of felt is laid; the skin thickness after the laying is 9 mm, and the flange is 100 mm.

6. The method for forming a composite material ship cabin outer plate according to claim 5, characterized in that: In step 6, plying is performed on various types of foams. When plying, the horizontal and vertical fibers are alternately and continuously cross-laid on the dry cloth. Specifically, a layer of [45°, -45°] biaxial cloth is first laid, and then two cycles of full-surface plying are performed on this basis. The plying order of 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, and then a layer of [90°, 0°] biaxial cloth, a layer of [-45°, 45°] biaxial cloth, and a layer of [0°, 90°] biaxial cloth are laid in sequence. 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 layer thickness is 11mm.

7. The method for forming a composite material ship cabin outer plate according to claim 4, characterized in that: The layering step in step 7 is to perform separate whole-surface layering on each of the longitudinal girder foams (6) of the bottom of the ship, specifically, firstly perform two cycles of separate whole-surface layering, and the sequence of the separate whole-surface layering in 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°]; after the two cycles of separate whole-surface layering are completed, the first layer of felt is laid, and two cycles of whole-surface layering are performed on the first layer of felt, and then the second layer of felt is laid, and two cycles of whole-surface layering are performed on the second layer of felt, and finally another layer of felt is laid, and the total thickness of the laying is 15 mm, and the flange is 200 mm.

8. The method for forming a composite material ship cabin outer plate according to claim 4, characterized in that: The laying step in step 10 is to carry out separate whole-surface laying on each side strong transverse beam foam (11) of the ship side, specifically, firstly carry out 2 cycles of separate whole-surface laying, and the order of separate whole-surface laying in 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°]; after the 2 cycles of separate whole-surface laying are completed, the first layer of felt is laid, and 2 cycles of whole-surface laying are carried out on the first layer of felt, and the second layer of felt is laid, and 2 cycles of whole-surface laying are carried out on the second layer of felt, and finally another layer of felt is laid, and the total laying thickness is 15 mm, and the flange is 200 mm.

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