A molding method for composite material compartments

Abstract

This invention discloses a method for molding composite material compartment sections, comprising the following steps: 1. Raw material preparation; 2. Mold preparation; 3. Deck molding; 4. Outer plate molding; 5. First transverse bulkhead molding; 6. Second transverse bulkhead molding; 7. Preparing two ballast tank platforms, several bottom flat plates, and two half-bulls; 8. Installing the first and second transverse bulkheads into the outer plate, with the first and second transverse bulkheads forming large ballast tanks at their respective ends relative to the front and rear bulkheads of the outer plate. Bottom flat plates are installed on the upper side of the large ballast tanks, and the ballast tank platforms are installed on the upper side of the bottom flat plates. After fixing, the half-bulls are installed on the upper side of the ballast tank platforms, dividing the large ballast tanks into two smaller ballast tanks. Finally, the deck is installed on the upper part of the outer plate. The outer plate of the compartment prepared using this invention is lighter, and the entire compartment section can be prepared without the aid of large equipment.

Description

Technical Field

[0001] This invention relates to the field of ship hull forming technology, and in particular to a method for forming composite material compartments. Background Technology

[0002] Composite material hulls are widely used in military vessels. Existing molding methods for military vessels mostly include autoclave molding, hand lay-up molding, and vacuum induction molding. Autoclave molding is known for its high material costs. Furthermore, composite material sections are large structural components, approximately 11m long, 10m wide, and 5m high. Autoclave molding requires large autoclave equipment, which is expensive, has a long construction period, and, as thick-walled components, requires segmented curing. Moving large components in and out of the autoclave is also difficult. Hand lay-up molding has low production efficiency, a long cycle, a harsh working environment, and makes it difficult to control product quality during molding, resulting in lower strength and dimensional accuracy. In the past, vacuum induction molding of hulls involved using wooden molds to create fiberglass molds before vacuum induction. Fiberglass mold molding is complex, has low sealing performance, uncontrollable deformation, and low surface accuracy. It has been found that large fiberglass molds do not offer a significant price advantage compared to steel molds. Using steel molds in composite material section molding effectively ensures the hull's surface accuracy and outer surface quality. Therefore, based on the above description, it is very meaningful to study a vacuum induction molding method that is simple to form, efficient and has high surface quality when dealing with a large composite material hull. Summary of the Invention

[0003] The purpose of this section is to outline some aspects of embodiments of the present invention and to briefly describe some preferred embodiments. Simplifications or omissions may be made in this section, as well as in the abstract and title of this application, to avoid obscuring the purpose of these documents; however, such simplifications or omissions should not be construed as limiting the scope of the invention.

[0004] In view of the problems existing in the above and / or existing hull manufacturing processes, the present invention is proposed.

[0005] Therefore, the purpose of this invention is to provide a molding method for composite material compartments. The molding process of this invention is simple, reduces the preparation cost, and can process the hull without the need for large equipment for hot pressing. This solves the problems of high cost, complicated and difficult operation, poor surface quality, and difficulty in accurate external dimensions of large composite material hulls in the prior art.

[0006] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a method for molding a composite material compartment, comprising the following steps,

[0007] 1. Raw material preparation; 2. Mold preparation; 3. Deck forming; 4. Outer plate forming; 5. First transverse bulkhead forming;

[0008] 6. Forming the second transverse bulkhead; 7. Preparing two ballast tank platforms, several bottom flat plates, and two half-bulls; 8. Installing the first and second transverse bulkheads into the outer plating respectively. The first and second transverse bulkheads form large ballast tanks at the ends of the front and rear bulkheads of the outer plating, respectively. Installing bottom flat plates on the upper side of the bottom inside the large ballast tanks, installing the ballast tank platforms on the upper side of the bottom flat plates, and fixing them. Then, installing the half-bulls on the upper side of the ballast tank platforms to divide the large ballast tanks into two smaller ballast tanks. Finally, installing the deck onto the upper part of the outer plating.

[0009] As a preferred embodiment of the molding method for composite material compartments in this invention, step 3 specifically includes the following steps: 301. Laying the base plate on the deck molding male mold according to the layup design. After laying, setting up a vacuum induction system, performing vacuum injection, and curing at room temperature after injection; 302. Installing several deck positioning longitudinal rib foams on the cured base plate. After fixing the deck positioning longitudinal rib foams, laying the entire surface on the base plate and deck positioning longitudinal rib foams according to the layup design. After laying, setting up a vacuum induction system, performing vacuum injection, and curing at room temperature after injection; 303. Installing longitudinal girder foams according to the designed positions. Installing several intermediate strong crossbeam foams spaced apart in the front-rear direction at the center position of the base plate. Several intermediate strong crossbeam foams on the left and right sides... Install intermediate longitudinal girder foam on the upper side of the bottom plate of each side. Install side longitudinal girder foam on the bottom plate to the left of the intermediate longitudinal girder foam on the left and the bottom plate to the right of the intermediate longitudinal girder foam on the right. Install transverse foam on the bottom plates to the left of the intermediate longitudinal girder foam on the left, to the right of the intermediate longitudinal girder foam on the right, and on both sides of the side longitudinal girder foam. 304. Lay the intermediate longitudinal girder foam, intermediate strong crossbeam foam, and side longitudinal girder foam according to the layup design. Set up a vacuum infusion system. After completion, perform vacuum injection. After injection, cure at room temperature. 305. Install deck longitudinal foam on the bottom plate between two adjacent transverse foams. Lay the deck longitudinal foam according to the layup design. Set up a vacuum infusion system. After completion, perform vacuum injection. After injection, cure at room temperature. 306. Demold.

[0010] As a preferred embodiment of the molding method for composite material compartments in this invention, step 4 specifically includes the following steps: 401. Laying the outer panel skin in the negative mold according to the layup design. After laying, setting up a vacuum induction system, vacuum injection, and curing at room temperature after injection; 402. Installing several bottom positioning longitudinal rib foams on the bottom and sides of the cured outer panel skin. Laying the entire side and bottom of the bottom positioning longitudinal rib foam according to the layup design. During the layup process, the fabric joints need to overlap and the overlap positions need to be staggered. After laying, setting up a vacuum induction system, vacuum injection, and curing at room temperature after injection; 403. Installing vertical fixtures on the bulkhead of the outer panel skin according to the designed positions. The first longitudinal foam is individually laid on each of the first longitudinal foams according to the layup design. A vacuum induction system is then installed, followed by vacuum injection, and finally, room temperature curing. 404. On the walls between the longitudinal foams at designated locations, vertically arranged second and third longitudinal foams with a thickness greater than the first longitudinal foam, and horizontally arranged transverse foams are installed. The thickness of the second, third, and transverse foams is the same, and the width of the second longitudinal foam is greater than the width of the third longitudinal foam. The transverse foam intersects with the various longitudinal foams. According to the layup design, the entire structure is laid on the second, third, and transverse foams. During layup, the dry fabric must be laid alternately and continuously in a cross pattern between the longitudinal and transverse fibers. The layup is then complete. Afterwards, install the vacuum induction system, followed by vacuum injection, and then cure at room temperature; 405. Install several bottom longitudinal girder foams at designated positions on the bottom of the ship. Lay each bottom longitudinal girder foam individually according to the layering design. After layering, install the vacuum induction system, followed by vacuum injection, and then cure at room temperature; 406. Install intermediate hardwood embedded parts on the bottom of the ship between two bottom longitudinal girder foams. Install several intermediate crossbeam foams spaced apart in the forward and backward directions on the bottom of the ship on both sides of the intermediate hardwood embedded parts. Install two first side keel foams stacked together in the height direction, spaced apart in the left and right directions, on the bottom of the ship on both sides of the intermediate hardwood embedded parts. Between two first side keel foams spaced apart in the left and right directions, two ship bottom longitudinal girder foams are respectively installed on the ship bottom 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 stacked together in the height direction connected to the ship bottom. Metal embedded parts are connected to the first side keel foams and the second side keel foams at the designated positions; 407. According to the layup design, complete the individual full-surface laying on the connected intermediate crossbeam foam, the first side keel foam and the intermediate hardwood embedded parts, the connected side hardwood embedded parts and the second side keel foams. After the layup is completed, a vacuum injection system is set up. After completion, vacuum injection is performed. After injection, it is cured at room temperature.408. Install several side beam foams spaced apart in the fore-and-aft direction on the bottom of the two side ribs, with the end of the side beam foam furthest from the corresponding side rib in the port and starboard directions installed on the side. Lay the foams onto each side beam foam according to the layup design. After the layup is completed, install a vacuum injection system, then vacuum sealant injection, followed by room temperature curing. 409. Install side girder foams on the side of the hull between two adjacent side beams according to the design position. Hand lay up each side girder foam according to the layup design. 410. Demolding; When installing the longitudinal foams, use structural adhesive to bond and fix them segment by segment from bottom to top. When installing the transverse foams, first use pre-set supporting wooden blocks to support the transverse foams before using structural adhesive to bond and fix them.

[0011] As a preferred embodiment of the molding method for composite material compartments in this invention, steps 5 and 6 are the same. Step 5 specifically includes the following steps: 501. Laying the transverse bulkhead skin on the first transverse bulkhead molding male mold (whose upper surface is flat) according to the layup design. During the layup process, the dry fabric joints overlap by 30mm and the overlap positions need to be staggered. After laying, the vacuum induction system is set up, and vacuum glue is injected after completion. After glue injection, it is cured at room temperature; 502. Installing several parallel transverse bulkhead longitudinal rib foams on the upper side of the transverse bulkhead skin according to the set position, and laying each transverse bulkhead longitudinal rib foam separately according to the layup design. After laying, the vacuum induction system is set up, and vacuum glue is injected after completion. After glue injection, it is cured at room temperature; 503. Laying the transverse bulkhead skin on the first transverse bulkhead molding male mold (whose upper surface is flat) according to the layup design. High-stretcher foam is installed on the upper side of the skin. The high-stretcher foam includes several longitudinal stapling foams, and transverse stapling foams are fixed on the longitudinal stapling foams. The transverse stapling foams are perpendicular to the longitudinal stapling foams. The longitudinal stapling foams are placed between the corresponding two adjacent transverse bulkhead longitudinal rib foams. The transverse stapling foams intersect with the transverse bulkhead longitudinal rib foams. According to the layup design, the high-stretcher foams are individually laid on the transverse bulkhead skin. During the layup process, the dry fabric joints overlap by 30mm and the overlap positions need to be staggered. After the layup is completed, the vacuum injection system is set up. After completion, vacuum injection is performed. After injection, it is cured at room temperature. 504 Demolding; 505 First, the outer contour is cut and polished according to the skin cutting line. According to the structural characteristics of the first transverse bulkhead, in order to be able to assemble with the hull, the interference points on the left and right sides are divided separately.

[0012] In a preferred embodiment of the molding method for the composite material compartment in this invention, step 301 involves the following steps: First, a first layer of felt is laid on the upper side of the deck molding male mold. Then, three cycles of full-surface laying are performed on the first layer of felt. The laying sequence for each cycle is as follows: one layer of [45°, -45°] biaxial fabric, one layer of [0°, 90°] biaxial fabric, one layer of 0° uniaxial fabric, one layer of [90°, 0°] biaxial fabric, one layer of [-45°, 45°] biaxial fabric, and one layer of [0°, 90°] biaxial fabric. Next, a second layer of felt is laid. Two more cycles of full-surface laying are then performed on the second layer of felt. The laying sequence for each cycle is as follows: one layer of felt... A layer of biaxial fabric at [45°, -45°], a layer of biaxial fabric at [0°, 90°], a layer of unidirectional fabric at 0°, a layer of biaxial fabric at [90°, 0°], and a layer of biaxial fabric at [-45°, 45°] are laid, with a total thickness of 12mm. Step 302 involves laying the fabric in three cycles based on step 301. Each cycle consists of a layer of biaxial fabric at [45°, -45°], a layer of biaxial fabric at [0°, 90°], a layer of unidirectional fabric at 0°, a layer of biaxial fabric at [90°, 0°], and a layer of biaxial fabric at [-45°, 45°], with a total thickness of 7mm. Step 30... In step 4, lay-up is performed separately on the interconnected intermediate strong crossbeam foam, intermediate longitudinal girder foam, and side longitudinal girder foam, using the same lay-up method, following interleaved and overlapping lay-up, with staggered overlaps at the overlap joints; the lay-up steps in step 305 are as follows: a full-surface lay-up is performed on the longitudinal deck foam, first laying a layer of [45°, -45°] biaxial fabric, then performing two cycles of full-surface lay-up on this basis, with the lay-up sequence of each cycle being a layer of 0° uniaxial 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. Next, lay a layer of biaxial fabric at [90°, 0°], a layer of biaxial fabric at [-45°, 45°], and a layer of felt in sequence. Continue laying layers on the felt, with the following order: a layer of biaxial fabric at [45°, -45°], a layer of biaxial fabric at [0°, 90°], a layer of uniaxial fabric at 0°, a layer of biaxial fabric at [90°, 0°], a layer of biaxial fabric at [-45°, 45°], a layer of biaxial fabric at [45°, -45°], a layer of biaxial fabric at [0°, 90°], a layer of uniaxial fabric at 0°, and a layer of biaxial fabric at [-45°, 45°]. Finally, lay another layer of felt, for a total thickness of 11mm.

[0013] As a preferred embodiment of the molding method for composite material compartments in this invention, the following steps are performed: Step 401 involves laying the material in two cycles within the mold: the upper part of the inner walls at both ends of the mold is designated as Zone I; the central recessed area at the bottom of the mold is designated as Zone III; the area containing the inner walls of the mold between Zones I and III is designated as Zone II; the areas containing the inner walls at the front and rear ends of the mold correspond to the outer wall of the outer plate. Two cycles of laying are performed within the mold. Each cycle involves laying the first layer of felt as a whole, followed by a first full-surface layup. The first full-surface layup sequence is: one layer of [45°, -45°] biaxial fabric, one layer of [0°, 90°] biaxial fabric, one layer of 0° uniaxial fabric, one layer of [90°, 0°] biaxial fabric, and one layer of [-45°, 45°] biaxial fabric. A first individual layup is then performed at Zone III, with the first individual layup sequence being: one layer of... A layer of biaxial fabric at [45°, -45°], a layer of biaxial fabric at [0°, 90°], a layer of unidirectional fabric at 0°, a layer of biaxial fabric at [90°, 0°], a layer of biaxial fabric at [-45°, 45°], and a layer of felt; based on two cycles of paving, the first separate paving is carried out at the bulkhead, Zone II, and Zone III locations. The paving sequence for the first separate paving is as follows: a layer of biaxial fabric at [45°, -45°], a layer of biaxial fabric at [0°, 90°], a layer of unidirectional fabric at 0°, a layer of biaxial fabric at [90°, 0°], and a layer of biaxial fabric at [-45°, 45°]. This process continues at the bulkhead and Zone III locations. The laying sequence is as follows: one layer of biaxial fabric at [45°, -45°], one layer of biaxial fabric at [0°, 90°], one layer of uniaxial fabric at 0°, one layer of biaxial fabric at [90°, 0°], and one layer of biaxial fabric at [-45°, 45°], followed by a second full-surface layup. A layer of felt is then laid on top of this second full-surface layup. A second separate layup is then performed at the bulkhead, Zone II, and Zone III locations, following the same laying sequence as the first separate layup. A third full-surface layup is then performed. The sequence of each full-surface layup is the same. Based on the third full-surface layup, a fourth full-surface layup is performed at Zone I, Zone II, and Zone III locations. The fourth full-surface layup consists of two cycles. The layup sequence for each cycle is as follows: one layer of biaxial fabric at [45°, -45°], one layer of biaxial fabric at [0°, 90°], one layer of unidirectional fabric at 0°, one layer of biaxial fabric at [90°, 0°], one layer of biaxial fabric at [-45°, 45°], one layer of biaxial fabric at [45°, -45°], one layer of biaxial fabric at [0°, 90°], one layer of unidirectional fabric at 0°, one layer of biaxial fabric at [90°, 0°], and one layer of biaxial fabric at [-45°, 45°]. A layer of felt is laid between the two cycles. The layup is interspersed in four locations and ends simultaneously.After the skin layup is completed, the skin thickness is 28mm in Zone III, 18mm in Zone II, 13mm in Zone I, and 22mm in the floor layer at the bulkhead.

[0014] As a preferred embodiment of the molding method for the composite material compartment in this invention, the laying step 402 is as follows: based on step 401, a full-surface layup is performed. Two cycles of full-surface layup are performed first. The layup sequence of each cycle is as follows: a layer of biaxial fabric at [45°, -45°], a layer of biaxial fabric at [90°, 0°], a layer of uniaxial fabric at 0°, a layer of biaxial fabric at [90°, 0°], and a layer of biaxial fabric at [-45°, 45°]. After the two cycles of full-surface layup are completed, a layer of felt is laid, and two more cycles of full-surface layup are performed on the felt. Finally, another layer of felt is laid. The thickness of the skin after the layup is 9 mm.

[0015] In a preferred embodiment of the molding method for the composite material compartment in this invention, step 403 involves laying layers individually on each of the first longitudinal foam layers of the bulkhead floor plate. The laying sequence is two cycles of full-surface laying, with each cycle consisting of a layer of [45°, -45°] biaxial fabric, a layer of [90°, 0°] biaxial fabric, a layer of 0° uniaxial fabric, a layer of [90°, 0°] biaxial fabric, and a layer of [-45°, -45°] uniaxial fabric. Biaxial fabric with angles of 45° and -45°; after two cycles of full-surface layup, a layer of felt is laid, followed by two more cycles of full-surface layup, and finally another layer of felt is laid; the final skin thickness after layup is 9mm, with a 100mm flange; the laying steps in step 404 are as follows: in step 6, layup is performed on various types of foam, with alternating and continuous cross-laying of dry fabric using transverse and longitudinal fibers. Specifically, first, a layer of biaxial fabric with angles of 45° and -45° is laid, followed by two cycles of full-surface layup. The entire surface is laid out in a cyclical manner. Each cycle consists of the following layup sequence: one layer of 0° uniaxial fabric, one layer of [90°, 0°] biaxial fabric, one layer of [-45°, 45°] biaxial fabric, one layer of [45°, -45°] biaxial fabric, and one layer of [0°, 90°] biaxial fabric. Then, another layer of [90°, 0°] biaxial fabric, another layer of [-45°, 45°] biaxial fabric, and a layer of felt are laid out. The entire surface is then laid out again on top of the felt. The layers are laid in sequence as follows: a layer of biaxial fabric at [45°, -45°], a layer of biaxial fabric at [0°, 90°], a layer of unidirectional fabric at 0°, a layer of biaxial fabric at [90°, 0°], a layer of biaxial fabric at [-45°, 45°], a layer of biaxial fabric at [45°, -45°], a layer of biaxial fabric at [0°, 90°], a layer of unidirectional fabric at 0°, and a layer of biaxial fabric at [-45°, 45°], and finally a layer of felt is laid; the layer thickness is 11mm.

[0016] As a preferred embodiment of the molding method for composite material compartments in this invention, the laying step 404 involves individually laying layers on each of the longitudinal girder foams of the ship's bottom. Specifically, two cycles of individually laid layers are performed, with the following sequence for each cycle: a layer of biaxial fabric at [45°, -45°], a layer of biaxial fabric at [0°, 90°], a layer of uniaxial fabric at 0°, a layer of biaxial fabric at [90°, 0°], and a layer of biaxial fabric at [-45°, 45°]. After the two cycles of individually laid layers are completed, a first layer of felt is laid, followed by two more cycles of laid layers on top of the first layer of felt, then a second layer of felt is laid, followed by two more cycles of laid layers on top of the second layer of felt, and finally, a third layer of felt is laid. The total thickness of the laid layers is 15 mm, with a 200 mm flange.

[0017] As a preferred embodiment of the molding method for composite material compartments in this invention, the layup step 405 is as follows: individual full-surface layup is performed on each longitudinal girder foam of the ship bottom. Two cycles of individual full-surface layup are performed first. The sequence of individual full-surface layup in each cycle is as follows: one layer of biaxial fabric at [45°, -45°], one layer of biaxial fabric at [0°, 90°], one layer of uniaxial fabric at 0°, one layer of biaxial fabric at [90°, 0°], and one layer of biaxial fabric at [-45°, 45°]. After the two cycles of individual full-surface layup are completed, the first layer of felt is laid, and two more cycles of full-surface layup are performed on the first layer of felt. The second layer of felt is laid, and two more cycles of full-surface layup are performed on the second layer of felt. Finally, one more layer of felt is laid. The total thickness of the layup is 15mm, and the flange is 200mm.

[0018] Compared with existing technologies, this invention has the following technical advantages: This invention uses fiberglass cloth to prepare various components such as decks, outer plates, and transverse bulkheads. When processing decks and transverse bulkheads, layers are laid on flat molds, and then combined with vacuum induction and room temperature curing processes to form the required decks and transverse bulkheads. When processing outer plates, vacuum induction molding is performed directly in a negative mold. For the hull bottom and side panels, different thicknesses of skin are prepared first through regional division. After preparation, positioning longitudinal ribs are installed on the skin of the hull bottom and side panels, and then the entire surface is laid up to achieve… For the remaining 9mm of skin preparation, corresponding longitudinal and transverse foams were fixedly installed on the skins of the bulkhead, bottom, and sides of the hull. Based on this, lay-up, vacuum inlet bags were placed, vacuuming was performed, and curing was carried out in sequence. By dividing the area for positioning, lay-up, and molding, the preparation of the outer skin was completed. Then, various types of foams were installed and laid up on the outer skin in sequence according to the steps. The molding process does not require the use of large equipment, which is simple and reduces molding costs. While meeting the strength requirements, it also ensures dimensional accuracy and appearance requirements, and completes the molding operation of the hull outer skin with high quality and high efficiency. Attached Figure Description

[0019] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. Wherein:

[0020] Figure 1 This is a three-dimensional structural diagram of a compartment prepared using the present invention.

[0021] Figure 2 This is a cross-sectional view of the transverse bulkhead assembled into the outer plate.

[0022] Figure 3 A cross-sectional view of the upper side of the hull where the flat bottom plate is assembled into the large ballast tank.

[0023] Figure 4 A cross-sectional view of the ballast tank platform being assembled onto the upper side of the ship's bottom flat plate.

[0024] Figure 5 A cross-sectional view of the semi-bullet assembly onto the upper side of the ballast tank platform.

[0025] Figure 6 A cross-sectional view showing the installation of several upper I-beams onto the upper sides of the intermediate and side longitudinal girders.

[0026] Figure 7 A cross-sectional view showing several lower I-beams installed on the upper side of the first and second side joists.

[0027] Figure 8 This is a cross-sectional view of several steel pipe supports fixed to the upper side of the corresponding lower I-beam.

[0028] Figure 9 This is a schematic diagram of vacuum introduction.

[0029] Figure 10 This is a three-dimensional structural diagram of the flat plate mold in this invention.

[0030] Figure 11 A three-dimensional structural diagram showing the installation of the deck positioning longitudinal rib foam onto the upper 2 / 3 of the skin.

[0031] Figure 12 This is a three-dimensional structural diagram of the deck before the longitudinal foam is installed.

[0032] Figure 13 This is a three-dimensional structural diagram of a deck manufactured using the present invention (with hatch openings for installing small hatches and hatch openings for installing hatch covers).

[0033] Figure 14 for Figure 13 A magnified view of a portion of point A in the middle.

[0034] Figure 15 for Figure 13 A magnified view of a section at point B in the middle.

[0035] Figure 16 This is a three-dimensional structural diagram of the outer plate prepared using the present invention.

[0036] Figure 17 for Figure 16 A magnified view of a section at point C.

[0037] Figure 18 A three-dimensional structural diagram showing the connection between the bottom and sides of the hull (after the outer panels of the hull conceal the bulkheads).

[0038] Figure 19 for Figure 18 A magnified view of a section at point D.

[0039] Figure 20 for Figure 18 A magnified view of a section at point E in the middle.

[0040] Figure 21 This is a three-dimensional structural diagram of the female mold in this invention.

[0041] Figure 22 This is a schematic diagram of the four thickness regions of the outer skin in this invention.

[0042] Figure 23 A schematic diagram showing the layout of the adhesive injection pipes for the outer skin section.

[0043] Figure 24 A schematic diagram of sewing and fixing the fabric for vertical wall support.

[0044] Figure 25 This is a schematic diagram showing the longitudinal skeleton foam of the transverse bulkhead installed on the upper side of the transverse bulkhead skin in this invention.

[0045] Figure 26 This is a schematic diagram showing the application and curing of foam onto the longitudinal ribs of the transverse bulkhead.

[0046] Figure 27 This is a schematic diagram showing the high-buttress foam installed on the transverse bulkhead skin and longitudinal ribs.

[0047] Figure 28 A schematic diagram of the application and curing of a high buttress foam (i.e., the transverse bulkhead in this application).

[0048] In the diagram: 100 Section, 101 Deck, 102 Outer Plating, 200 Deck Forming Assembly, 201 Flat Plate Mold, 202 Bottom Plate, 202a 2 / 3 Skin, 202b 1 / 3 Skin, 203 Deck Positioning Longitudinal Rib Foam, 204 Positioning Transverse Rib Foam, 205 Precast Panel, 206 Intermediate Longitudinal Girder Foam, 207 Intermediate Longitudinal Girder, 208 Side Longitudinal Girder Foam, 209 Side Longitudinal Girder, 210 Second Side Transverse Reinforcing Rib, 211 First Side Transverse Reinforcing Rib, 213 First Side Transverse Reinforcing Foam, 214 Second Side Transverse Reinforcing Foam, 215 First Intermediate Transverse Reinforcing Rib, 216 Second Intermediate Transverse Reinforcing Rib, 217 Third Intermediate Transverse Reinforcing Rib, 218 Deck Longitudinal Foam, 219 Longitudinal Reinforcing Rib, 220 Positioning Longitudinal Rib, 221 Positioning Transverse Rib, 222 Intermediate Strong Transverse Beam; 300 Outer Plating Forming Assembly, 3 01 Second longitudinal foam, 302 First longitudinal foam, 303 Third longitudinal foam, 304 Outer plate transverse foam, 305 First side keel foam, 306 Bottom longitudinal girder foam, 307 Bottom strong transverse beam, 308 Side keel precast plate, 308, 309 Intermediate transverse beam, 310 Second side keel foam, 311 Side strong transverse beam foam, 312 Side longitudinal girder foam, 313 Female mold, 314 Bulkhead, 400 Transverse bulkhead molding assembly, 401 Transverse bulkhead skin, 402 Transverse bulkhead longitudinal girder foam, 403 Transverse bulkhead longitudinal girder, 404 High buttress foam, 404a Longitudinal buttress foam, 404b Transverse buttress foam, 405 High buttress cap reinforcement. Detailed Implementation

[0049] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0050] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0051] 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 phrase "in one embodiment" appearing in different places in this specification does not necessarily refer to the same embodiment, nor is it a single or selective embodiment that is mutually exclusive with other embodiments.

[0052] Example 1

[0053] Reference Figures 1 to 21 This is the first embodiment of the present invention. This embodiment provides a molding method for composite material compartments, which can realize the molding of various components in the compartment and the installation of the compartment without the aid of large equipment, and is easy to operate.

[0054] For ease of labeling, the equipment used for deck forming and the various components in the deck are collectively referred to as deck forming assembly 200, the equipment used for outer plate forming and the various components in the outer plate are collectively referred to as outer plate forming assembly 300, and the various components in the first transverse bulkhead are collectively referred to as transverse bulkhead forming assembly 400.

[0055] A method for molding a composite material compartment includes the following steps: 1. Raw material preparation, comprising unidirectional glass fiber cloth, biaxial glass fiber (45 / -45) cloth, biaxial glass fiber (0 / 90) cloth, chopped strand mat, metal embedded parts, hardwood embedded parts, curing agent, vinyl ester resin, and flame-retardant vinyl ester resin; 2. Mold preparation, cleaning the molding surfaces of each mold and the flat mold 201 with acetone to remove oil, dust, and other excess substances from the mold surface. After the acetone on the mold surface has evaporated, apply 770NC release agent to the mold surface using wiping paper. New molds should be coated with at least 8 layers of release agent, with an interval of at least 15 minutes between each layer to ensure complete curing of the release agent;

[0056] 3. Reference Figures 10-15 The forming of deck 101 includes the following steps:

[0057] 301. Lay the base plate 202 on the positive mold according to the layup design, and complete the layup of 2 / 3 of the skin 202a. During the layup process, the dry cloth joints should overlap by 30mm and the overlap positions should be staggered. Ensure that the layup surface is flat and wrinkle-free. The dry cloth in the flanged area should be fixed with 3M spray adhesive to facilitate the subsequent vacuum system layout. After the layup is completed, install the vacuum inlet system for the base plate 202 skin. After completion, perform vacuum injection. After the injection is completed, cure at room temperature.

[0058] 302. Use a measuring tape, laser level, and chalk line to mark the placement positions of the longitudinal rib foam 203 on the deck. After passing inspection, classify the longitudinal rib foam and pre-lay it according to its location. At the same time, place the prefabricated plate 205 at the bulkhead 314 assembly position (the position where two adjacent longitudinal rib foams need to be combined in the longitudinal direction). The prefabricated plate 205 is made of fiberglass. To prevent the foam from moving, use vinyl ester resin with 5% hardener, mix it evenly, apply it to the bonding surface, and use an iron plate to compact it while waiting for the resin to cure. To facilitate subsequent layup and glue injection, when bonding, mix a viscous resin and use a scraper to scrape the R-corners into an arc shape. After the foam is fixed in place, lay up the entire surface according to the layup design to complete the layup of the remaining 1 / 3 of the skin 202b. When laying up, use wood to hold the R-corners and tap them with a wooden mallet to ensure the R-corners are secure. The corners should be rolled out with dry cloth without any gaps. During the layering process, the dry cloth joints should overlap by 30mm and the overlap positions should be staggered. The layered surface should be flat and wrinkle-free. After the layering is completed, the edges and drainage holes should be trimmed. After the layering is completed, the vacuum bag system should be made using the same glue injection principle as the bottom plate 202 skin. Before bagging, the reserved drainage should be filled with silicone rods. The vacuum bag system should be properly arranged in all the cap-shaped rib R areas (the junction of the positioning longitudinal rib 220 and the bottom plate 202, which is called the positioning longitudinal rib 220 after the deck positioning longitudinal rib foam 203 is laid and cured) to ensure the smooth progress of vacuum glue injection. After the vacuum bag system is completed, vacuum glue injection can be carried out. After the glue is injected, it should be cured at room temperature. After it has basically hardened and stood for 12 hours, the bags can be removed.

[0059] 303. Install longitudinal girder according to the three designed areas. Install several intermediate strong crossbeams 222 foams spaced apart in the front-to-back direction at the upper end of the center position of the base plate 202. Install intermediate longitudinal girder foams 206 on the upper side of the base plate 202 on both sides of the intermediate strong crossbeams 222 foams. In the height direction, two intermediate longitudinal girder foams 206 are stacked together at corresponding positions. In the longitudinal direction, hardwood embedded parts are placed at the positions where two adjacent intermediate longitudinal girder foams 206 need to be combined. In the height direction, precast slabs 205 are placed between the two stacked intermediate longitudinal girder foams 206. The skin on the left side of the intermediate longitudinal girder foam 206 and the skin on the right side of the intermediate longitudinal girder foam 206 are connected. Side longitudinal girder foam 208 is installed on the upper part of the skin on the right side of the girder foam 206. In the longitudinal direction, hardwood embedded parts are placed at the positions where two adjacent side longitudinal girder foams 208 need to be combined. The first side transverse reinforcing foam 213 is installed on the bottom plate 202 on the left side of the hardwood embedded part on the left side of the side longitudinal girder foam 208 and the right side of the hardwood embedded part on the right side of the side longitudinal girder foam 208. Steel plate embedded parts are placed on the side longitudinal girder foam 208 and the middle longitudinal girder foam 206 respectively, corresponding to the positions of the hatch openings to be opened. Resin is applied to the bonding surface for installation and fixation. Then, two layers of felt are hand-laid on the surface for reinforcement and fixation to prevent the steel plate from tipping over and to ensure the safety of the operators.

[0060] 304. According to the layup design, the foam is laid on the middle longitudinal girder foam 206, the middle strong crossbeam foam 222, the side longitudinal girder foam 208, and the first side transverse reinforcement foam 213 respectively. After the layup is completed in each area, the vacuum injection system is arranged in each area. After vacuum injection, the adhesive is injected and cured at room temperature. After it has basically hardened, a heating blanket is used to fully heat up the area to ensure that it is completely cured. After curing, the bag is removed, and visual inspection, hammer tapping test, thickness measurement, longitudinal and transverse spacing measurement, and hardness test are performed (all of the above tests are existing technologies and will not be described in detail). The results are recorded. After all tests are qualified, proceed to step S05.

[0061] 305. First intermediate transverse reinforcing foam is installed on the bottom plate 202 between the intermediate longitudinal girder 207 and the corresponding side longitudinal girder 209 on both sides of the hatch opening. A steel plate embedded part is placed on the side of the first intermediate transverse reinforcing foam opposite to the hatch opening. Resin is applied to the bonding surface for installation and fixation. Then, two layers of felt are hand-laid on the surface for reinforcement and fixation to prevent the steel plate from tipping over and to ensure the safety of the operators. Several second side transverse reinforcing ribs 211 (the part after the first side transverse reinforcing foam 213 is laid and cured is called the first side transverse reinforcing rib 211) are installed on the bottom plate 202 on the left side of the side longitudinal girder 209 on both sides of the hatch opening. Several second-side transverse reinforcing foams 214 are also installed on the bottom plate 202 on the right side of the side longitudinal girders 209 on both sides of the first transverse reinforcing rib 211 on the right. Second-intermediate transverse reinforcing foams and third-intermediate transverse reinforcing foams are installed on the bottom plate 202 on the right side of the side longitudinal girders 209 and the left side of the middle longitudinal girders 207 on the left. Second-intermediate transverse reinforcing foams and third-intermediate transverse reinforcing foams are also installed on the bottom plate 202 on the right side of the middle longitudinal girders 207 and the left side of the side longitudinal girders 209 on the right. There is a gap between the second-intermediate transverse reinforcing foams and the corresponding third-intermediate transverse reinforcing foams.

[0062] 306. According to the layup design, lay the foam on the second side transverse reinforcement foam 214, the first intermediate transverse reinforcement foam, the second intermediate transverse reinforcement foam and the third intermediate transverse reinforcement foam respectively. After the layup is completed in each area, arrange the vacuum injection system in each area. After vacuum injection, cure at room temperature. After it has basically hardened, use a heating blanket to fully heat up the temperature to ensure that it is completely cured. After curing, remove the bag and visually inspect, test by tapping with a small hammer, measure the thickness, measure the longitudinal and transverse spacing and hardness (all of the above tests are existing technologies and will not be described in detail). Record the results. After all tests are qualified, proceed to step 307.

[0063] 307. According to the layup design, lay the foam on the second side transverse reinforcement foam 214, the first intermediate transverse reinforcement foam, the second intermediate transverse reinforcement foam and the third intermediate transverse reinforcement foam respectively. After the layup is completed in each area, arrange the vacuum injection system in each area. After vacuum injection, cure at room temperature. After it has basically hardened, use a heating blanket to fully heat up the temperature to ensure that it is completely cured. After curing, remove the bag and visually inspect, test by hammering, measure the thickness, measure the longitudinal and transverse spacing and hardness (all of the above tests are existing technologies and will not be described in detail). Record the results. After all tests are qualified, proceed to step S08.

[0064] 308. Install deck longitudinal foam 218 on the base plate 202 between the second intermediate transverse reinforcing rib 216 and the corresponding third intermediate transverse reinforcing rib 217. One side of the deck longitudinal foam 218 in the front-rear direction is connected to the corresponding third transverse reinforcing foam, and the other side of the deck longitudinal foam 218 in the front-rear direction is flush with the front side of the base plate 202. Lay it on the deck longitudinal foam 218 according to the layup design, arrange the vacuum inlet system, and perform vacuum injection after completion. After the injection is completed, it is cured at room temperature.

[0065] 309. Demolding.

[0066] For ease of description, 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. The right side of the deck positioning longitudinal foam 203 to the left of the left longitudinal foam is provided with several positioning transverse foams 204 spaced apart in the front-back direction (the positioning transverse foams 204 are installed in step S4). When placing the longitudinal foam, the left side of the left longitudinal foam is attached to the right side of the left positioning transverse foam 204, and the right side of the right longitudinal foam is attached to the left side of the right positioning transverse foam 204.

[0067] The longitudinal positioning foam 203, the transverse positioning foam 204, and the longitudinal foam components after being laid and cured are respectively called longitudinal positioning ribs 220, transverse positioning ribs 221, and longitudinal reinforcing ribs 219. The combined arrangement of longitudinal positioning ribs 220, transverse positioning ribs 221, and corresponding longitudinal reinforcing ribs 219 forms a space for accommodating small hatches, facilitating the connection and positioning of small hatches.

[0068] 4. Reference Figures 16-21 The forming of the outer panel 102 includes the following steps:

[0069] 401. According to the layup design, lay the outer panel 102 skin in the female mold 313. After the layup is completed, set up the vacuum injection system, and then vacuum inject adhesive. After the adhesive is injected, cure at room temperature.

[0070] 402. Install several bottom positioning longitudinal foams on the bottom and sides of the cured outer panel 102 skin. Lay the bottom positioning longitudinal foams on the sides and bottom of the ship according to the layup design. During the layup process, the fabric joints need to overlap and the overlapping positions need to be staggered. After the layup is completed, set up the vacuum injection system. After completion, vacuum injection is performed. After the injection is completed, the adhesive is cured at room temperature.

[0071] 403. Install the vertically arranged first longitudinal foam 302 on the bulkhead 314 of the outer panel 102 skin according to the designed position. According to the layup design, lay each first longitudinal foam 302 separately, arrange the vacuum inlet system, and then perform vacuum injection. After the injection is completed, cure at room temperature.

[0072] 404. Install vertically arranged second longitudinal foam 301, third longitudinal foam 303 with a thickness greater than the first longitudinal foam 302, and horizontally arranged outer plate transverse foam 304 on the bulkhead 314 between the longitudinal foams at the set position. The thickness of the second longitudinal foam 301, third longitudinal foam 303 and outer plate transverse foam 304 is the same. The width of the second longitudinal foam 301 is greater than the width of the third longitudinal foam 303. The outer plate transverse foam 304 intersects with various longitudinal foams. According to the layup design, the entire structure is laid on the second longitudinal foam 301, third longitudinal foam 303 and outer plate transverse foam 304. During the layup, the dry cloth should be laid in a continuous cross-layup with alternating longitudinal and transverse fibers. After the layup is completed, a vacuum introduction system is set up. After completion, vacuum injection is performed. After the injection is completed, it is cured at room temperature.

[0073] 405. Install several bottom longitudinal girder foams 306 at the designated positions on the bottom of the ship. Lay them individually on each bottom longitudinal girder foam 306 according to the layup design. After the layup is completed, install a vacuum injection system. After vacuum injection, the foam will cure at room temperature.

[0074] 406. Install intermediate hardwood embedded parts on the bottom of the ship between the two longitudinal girder foams 306. Install several intermediate crossbeams 309 foams spaced apart in the forward and backward directions on the bottom of the ship between the front and rear sides of the intermediate hardwood embedded parts. Install two first side keel foams 305 stacked together in the height direction and spaced apart in the left and right directions on the bottom of the ship between the front and rear sides of the intermediate hardwood embedded parts. The intermediate crossbeams 309 foams are between the two first side keel foams 305 spaced apart in the left and right directions. Install side hardwood embedded parts on the bottom of the two longitudinal girder foams 306 that are far apart from each other in the left and right directions. Connect the front and rear sides of the side hardwood embedded parts to two second side keel foams 310 stacked together in the height direction on the bottom of the ship. Connect metal embedded parts at the designated positions of the first side keel foams 305 and the second side keel foams 310.

[0075] 407. According to the layup design, individual full-surface laying is completed on the interconnected intermediate crossbeam 309 foam, the first side keel foam 305, the intermediate hardwood embedded parts, the interconnected side hardwood embedded parts, and the second side keel foam. After the layup is completed, a vacuum injection system is installed, followed by vacuum adhesive injection. After adhesive injection, it is cured at room temperature. The component at the location of the second side keel foam 310 after curing is called the second side keel, and the component at the location of the first side keel foam 305 after curing is called the first side keel. In the left and right directions, on the first side keel foam 305, the second side keel foam 305 is called the first side keel. Several 307 foam slabs for the bottom of the ship are installed on the bottom between the keel and the corresponding longitudinal girder, and between the second keel and the adjacent longitudinal girder. The 307 foam slabs for the bottom of the ship are laid according to the layup design. The layup sequence is the same as that for the 306 foam slabs for the longitudinal girder. The total thickness of the slabs is 15mm, with a 200mm flange. After the layup is completed, a vacuum injection system is installed. After vacuum injection, the slabs are cured at room temperature. The component at the location of the 307 foam slabs for the bottom of the ship is called the 307 foam slabs for the bottom of the ship.

[0076] 408. Install several side beam foams 311 spaced apart in the fore-and-aft direction on the bottom of the ship on the side away from each other of the two side bones. The side beam foams 311 are installed on the side in the left-right direction with the end away from the corresponding side bone. Lay them on each side beam foam 311 according to the layup design. After the layup is completed, install a vacuum injection system. After completion, vacuum glue injection is performed. After glue injection, it is cured at room temperature.

[0077] 409. Install side longitudinal girder foam 312208 on the side of the ship between two adjacent side strong transverse beams according to the design position, and perform hand lay-up molding on each side longitudinal girder foam 312208 according to the lay-up design.

[0078] 410. Demolding;

[0079] When installing each longitudinal foam section, structural adhesive is used to bond and fix them sequentially from bottom to top. When installing the outer panel transverse foam 304, pre-set supporting wooden blocks are used to support the outer panel transverse foam 304 before structural adhesive is used to bond and fix it.

[0080] 5. Reference Figures 25-28 The forming of the first transverse bulkhead 314 includes the following steps:

[0081] 501. According to the layup design, lay the transverse bulkhead skin 401 on the first transverse bulkhead 314 forming male mold. During the layup process, the dry cloth joints overlap by 30mm and the overlap positions need to be staggered. After the layup is completed, set up the vacuum injection system, and then vacuum inject adhesive. After the adhesive is injected, it will be cured at room temperature.

[0082] 502. Install several parallel transverse bulkhead longitudinal rib foams 402 on the upper side of the transverse bulkhead skin 401 according to the set position. Lay each transverse bulkhead longitudinal rib foam 402 separately according to the layup design. After the laying is completed, set up the vacuum injection system. After vacuum injection, the adhesive is cured at room temperature.

[0083] 503. Install high-stretcher foam 404 on the upper side of the transverse bulkhead skin 401. The high-stretcher foam 404 includes several longitudinal stapling foams 404a, and transverse stapling foams 404b are fixed on the longitudinal stapling foams 404a. The transverse stapling foams 404b are perpendicular to the longitudinal stapling foams 404a. The longitudinal stapling foams 404a are located between two corresponding adjacent transverse bulkhead longitudinal rib foams 402. The transverse stapling foams 404b intersect with the transverse bulkhead longitudinal rib foams 402. According to the layup design, the high-stretcher foams 404 are individually installed on the transverse bulkhead skin 401. During the laying process, the dry cloth joints should overlap by 30mm and the overlap positions should be staggered. After laying, the vacuum infusion system should be set up, and vacuum glue should be injected after completion. After the glue is injected, it should be cured at room temperature. 504 Demolding; 505 First, the outer contour is cut and polished according to the skin cutting line. According to the structural characteristics of the first transverse bulkhead 314, in order to be able to be assembled with the hull, the interference points on the left and right sides are divided to obtain two side transverse bulkheads 314 and a middle transverse bulkhead 314 (the left and right sides of the middle transverse bulkhead 314 can be spliced ​​together with the side transverse bulkheads 314 respectively).

[0084] 6. The forming of the second transverse bulkhead 314 is the same as that of the first transverse bulkhead 314, except that the size is different, which will not be described in detail in this application.

[0085] 7. Prepare two pre-made ballast tank platforms, several bottom flats, and two half-bulls 314;

[0086] 8. Reference Figures 1 to 8The first and second transverse bulkheads 314 are installed into the outer plate 102 respectively. (The assembly methods for the first and second transverse bulkheads 314 are the same. The installation of the first transverse bulkhead 314 will be used as an example. First, connect the two side transverse bulkheads 314 to the inner wall of the outer plate 102, and then assemble the middle transverse bulkhead 314. Specifically, first, mark the theoretical position lines of the transverse bulkheads 314 on the outer plate 102, then use a crane to lift the bulkheads 314 to the installation position, and then repair the longitudinal rib through holes on the bulkheads 314. After all through holes are repaired...) For assembly, first assemble the two transverse bulkheads 314 near the sides of the hull. Align the theoretical line surface of the transverse bulkhead 314 with the theoretical line on the outer plate 102. Check if the upper opening of the bulkhead 314 is vertical near the center. If not, adjust it to be vertical. Then, use timber to support and fix the upper opening, lower opening, and sides of the bulkhead 314. Hand lay-up the connection. After the hand lay-up of the two transverse bulkheads 314 is completed, assemble the middle transverse bulkhead 314. Align the theoretical line surface of the lower opening of the middle transverse bulkhead 314 with the theoretical line of the outer plate 102, and align the two sides with the two transverse bulkheads 314. The three transverse bulkheads 314 are then assembled. 4. After the upper openings are aligned in a straight line and positioned, they are fixed with wooden supports and then handed over to the hand lay-up process to complete the connection, thus achieving the connection between the first transverse bulkhead 314 and the outer plate 102. The first transverse bulkhead 314 and the second transverse bulkhead 314 respectively form large ballast tanks at one end of the front and rear bulkheads 314 of the outer plate 102. A flat hull plate is installed on the upper side of the hull bottom inside the large ballast tank. The ballast tank platform is then installed on the upper side of the flat hull bottom and fixed. The half-bullshoulder 314 is then installed on the upper side of the ballast tank platform, dividing the large ballast tank into two smaller ballast tanks, respectively located on the first side of the hull. Lower I-beams are fixedly connected to the upper side of the keel and the upper side of the two adjacent second side keels (at the middle of the bottom strong beam 307 in the fore-aft direction). Steel pipe supports are fixedly connected to the upper side of the lower I-beams. Upper I-beams are fixedly connected to the upper side of the side longitudinal girder 209 and the upper side of the two adjacent intermediate longitudinal girder 207 (at the middle of the intermediate strong beam 222 in the fore-aft direction). Finally, the deck 101 (with the end where the upper I-beam is located facing down) is installed on the upper end of the outer plate 102, so that the upper I-beam is aligned with the corresponding steel pipe support. The upper I-beam and the steel pipe support are fixedly connected together to realize the assembly of the compartment 100.

[0087] The resin used in the molding of the outer plate 102 is vinyl ester resin; the resin used in the deck 101, the first transverse bulkhead 314, the second transverse bulkhead 314 and their components is flame-retardant vinyl ester resin; the foam core material is PVC foam of appropriate density; the unidirectional fabric and biaxial fabric are both fiberglass fabric, and the felt is also made of fiberglass; after being laid and cured on the first intermediate transverse reinforcing foam, the second intermediate transverse reinforcing foam and the third intermediate transverse reinforcing foam, they are successively called the first intermediate transverse reinforcing rib 215, the second intermediate transverse reinforcing rib 216, and the third intermediate transverse reinforcing rib 217; the components after being laid and cured on the first side transverse reinforcing foam 213 and the second side transverse reinforcing foam 214 are respectively called the first side transverse reinforcing rib 211 and the second side transverse reinforcing rib 210; the component at the position of the longitudinal foam 218 of the deck after being laid and cured is called the longitudinal reinforcing rib 219 of the deck 101; such as Figure 8 As shown, the first and second keels in this application are collectively referred to as the bottom longitudinal skeletons; as Figure 6 As shown, the components prepared at the locations of the cured intermediate longitudinal girder foam 206 and the side longitudinal girder foam 208 are collectively referred to as the deck 101 strong longitudinal skeleton, and the components prepared at the locations of the cured intermediate strong transverse beam foam 222 and the outer plate transverse foam 304 are collectively referred to as the deck strong transverse beam.

[0088] This embodiment can produce the hull section 100 without the need for large-scale hot pressing equipment. The operation process is simple and the molding efficiency is high.

[0089] Example 2

[0090] Reference Figures 22-24 This is the second embodiment of the present invention. This embodiment provides a molding method for a composite material compartment 100, which further realizes the design of the lay-up in each process of the hull molding process and the vacuum system arrangement and glue injection method of key parts, so as to ensure the reliable molding of each component in the compartment 100.

[0091] The specific laying steps of step 301 are as follows: First, lay the first layer of felt on the upper side of the forming positive mold of deck 101. Then, perform three cycles of full-surface laying on the first layer of felt. The laying sequence for each cycle is: one layer of [45°, -45°] biaxial fabric, one layer of [0°, 90°] biaxial fabric, one layer of 0° uniaxial fabric, one layer of [90°, 0°] biaxial fabric, one layer of [-45°, 45°] biaxial fabric, and one layer of [0°, 90°] biaxial fabric. Next, lay the second layer of felt. Then, perform two cycles of full-surface laying on the second layer of felt. The laying sequence for each cycle is: one layer of [45°, -45°] biaxial fabric, one layer of […]. The first layer consists of a biaxial fabric with angles of 0° and 90°, a uniaxial fabric with angles of 0°, a biaxial fabric with angles of 90° and 0°, and a biaxial fabric with angles of -45° and 45°, with a total thickness of 12mm. Step 302 involves laying the fabric in three cycles, building upon step 301. Each cycle consists of a biaxial fabric with angles of 45° and -45°, a biaxial fabric with angles of 0° and 90°, a uniaxial fabric with angles of 0°, a biaxial fabric with angles of 90° and 0°, and a biaxial fabric with angles of -45° and 45°, with a total thickness of 7mm. Step 304 involves laying the fabric on the connected intermediate crossbeams. Lay-up layers are applied to foam 222, intermediate longitudinal girder foam 206, and side longitudinal girder foam 208, using the same method, following an interlacing and overlapping pattern, with staggered overlaps at the joints. Step 305 involves laying up the entire surface of the deck longitudinal foam 218, first laying a layer of [45°, -45°] biaxial fabric, then performing two cycles of full-surface lay-up. The lay-up sequence for each cycle is: a layer of 0° uniaxial 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, then... First, lay a layer of biaxial fabric at [90°, 0°], a layer of biaxial fabric at [-45°, 45°], and a layer of felt. Continue laying layers on the felt, in the following order: a layer of biaxial fabric at [45°, -45°], a layer of biaxial fabric at [0°, 90°], a layer of uniaxial fabric at 0°, a layer of biaxial fabric at [90°, 0°], a layer of biaxial fabric at [-45°, 45°], a layer of biaxial fabric at [45°, -45°], a layer of biaxial fabric at [0°, 90°], a layer of uniaxial fabric at 0°, and a layer of biaxial fabric at [-45°, 45°]. Finally, lay another layer of felt, for a total thickness of 11mm.

[0092] During the above layering process, a right-handed coordinate system is defined, with the length direction of the longitudinal strut foam as 0° and the horizontal direction perpendicular to the length direction of the longitudinal strut foam as 90°.

[0093] The laying steps in step 401 are as follows: the upper part of the inner wall of the left and right ends of the female mold 313 is designated as Zone I; the central recessed area at the bottom of the female mold 313 is designated as Zone III; the area of ​​the inner wall of the female mold 313 between Zone I and Zone III is designated as Zone II; the area of ​​the inner wall of the front and rear ends of the female mold 313 corresponds to the bulkhead 314 of the outer plate 102. Two cycles of laying are performed within the female mold 313. The laying process for each cycle is as follows: first, the first layer of felt is laid as a whole; then, a first full-surface layer is laid on top of the first layer of felt. The first full-surface layer sequence is: one layer of biaxial fabric at [45°, -45°], one layer of biaxial fabric at [0°, 90°], one layer of unidirectional fabric at 0°, one layer of biaxial fabric at [90°, 0°], and one layer of biaxial fabric at [-45°, 45°]. A first separate layer is then laid at the location of Zone III. The sequence is as follows: one layer of biaxial fabric at [45°, -45°], one layer of biaxial fabric at [0°, 90°], one layer of unidirectional fabric at 0°, one layer of biaxial fabric at [90°, 0°], one layer of biaxial fabric at [-45°, 45°], and one layer of felt. Based on two cycles of application, a first separate application is performed at locations 314, Zone II, and Zone III of bulkhead. The first separate application sequence is as follows: one layer of biaxial fabric at [45°, -45°], one layer of biaxial fabric at [0°, 90°], one layer of unidirectional fabric at 0°, one layer of biaxial fabric at [90°, 0°], and one layer of biaxial fabric at [-45°, 45°]. This is applied to bulkheads 314 and I... Continue laying the fabric in Zone II, following the sequence of layers: one layer of [45°, -45°] biaxial fabric, one layer of [0°, 90°] biaxial fabric, one layer of 0° uniaxial fabric, one layer of [90°, 0°] biaxial fabric, and one layer of [-45°, 45°] biaxial fabric for a second full-surface layup. On top of this second full-surface layup, lay a layer of felt. Then, lay a second separate layer of felt at locations 314, Zone II, and Zone III. The second separate layer follows the same laying sequence as the first separate layer. Then, perform a third full-surface layup. The sequence of each full-surface layup is the same. Based on the third full-surface layup, in Zones I, II, and III... The fourth full-surface layup is then performed at the location. This fourth full-surface layup consists of two cycles. The layup sequence for each cycle is as follows: one layer of biaxial fabric at [45°, -45°], one layer of biaxial fabric at [0°, 90°], one layer of unidirectional fabric at 0°, one layer of biaxial fabric at [90°, 0°], one layer of biaxial fabric at [-45°, 45°], one layer of biaxial fabric at [45°, -45°], one layer of biaxial fabric at [0°, 90°], one layer of unidirectional fabric at 0°, one layer of biaxial fabric at [90°, 0°], and one layer of biaxial fabric at [-45°, 45°]. A layer of felt is also laid between the two cycles. The layup is interspersed at the four locations, and the layup is completed simultaneously.After the layup was completed, the skin thickness in Zone III was 28 mm, in Zone II it was 18 mm, in Zone I it was 13 mm, and the layup thickness of the floor plate 202 at bulkhead 314 was 22 mm.

[0094] Since the outer panel 102 is 5mm high, the dry fiber fabric laid on the large facade is prone to falling off and slipping. When laying the entire layer, the dry cloth needs to be extended to the back of the mold. The tension of the dry cloth itself is used to counteract its weight. When using the facade, more 3M setting agent needs to be sprayed. When using, it is necessary to spray a large area 1 meter away from the product. It is not allowed to spray the same area repeatedly. This method can ensure the surface quality.

[0095] When laying the layers, when transitioning from Zone II to Zone I, place strong hooks and magnets at multiple points in the transition area to assist in fixing the layers. When laying the layers in subsequent layers, remove the magnets one by one and lay the dry cloth.

[0096] During the layering process, overlapping is used, and the overlapping joints are staggered to ensure product strength. Each layer is pressed together with a rolling pin to ensure the fabric is flat and free of obvious wrinkles.

[0097] The specific process of arranging a vacuum system is as follows:

[0098] On the outer panel 102 skin, the peeling cloth, the flow guide net, the glue injection pipe, and the breathable felt are laid in sequence. Based on vacuum induction experience, the peeling cloth should cover the entire surface of the product and be flat and wrinkle-free. The flow guide net and the flow guide spiral pipe are laid according to the designed glue injection direction. A speed bump is set on the skin surface of one of the chamber walls 314 to ensure that all glue injection is completed at the same time and to prevent the situation where the lower surface has been glued while the higher surface has not been glued.

[0099] Lay out the vacuum induction auxiliary materials according to the above requirements and fix them with masking tape to complete the vacuum bag production. To prevent the vacuum bag from leaking, make a double-layer sealed vacuum bag. After the first layer of vacuum bag is sealed, check the vacuum degree. It is required that the vacuum degree exceeds -0.09MPa when vacuuming, and the pressure drop does not exceed 0.01MPa after holding the pressure for 10 minutes. After the vacuum degree meets the requirements, seal the second layer of vacuum bag. The vacuum pump system must ensure that the vacuum degree reaches above -0.09MPa for 1 hour before vacuum induction glue injection can be prepared. To prevent resin from flowing into the vacuum pump, a buffer tank must be connected between the glue outlet and the vacuum pump.

[0100] When injecting adhesive, start from the middle of the hull bottom and introduce it to both sides. When it reaches the side chord, simultaneously open the adhesive injection ports on the bow and stern panels and inject adhesive upwards in a sloping manner (see reference). Figure 23 ).

[0101] After the adhesive is injected, it is cured at room temperature. After it has basically hardened, a heating blanket is used to fully heat it to make it completely cured, or it is left to stand for 48 hours before demolding.

[0102] After unpacking and demolding, use calipers or height gauges to check and record the thickness at multiple points. Visually inspect the skin surface for any obvious defects, and use a Barcol hardness tester to perform multiple tests. If the Barcol hardness reaches 40 or above, proceed to the next step.

[0103] The laying steps in step 402 are as follows: based on step 401, a full-surface lay-up is performed. First, two cycles of full-surface lay-up are performed. The lay-up sequence in each cycle is as follows: one layer of biaxial fabric at [45°, -45°], one layer of biaxial fabric at [90°, 0°], one layer of uniaxial fabric at 0°, one layer of biaxial fabric at [90°, 0°], and one layer of biaxial fabric at [-45°, 45°]. After the two cycles of full-surface lay-up are completed, a layer of felt is laid, and then two more cycles of full-surface lay-up are performed on the felt. Finally, another layer of felt is laid. The thickness of the skin after the lay-up is 9mm.

[0104] The laying steps in step 403 are as follows: each of the first longitudinal foams 302 on the bottom plate 202 of the bulkhead 314 is individually laid out. The laying sequence is as follows: two cycles of full-surface laying are performed. The full-surface laying sequence of each cycle is as follows: one layer of biaxial fabric at [45°, -45°], one layer of biaxial fabric at [90°, 0°], one layer of uniaxial fabric at 0°, one layer of biaxial fabric at [90°, 0°], and one layer of biaxial fabric at [-45°, 45°]. After the two cycles of full-surface laying are completed, a layer of felt is laid out, and two more cycles of full-surface laying are performed on the felt. Finally, another layer of felt is laid out. The thickness of the skin after the laying is 9 mm, and the flange is 100 mm.

[0105] Step 404 involves laying layers on various types of foam, with the dry fabric being laid in a continuous, alternating cross-lay pattern of transverse and longitudinal fibers. Specifically, first, a layer of [45°, -45°] biaxial fabric is laid. Then, two cycles of full-surface laying are performed on this foundation. The laying sequence for each cycle is as follows: a layer of 0° uniaxial 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. Then, a layer of [90°, 0°] biaxial fabric and a layer of [-45°, 45°] biaxial fabric are laid sequentially. A layer of biaxial fabric with angles of 5° and 45° and a layer of felt are laid on top of the felt. The laying sequence is as follows: a layer of biaxial fabric with angles of 45° and -45°, a layer of biaxial fabric with angles of 0° and 90°, a layer of uniaxial fabric with angles of 0°, a layer of biaxial fabric with angles of 90° and 0°, a layer of biaxial fabric with angles of -45° and 45°, a layer of biaxial fabric with angles of 45° and -45°, a layer of biaxial fabric with angles of 0° and 90°, a layer of uniaxial fabric with angles of 0° and a layer of biaxial fabric with angles of 0° and 45°, and finally a layer of felt is laid. The layer thickness is 11 mm.

[0106] In steps 403 and 404, when laying the vertical layers, each layer of fabric needs to be fixed to ensure that the fabric does not slip. Use a 5mm long drill bit to make holes for the wiring at the top, middle and tail of the wall material. After laying one layer, prepare to insert a silver needle with a single fiber, surround the wiring hole, and sew the fabric to the foam. Use 3M spray adhesive to fix the edge. Repeat this step to lay the fabric for all the wall material cap-shaped ribs (each vertical foam is a wall material).

[0107] Step 405 involves laying individual layers on the foam 306 of each longitudinal girder at the bottom of the ship. Specifically, two cycles of individual layer laying are performed, with the following sequence for each cycle: a layer of biaxial fabric at [45°, -45°], a layer of biaxial fabric at [0°, 90°], a layer of uniaxial fabric at 0°, a layer of biaxial fabric at [90°, 0°], and a layer of biaxial fabric at [-45°, 45°]. After the two cycles of individual layer laying are completed, the first layer of felt is laid, followed by two more cycles of layer laying, then the second layer of felt, and finally another layer of felt. The total thickness of the layer is 15mm, with a 200mm gusset.

[0108] The layup steps in step 406 are as follows: individual full-surface layup is performed on each of the longitudinal girder foam 306 at the bottom of the ship. Two cycles of individual full-surface layup are performed first. The layup sequence of each cycle is as follows: one layer of biaxial fabric at [45°, -45°], one layer of biaxial fabric at [0°, 90°], one layer of uniaxial fabric at 0°, one layer of biaxial fabric at [90°, 0°], and one layer of biaxial fabric at [-45°, 45°]. After the two cycles of individual full-surface layup are completed, the first layer of felt is laid. Two more cycles of full-surface layup are performed on the first layer of felt. The second layer of felt is laid. Two more cycles of full-surface layup are performed on the second layer of felt. Finally, one more layer of felt is laid. The total thickness of the layup is 15mm, with a 200mm flange.

[0109] The layup steps in step 408 are as follows: individual full-surface layup is performed on each side strong beam foam 311 of the ship's side. Specifically, two cycles of individual full-surface layup are performed first. The layup sequence of each cycle is as follows: one layer of biaxial fabric at [45°, -45°], one layer of biaxial fabric at [0°, 90°], one layer of uniaxial fabric at 0°, one layer of biaxial fabric at [90°, 0°], and one layer of biaxial fabric at [-45°, 45°]. After the two cycles of individual full-surface layup are completed, the first layer of felt is laid. Two more cycles of full-surface layup are performed on the first layer of felt, followed by the second layer of felt. Two more cycles of full-surface layup are performed on the second layer of felt, and finally, one more layer of felt is laid. The total thickness of the layup is 15mm, with a 200mm flange.

[0110] During the above layering process, a right-handed coordinate system is defined, with the length direction of the longitudinal foam for positioning the bottom of the ship as 0° and the horizontal direction perpendicular to the length direction of the longitudinal foam for positioning the bottom of the ship as 90°.

[0111] The layup steps in step 501 are as follows: a layer of felt is laid on the upper surface of the flat plate, and two cycles of full-surface layup are performed on the felt. The layup sequence of each cycle is as follows: a layer of biaxial fabric at [45°, -45°], a layer of biaxial fabric at [0°, 90°], a layer of uniaxial fabric at 0°, a layer of biaxial fabric at [90°, 0°], and a layer of biaxial fabric at [-45°, 45°]. After the two cycles of full-surface layup are completed, a layer of felt is laid, and then four cycles of full-surface layup are performed on the felt. After the four cycles of full-surface layup are completed, a layer of felt is laid, and then two more cycles of full-surface layup are performed. The total layup thickness is 19 mm.

[0112] After laying all the fabric sheets, lay the release fabric on the surface of the top layer of fabric, place the flow guide net on the surface of the release fabric (note the direction of the flow guide net), place the corrugated pipe on the surface of the flow guide net, place the glue injection port in the appropriate position, and finally lay the vacuum bag, seal the vacuum bag to the mold, and connect the glue injection port and the glue outlet to the vacuum pump system.

[0113] Connect the vacuum system and check for leaks, blockages, or other issues with the vacuum bag system.

[0114] Prepare the resin according to the theoretical weight of the part, leaving an appropriate margin, and record the resin preparation time, weight, and state.

[0115] Ensure the resin is free of air bubbles before starting the injection process. Strictly follow the process specifications to ensure the resin penetrates all areas of the part. Turn off the injection system and begin the curing process. Use room temperature curing. After it has basically hardened, use a heating blanket to fully heat it until it is completely cured.

[0116] The layup steps in step 502 are as follows: according to the dimensions of each transverse bulkhead longitudinal rib foam 402, cut the sheet and lay it up in two cycles on the transverse bulkhead longitudinal rib foam 402 on the upper side of the transverse bulkhead skin 401. The layup sequence of each cycle is as follows: one layer of biaxial fabric at [45°, -45°], one layer of biaxial fabric at [90°, 0°], one layer of uniaxial fabric at 0°, one layer of biaxial fabric at [90°, 0°], and one layer of biaxial fabric at [-45°, 45°]. After the two cycles of full-surface layup are completed, a layer of felt is laid up, and two more cycles of layup are performed on the felt. Finally, another layer of felt is laid up. The thickness of the skin after the layup is completed is 9 mm.

[0117] For vacuum injection and curing, a separate vacuum system needs to be made and the adhesive is injected from top to bottom. The small edge buttresses can be vacuum injected together with the adjacent large buttresses. After the vacuum bag system is completed, vacuum injection work is carried out in sequence. After the adhesive is injected, room temperature curing is also used. After it has basically hardened, a heating blanket is used to fully heat up the temperature to ensure that it is completely cured (the part that is laid on the longitudinal foam 402 of the transverse bulkhead and cured is called the longitudinal foam 403 of the transverse bulkhead). After curing, visual inspection, thickness measurement, spacing measurement of the skeletons and hardness testing are carried out.

[0118] Step 503 involves the following layup steps: First, lay a layer of biaxial fabric at [45°, -45°]. Then, perform two cycles of full-surface layup. The layup sequence for each cycle is as follows: one layer of 0° uniaxial fabric, one layer of [90°, 0°] biaxial fabric, one layer of [-45°, 45°] biaxial fabric, one layer of [45°, -45°] biaxial fabric, and one layer of [0°, 90°] biaxial fabric. Next, lay a layer of [90°, 0°] biaxial fabric, one layer of [-45°, 45°] biaxial fabric, and one layer of felt. Continue laying on top of the felt. The entire surface is laid out in the following order: one layer of biaxial fabric at [45°, -45°], one layer of biaxial fabric at [0°, 90°], one layer of unidirectional fabric at 0°, one layer of biaxial fabric at [90°, 0°], one layer of biaxial fabric at [-45°, 45°], one layer of biaxial fabric at [45°, -45°], one layer of biaxial fabric at [0°, 90°], one layer of unidirectional fabric at 0°, and one layer of biaxial fabric at [-45°, 45°]. Finally, a layer of felt is laid, with a total thickness of 11mm and a 150mm folded edge. When laying the fabric, the horizontal and vertical fibers should be laid continuously and crosswise, and the rounded corners should be rolled firmly without any gaps.

[0119] During the above layup process, a right-handed coordinate system is defined, with the length direction of the transverse bulkhead longitudinal rib foam 402 as 0° and the horizontal direction perpendicular to the length direction of the transverse bulkhead longitudinal rib foam 402 as 90°. Based on the characteristics of the transverse and longitudinal layup, this support wall material now requires the overall arrangement of vacuum induction auxiliary materials to create a vacuum system. The glue inlet is also placed in the center of the cap-shaped rib panel, and the glue outlet spiral tube needs to be continuously laid in an S-shape around the longitudinal and transverse support wall materials. After the vacuum bag is made, vacuum induction is performed and it is cured at room temperature (the component laid and cured on the high support wall foam 404 is called the high support wall cap-shaped rib 405). After curing, visual inspection, thickness measurement, rib spacing measurement, and hardness testing are performed. After the first transverse bulkhead 314 is completely cured, the auxiliary material is peeled off, and the product is flipped over to facilitate cutting and grinding according to the cutting lines. First, the outer contour is cut and ground according to the skin cutting lines. Based on the structural characteristics of the first and second transverse bulkheads 314, in order to assemble with the hull, the interference points on both sides need to be divided. The arrangement of the vacuum system and the dispensing of adhesive, which are not mentioned in this application, can be achieved using conventional techniques and are not improvements of this application.

[0120] Through the two embodiments in this application, the strength requirements are met while also ensuring dimensional accuracy and appearance requirements, and the overall preparation of the ship cabin is completed with high quality and high efficiency. It does not require the use of large equipment for molding, is simple to operate, and has low preparation cost.

Claims

1. A method for molding a composite material compartment, characterized in that: Includes the following steps, 1. Raw material preparation; 2. Mold preparation; 3. Deck forming; 4. Forming of outer panels; 5. Forming of the first transverse bulkhead; 6. Forming of the second transverse bulkhead; 7. Prepare two ballast tank platforms, several bottom flats, and two half-bulls; 8. Install the first and second transverse bulkheads into the outer plating respectively. The first and second transverse bulkheads form large ballast tanks at the ends of the front and rear bulkheads of the outer plating respectively. Install the bottom plate on the upper side of the bottom of the large ballast tanks respectively. Install the ballast tank platform on the upper side of the bottom plate and fix it. Then install the half bulkhead on the upper side of the ballast tank platform to divide the large ballast tank into two smaller ballast tanks. Finally, install the deck on the upper part of the outer plating. Step 3 specifically includes the following steps:

301. Lay the base plate on the deck forming positive mold according to the layup design. After the layup is completed, set up the vacuum injection system, and then vacuum inject adhesive. After the adhesive is injected, cure at room temperature.

302. Install several deck positioning longitudinal foams on the cured base plate. After the deck positioning longitudinal foams are fixed, lay up the entire surface of the base plate and deck positioning longitudinal foams according to the layup design. After the laying is completed, set up the vacuum injection system. After completion, vacuum injection is performed. After the injection is completed, the foam is cured at room temperature.

303. Install longitudinal girder foam according to the designed position. Install several intermediate strong crossbeam foams spaced apart in the front and back directions at the center position of the base plate. Install intermediate longitudinal girder foams on the upper side of the base plate on both sides of the intermediate strong crossbeam foams. Install side longitudinal girder foams on the base plate to the left of the left intermediate longitudinal girder foam and on the base plate to the right of the right intermediate longitudinal girder foam. Install transverse foams on the left side of the left intermediate longitudinal girder foam, the right side of the right intermediate longitudinal girder foam, and on the base plates on both sides of the side longitudinal girder foams.

304. According to the layup design, lay the foam on the middle longitudinal girder foam, the middle strong crossbeam foam and the side longitudinal girder foam respectively, set up the vacuum inlet system, and then perform vacuum injection. After the injection is completed, it will be cured at room temperature.

305. Install the longitudinal foam of the deck on the base plate between two adjacent transverse foams, lay it on the longitudinal foam of the deck according to the layup design, set up the vacuum inlet system, and then perform vacuum injection. After the injection is completed, it will be cured at room temperature.

306. Demolding.

2. The molding method for the composite material compartment as described in claim 1, characterized in that: Step 4 specifically includes the following steps:

401. Lay the outer panel skin in the negative mold according to the layup design. After the layup is completed, set up the vacuum injection system and vacuum inject adhesive. After the adhesive is injected, cure at room temperature.

402. Install several bottom positioning longitudinal foams on the bottom and sides of the cured outer skin. Lay the bottom positioning longitudinal foams on the sides and bottom of the ship according to the layup design. During the layup process, the fabric joints need to overlap and the overlapping positions need to be staggered. After the layup is completed, set up the vacuum injection system. After completion, vacuum glue injection is performed. After the glue injection is completed, it is cured at room temperature.

403. Install the first longitudinal foam vertically on the outer skin bulkhead according to the designed position. According to the layup design, lay each first longitudinal foam individually, set up the vacuum inlet system, and then perform vacuum injection. After the injection is completed, cure at room temperature.

404. Install vertically arranged second and third longitudinal foams with a thickness greater than the first longitudinal foam and horizontally arranged outer plate transverse foam on the bulkhead between the longitudinal foams at the designated positions. The thickness of the second and third longitudinal foams and the outer plate transverse foam are the same, and the width of the second longitudinal foam is greater than the width of the third longitudinal foam. The outer plate transverse foam and various longitudinal foams intersect. According to the layup design, the entire structure is laid on the second and third longitudinal foams and the outer plate transverse foam. During the layup, the dry cloth should be laid in a continuous and cross-laid manner with alternating longitudinal and transverse fibers. After the layup is completed, a vacuum induction system is set up. After completion, vacuum glue injection is performed. After glue injection, it is cured at room temperature.

405. Install several longitudinal girder foams at the designated positions on the bottom of the ship. Lay them individually on each longitudinal girder foam according to the layup design. After the layup is completed, install a vacuum injection system. After vacuum injection, the foam will cure at room temperature.

406. Install intermediate hardwood embedded parts on the bottom of the ship between the two longitudinal girder foams. Install several intermediate crossbeam foams spaced apart in the forward and backward directions on the bottom of the ship on both sides of the intermediate hardwood embedded parts. Install two first side keel foams stacked together in the height direction on the bottom of the ship on both sides of the intermediate hardwood embedded parts. The stacked first side keel foams are connected by side keel precast plates. Use the surface of the lower side keel foam as the mold surface for hand lay-up. First, position, install and fix the lower side keel foam. First, cut a blanking template that is exactly the size to cover the shape. Cut 4 layers of four-axis fabric according to the template. The hand lay-up resin and curing agent are mixed in a ratio of 1000:(3~5) for 2k g. During hand lay-up, use a wool roller to soak the dry cloth with resin and spread it evenly. If air bubbles or wrinkles appear between layers, use a threaded roller to compact them. After hand lay-up, check the surface quality. If there is insufficient glue, add an appropriate amount of glue. After the hand lay-up has cured, cut and sand the excess fabric along the edge of the foam. Sand the raised parts of the surface smooth to facilitate subsequent foam installation. The middle crossbeam foam is between two first side keel foams that are spaced apart in the left and right directions. The two bottom longitudinal girder foams are respectively installed with side hardwood embedded parts on the bottom of the boat 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 that are stacked together in the height direction and connected to the bottom of the boat. Metal embedded parts are connected to the set positions of the first side keel foam and the second side keel foam.

407. According to the layup design, complete the individual full-surface laying on the connected intermediate crossbeam foam, the first side keel foam and the intermediate hardwood embedded part, the connected side hardwood embedded part and the second side keel foam respectively. After the layup is completed, install the vacuum injection system, and then perform vacuum injection. After the injection is completed, cure at room temperature.

408. Install several side beam foams spaced apart in the fore-and-aft direction on the bottom of the ship on the side away from each other of the two side bones. The side beam foams are installed on the side of the ship with the end away from the corresponding side bone in the left-right direction. Lay them on each side beam foam according to the layup design. After the layup is completed, install a vacuum injection system. After completion, vacuum injection is performed. After injection, the foam is cured at room temperature.

409. Install side longitudinal girder foam on the side of the ship between two adjacent side strong transverse beams according to the design position, and perform hand lay-up molding on each side longitudinal girder foam according to the lay-up design; 410. Demolding; When installing each longitudinal foam section, structural adhesive is used to bond and fix them sequentially from bottom to top. When installing the transverse foam of the outer panel, pre-set supporting wooden blocks are used to support the transverse foam of the outer panel before structural adhesive is used to bond and fix it.

3. The molding method for the composite material compartment as described in claim 1, characterized in that: The molding methods for steps 5 and 6 are the same. Step 5 specifically includes the following steps:

501. Lay the transverse bulkhead skin on the first transverse bulkhead forming positive mold according to the layup design. During the layup process, the dry cloth joints overlap by 30mm and the overlap positions need to be staggered. After the layup is completed, set up the vacuum injection system and vacuum injection. After the injection is completed, the sealant will be cured at room temperature.

502. Install several parallel transverse bulkhead longitudinal rib foams on the upper side of the transverse bulkhead skin according to the set position. Lay each transverse bulkhead longitudinal rib foam separately according to the layup design. After the laying is completed, set up the vacuum inlet system. After vacuum injection, the adhesive is cured at room temperature after the adhesive injection is completed.

503. Install high-stretcher foam on the upper side of the transverse bulkhead skin. The high-stretcher foam includes several longitudinal stapling foams. Transverse stapling foams are fixed on the several longitudinal stapling foams. The transverse stapling foams are perpendicular to the longitudinal stapling foams. The longitudinal stapling foams are placed between the corresponding two adjacent transverse bulkhead longitudinal rib foams. The transverse stapling foams intersect with the transverse bulkhead longitudinal rib foams. According to the layup design, the high-stretcher foams are laid separately on the transverse bulkhead skin. During the layup process, the dry fabric joints overlap by 30mm and the overlap positions need to be staggered. After the layup is completed, set up the vacuum injection system. After completion, vacuum injection is performed. After the injection is completed, the foam is cured at room temperature.

504. Demolding; 505. First, the outer contour is cut and polished according to the skin cutting line. Based on the structural characteristics of the first transverse bulkhead, the interference points on the left and right sides are divided separately in order to be able to be assembled with the hull.

4. The molding method for the composite material compartment as described in claim 1, characterized in that: The laying steps in step 301 are as follows: First, lay the first layer of felt on the upper side of the deck forming male mold. Then, perform three cycles of full-surface laying on the first layer of felt. The laying sequence for each cycle is: one layer of [45°, -45°] biaxial fabric, one layer of [0°, 90°] biaxial fabric, one layer of 0° uniaxial fabric, one layer of [90°, 0°] biaxial fabric, one layer of [-45°, 45°] biaxial fabric, and one layer of [0°, 90°] biaxial fabric. Next, lay the second layer of felt. Then, perform two cycles of full-surface laying on the second layer of felt. The laying sequence for each cycle is: one layer of [45°, -45°] biaxial fabric, one layer of [0°...] biaxial fabric... The first step involves laying a biaxial fabric at [90°, 0°], a uniaxial fabric at 0°, a biaxial fabric at [90°, 0°], and a biaxial fabric at [-45°, 45°], with a total thickness of 12mm. Step 302 involves laying the fabric in three cycles, building upon step 301. Each cycle consists of a biaxial fabric at [45°, -45°], a biaxial fabric at [0°, 90°], a uniaxial fabric at 0°, a biaxial fabric at [90°, 0°], and a biaxial fabric at [-45°, 45°], with a total thickness of 7mm. In step 304, the layers are laid in the middle of the connected sections... Lay-up layers are applied to the strong crossbeam foam, the intermediate longitudinal girder foam, and the side longitudinal girder foam, using the same lay-up method. The layers are interleaved and overlapped, with staggered overlaps at the joints. Step 305 involves laying a full-surface layer on the longitudinal deck foam. First, lay a layer of biaxial fabric at [45°, -45°]. Then, perform two cycles of full-surface lay-up. The lay-up sequence for each cycle is: one layer of 0° uniaxial fabric, one layer of [90°, 0°] biaxial fabric, one layer of [-45°, 45°] biaxial fabric, one layer of [45°, -45°] biaxial fabric, and one layer of [0°, 90°] biaxial fabric. Then, lay another layer of... A layer of biaxial fabric with [90°, 0°], a layer of biaxial fabric with [-45°, 45°], and a layer of felt are laid on top of the felt. The laying sequence is as follows: a layer of biaxial fabric with [45°, -45°], a layer of biaxial fabric with [0°, 90°], a layer of unidirectional fabric with 0°, a layer of biaxial fabric with [90°, 0°], a layer of biaxial fabric with [-45°, 45°], a layer of biaxial fabric with [45°, -45°], a layer of biaxial fabric with [0°, 90°], a layer of unidirectional fabric with 0°, and a layer of biaxial fabric with [-45°, 45°]. Finally, a layer of felt is laid, with a total thickness of 11mm.

5. The molding method for the composite material compartment as described in claim 2, characterized in that: The laying steps in step 401 are as follows: the upper part of the inner wall of the left and right ends of the female mold is designated as Zone I; the central recessed area at the bottom of the female mold is designated as Zone III; the area of ​​the inner wall of the female mold between Zone I and Zone III is designated as Zone II; the area of ​​the inner wall of the front and rear ends of the female mold corresponds to the bulkhead of the outer plate. Two cycles of laying are performed within the female mold. The laying process for each cycle is as follows: first, the first layer of felt is laid as a whole; then, a first full-surface lay-up is performed on top of the first layer of felt. The first full-surface lay-up sequence is: one layer of biaxial fabric at [45°, -45°], one layer of biaxial fabric at [0°, 90°], one layer of unidirectional fabric at 0°, one layer of biaxial fabric at [90°, 0°], and one layer of biaxial fabric at [-45°, 45°]. A first separate lay-up is performed at the location of Zone III, with the first separate lay-up sequence being: one layer of biaxial fabric at [45°, -45°]. The process involves: one layer of [0°, 90°] biaxial fabric, one layer of 0° uniaxial fabric, one layer of [90°, 0°] biaxial fabric, one layer of [-45°, 45°] biaxial fabric, and one layer of felt. Following two cycles of application, a first separate application is performed on the bulkhead, in Zone II, and Zone III. The first separate application sequence is: one layer of [45°, -45°] biaxial fabric, one layer of [0°, 90°] biaxial fabric, one layer of 0° uniaxial fabric, one layer of [90°, 0°] biaxial fabric, and one layer of [-45°, 45°] biaxial fabric. This process continues on the bulkhead and in Zone III, with the layer sequence being: one layer of [45°, -45°] biaxial fabric... A second full-surface layup is performed using one layer of [0°, 90°] biaxial fabric, one layer of 0° uniaxial fabric, one layer of [90°, 0°] biaxial fabric, and one layer of [-45°, 45°] biaxial fabric. A layer of felt is then laid on top of this second full-surface layup. A second separate layup is performed at the bulkhead, Zone II, and Zone III locations, following the same layup sequence as the first separate layup. A third full-surface layup is then performed. The sequence of each full-surface layup is the same. Based on the third full-surface layup, a fourth full-surface layup is performed at Zone I, Zone II, and Zone III locations. This fourth full-surface layup consists of two cycles, with each cycle consisting of one layer of [45°, -45°] biaxial fabric. A layer of biaxial fabric with [0°, 90°], a layer of unidirectional fabric with 0°, a layer of biaxial fabric with [90°, 0°], a layer of biaxial fabric with [-45°, 45°], a layer of biaxial fabric with [45°, -45°], a layer of biaxial fabric with [0°, 90°], a layer of unidirectional fabric with 0°, a layer of biaxial fabric with [90°, 0°], and a layer of biaxial fabric with [-45°, 45°]. A layer of felt is also laid between two cycles of laying; the four positions are interleaved and the laying ends at the same time; after laying, 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 layer thickness at the bulkhead is 22mm.

6. The molding method for the composite material compartment as described in claim 3, characterized in that: The laying steps in step 402 are as follows: based on step 401, a full-surface lay-up is performed. First, two cycles of full-surface lay-up are performed. The lay-up sequence in each cycle is as follows: one layer of biaxial fabric at [45°, -45°], one layer of biaxial fabric at [90°, 0°], one layer of uniaxial fabric at 0°, one layer of biaxial fabric at [90°, 0°], and one layer of biaxial fabric at [-45°, 45°]. After the two cycles of full-surface lay-up are completed, a layer of felt is laid, and then two more cycles of full-surface lay-up are performed on the felt. Finally, another layer of felt is laid. The thickness of the skin after the lay-up is 9mm.

7. The molding method for the composite material compartment as described in claim 6, characterized in that: Step 403 involves laying individual layers on each of the first longitudinal foam layers of the bulkhead floor. The laying sequence is two cycles of full-surface laying, with each cycle consisting of one layer of biaxial fabric at [45°, -45°], one layer of biaxial fabric at [90°, 0°], one layer of uniaxial fabric at 0°, one layer of biaxial fabric at [90°, 0°], and one layer of biaxial fabric at [-45°, 45°]. Two cycles of full-surface laying are then performed. After the first layer is laid, a layer of felt is laid, followed by two more cycles of full-surface laying, and finally another layer of felt is laid. The final skin thickness after laying is 9mm, with a 100mm flange. The laying steps in step 404 are as follows: In step 6, layers are laid on various types of foam. During the laying process, the dry fabric is laid in a continuous, alternating pattern of horizontal and vertical fibers. Specifically, a layer of biaxial fabric at [45°, -45°] is first laid, followed by two cycles of full-surface laying. Each cycle of laying... The layering sequence is as follows: one layer of 0° uniaxial fabric, one layer of [90°, 0°] biaxial fabric, one layer of [-45°, 45°] biaxial fabric, one layer of [45°, -45°] biaxial fabric, and one layer of [0°, 90°] biaxial fabric. Then, one layer of [90°, 0°] biaxial fabric, one layer of [-45°, 45°] biaxial fabric, and one layer of felt are laid in sequence. On the basis of the felt, the entire surface is continued to be laid, and the layering sequence is as follows: one layer of [4... The fabric consists of a biaxial fabric layer with angles of 5° and -45°, a biaxial fabric layer with angles of 0° and 90°, a uniaxial fabric layer with angles of 0°, a biaxial fabric layer with angles of 90° and 0°, a biaxial fabric layer with angles of -45° and 45°, a biaxial fabric layer with angles of 45° and -45°, a biaxial fabric layer with angles of 0° and 90°, a uniaxial fabric layer with angles of 0° and a biaxial fabric layer with angles of -45° and 45°, and finally a layer of felt. The total thickness of the layers is 11 mm.

8. The molding method for the composite material compartment as described in claim 7, characterized in that: Step 404 involves laying individual layers on the foam of each longitudinal girder of the ship's bottom. Specifically, two cycles of individual layer laying are performed, with the following sequence for each cycle: a layer of biaxial fabric at [45°, -45°], a layer of biaxial fabric at [0°, 90°], a layer of uniaxial fabric at 0°, a layer of biaxial fabric at [90°, 0°], and a layer of biaxial fabric at [-45°, 45°]. After the two cycles of individual layer laying are completed, the first layer of felt is laid, followed by two more cycles of layer laying, then the second layer of felt, and finally another layer of felt. The total thickness of the layer is 15mm, with a 200mm gusset.

9. The molding method for the composite material compartment as described in claim 8, characterized in that: Step 405 involves laying individual layers on the foam of each longitudinal girder at the bottom of the ship. Two cycles of individual layer laying are performed, with the following sequence for each cycle: a layer of biaxial fabric at [45°, -45°], a layer of biaxial fabric at [0°, 90°], a layer of uniaxial fabric at 0°, a layer of biaxial fabric at [90°, 0°], and a layer of biaxial fabric at [-45°, 45°]. After two cycles of individual layer laying, the first layer of felt is laid, followed by two more cycles of layer laying, then the second layer of felt, and finally another layer of felt. The total thickness of the layer is 15mm, with a 200mm flange.

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