Preparation method of all-composite mast

Abstract

The invention discloses a preparation method of an all-composite mast, which belongs to the technical field of ships and comprises the following steps: a, preparing a bottom flange; b, preparing a mast main body, and winding an inner skin on the mast main body; c, the bottom flange is assembled to the mast body, and the inner skin is pre-cured; d, the boundary dimension of the inner skin is machined, and the honeycomb core is bonded to the surface of the inner skin; e, stabilizing the honeycomb core, and winding an outer skin on the honeycomb core; f, carrying out integral curing treatment, and carrying out boundary dimension processing and finishing on the cured outer skin; and g, demolding. The bottom flange is prepared and formed by the composite material through the autoclave technology, the bottom flange is inserted into the mast body to be integrally formed, the bottom flange prepared through the technology is light in weight, high in strength, easy to machine and good in connecting performance with the mast body, the strength and stability of the connecting part are improved, and the number and complexity of connecting pieces are reduced.

Description

Technical Field

[0001] The invention relates to the technical field of ships, and in particular to a method for preparing a full-composite material mast. Background Art

[0002] The mast of a sailboat is an important component on a sailboat and an important device for propelling the sailboat. In addition, it can also be used to install signal lights, hang flags, set up telegraph antennas, support cargo booms, and hoist and unload cargo. Traditional masts are generally long round wooden poles or metal columns. As human beings further develop the ocean, our requirements for ship structures are also gradually increasing. However, the bottom flange of traditional masts is made of metal flanges or winding. Metal flanges have disadvantages such as heavy weight and poor bonding performance with composite materials. The winding flange has poor dimensional designability and needs to be cut before use. The flange end face processing performance after cutting is poor, and end face drilling is prone to defects such as stratification. After the mast is installed, the flange is prone to cracking, which cannot keep up with the development needs of ship technology. Summary of the invention

[0003] The main purpose of the present invention is to solve the above-mentioned technical problems to a certain extent, and to provide a method for preparing a full composite mast, comprising the following steps: a. Prepare the bottom flange; b. Prepare the mast body and wrap the inner skin around the mast body; c. Assemble the bottom flange to the mast body and pre-cure the inner skin; d. Process the outer dimensions of the inner skin and bond the honeycomb core to the surface of the inner skin; e. Stabilizing the honeycomb core and wrapping the outer skin around the honeycomb core; f. Overall curing treatment, and external dimension processing and trimming of the cured outer skin; g. Demoulding.

[0004] In some embodiments, the bottom flange in step a is formed by laying out the carbon fiber prepreg by splicing, wherein the splicing seams of different layers are staggered by more than 20 mm, and after the laying is completed, the flange is bagged and vacuumized, and finally cured in an autoclave; by adopting the bottom flange formed by laying out the carbon fiber prepreg, and the splicing, punching, vacuumizing and autoclave curing processes, the advantages of the bottom flange being light weight, high strength, easy processing and good connection performance with the mast winding layer are achieved.

[0005] In some embodiments, the autoclave is pressurized at 0.5 MPa during curing, and cured at 80°C for 1 hour, followed by fixing at 120°C for 4 hours. The curing process of the bottom flange ensures the stability and mechanical properties of the bottom flange structure through precise temperature and time control, as well as pressurization measures, thereby improving the reliability of the overall mast.

[0006] In some embodiments, in step b, the inner skin is immersed in the winding resin and pre-baked at 80°C for 2 hours, and then the inner skin is wrapped around the mast body by circumferential winding and spiral winding, wherein the circumferential winding and spiral winding are performed alternately, the ratio of spiral winding to circumferential winding is 3:1-5:1, the spiral winding angle is 25-35°, and the tension is reduced during the winding process, and the tension decreases by 1N for each layer of winding, and the spiral winding position at the top of the mast retreats 100-300mm for each additional layer of spiral winding. After the inner skin is wrapped, the outer diameter of the bottom of the mast body assembly position is 0.5-1mm larger than the inner diameter of the bottom flange; the inner skin winding process adopts a tension reduction method to ensure the uniformity and tightness of the winding layer, thereby improving the structural strength and dimensional accuracy of the inner skin.

[0007] In some embodiments, after grinding the inner wall of the bottom flange assembly position with 200-300 grit sandpaper in step c, the bottom flange is pushed along the top of the inner skin to a position 10-150 mm away from the bottom of the inner skin and fixed, and pre-cured at 80°C for 2 hours, and then pre-cured at 100-120°C for 4 hours, and rotated at a speed of 1-5 rpm during the curing process.

[0008] In some embodiments, in step d, the outer dimensions of the inner skin after curing are machined, and after machining, the surface is cleaned and polished, and the ring film is laid on the inner skin. After laying, the bubbles on the film are cut with a blade, and the honeycomb core is laid on the film, and the glass fiber yarn is wrapped around the surface of the honeycomb core to fix the honeycomb core.

[0009] In some embodiments, in step e, the honeycomb core is heated at 80°C for 2h and then heated at 100°C for 2h for stabilization treatment, the outer skin is immersed in the winding resin and pre-baked at 80°C for 2h, and then the outer skin is wound onto the honeycomb core by circumferential winding and spiral winding, wherein the circumferential winding and spiral winding are performed alternately, the ratio of spiral winding to circumferential winding is 3:1-5:1, the spiral winding angle is 25-35°, and the tension is reduced during the winding process, and the tension is reduced by 1N for each layer of winding, and for each additional layer of spiral winding, the spiral winding position at the top of the mast retreats 100-300mm; the heating process of the honeycomb core ensures good bonding between the honeycomb core and the inner skin, enhances the overall rigidity of the mast, and facilitates the installation of other parts. At the same time, the winding process of the outer skin also adopts a tension reduction method to ensure the uniformity and tightness of the outer skin, and improves the structural strength and dimensional accuracy of the outer skin.

[0010] In some embodiments, the winding resin in step b and step e uses E51A resin and curing agent E51B in a mass ratio of 100:50-100:100, and the resin is stirred for 10-20 minutes after the resin is prepared.

[0011] In some embodiments, in step f, the material is cured at 80°C for 0.5h, then cured at 130-150°C for 6h, and rotated at a speed of 1-5 rpm during the curing process. After the curing is completed, the outer skin is processed and trimmed, and a layer of epoxy resin is applied on its surface. Finally, the material is cured at 80°C for 0.5h, and then cured at 100°C for 1h. Through precise temperature and time control, as well as rotation measures, the overall structural stability and mechanical properties of the mast are ensured, and the reliability and service life of the mast are improved.

[0012] In some embodiments, after the product in step g returns to room temperature, the product is placed on a demolding machine, the demolding tooling is installed on the product surface, the demolding machine is started to eject the mold core, and the demolding is completed after the product returns to room temperature, thereby avoiding stress concentration and deformation caused by temperature changes and ensuring the final dimensional accuracy and appearance quality of the product.

[0013] The above technical solution provided by this application has the following advantages compared with the prior art: The bottom flange of the present invention is prepared and formed from composite materials through an autoclave process, and the bottom flange is inserted into the mast body for integral molding. The bottom flange prepared by this process is light in weight, high in strength, easy to process, and has good connection performance with the mast body, thereby improving the strength and stability of the connection part and reducing the number and complexity of the connecting parts.

[0014] The mast main body of the present invention is wound in a "layer-by-layer backward" manner, which can significantly improve the thickness uniformity of the winding layer of the tapered mast.

[0015] A honeycomb core is added in the middle of the mast body of the present invention to form an inner skin-honeycomb core-outer skin sandwich structure, which significantly improves the rigidity of the mast. At the same time, a pad can be pre-embedded at the sandwich position to facilitate the installation of other parts on the mast. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the structures shown in these drawings without paying creative work.

[0017] Figure 1 The process flow chart of the preparation method of the all-composite mast of the present invention is as follows; Figure 2 It is a structural diagram of the all-composite mast of the present invention; Figure 3 It is a structural diagram of the mast body of the present invention. DETAILED DESCRIPTION

[0018] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0019] It should be noted that if the embodiments of the present invention involve directional indications (such as up, down, left, right, front, back, etc.), the directional indications are only used to explain the relative position relationship, movement status, etc. between the components in a certain specific posture. If the specific posture changes, the directional indication will also change accordingly.

[0020] In addition, if there are descriptions involving "first", "second", etc. in the embodiments of the present invention, the descriptions of "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying their relative importance or implicitly indicating the number of technical features indicated. Therefore, the features limited to "first" and "second" may explicitly or implicitly include at least one of the features. In addition, if "and / or" or "and / or" appears in the full text, its meaning includes three parallel solutions. Taking "A and / or B" as an example, it includes solution A, solution B, or solutions that satisfy both A and B. In addition, the technical solutions between the various embodiments can be combined with each other, but it must be based on the ability of ordinary technicians in this field to implement. When the combination of technical solutions is contradictory or cannot be implemented, it should be deemed that such combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0021] like Figure 1-3 As shown, the present invention proposes a method for preparing a full composite mast, comprising the following steps: First, a bottom flange is prepared. Specifically, in this step, the bottom flange is formed by laying carbon fiber prepreg in a splicing manner, wherein the splicing seams of different layers are staggered by more than 20 mm, and after the laying is completed, the flange is bagged and vacuumized, and finally cured in an autoclave. By adopting a bottom flange formed by laying carbon fiber prepreg, as well as splicing, punching, vacuumizing and autoclave curing processes, the bottom flange has the advantages of light weight, high strength, easy processing and good connection performance with the mast winding layer.

[0022] Furthermore, during the autoclave curing process of the bottom flange, a pressure of 0.5 MPa is applied, and the bottom flange is cured at 80°C for 1 hour, and then fixed at 120°C for 4 hours. The curing process of the bottom flange ensures the stability and mechanical properties of the bottom flange structure through precise temperature and time control, as well as pressurization measures, thereby improving the reliability of the entire mast.

[0023] In this embodiment, the bottom flange is made of composite materials through an autoclave process, and the bottom flange is inserted into the mast body for integral molding. The bottom flange prepared by this process is light in weight, high in strength, easy to process, and has good connection performance with the mast body, thereby improving the strength and stability of the connection part and reducing the number and complexity of the connecting parts.

[0024] Secondly, prepare a mast body and wrap an inner skin on the mast body; in this step, the inner skin is immersed in a winding resin and pre-baked at 80°C for 2 hours, and then the inner skin is wrapped around the mast body by circumferential winding and spiral winding, wherein the circumferential winding and spiral winding are performed alternately, the ratio of spiral winding to circumferential winding is 3:1-5:1, the spiral winding angle is 25-35°, and the tension is reduced during the winding process, and the tension is reduced by 1N for each layer of winding, and the spiral winding position of the top of the mast retreats 100-300mm for each additional layer of spiral winding. After the inner skin is wrapped, the outer diameter of the bottom of the mast body assembly position is 0.5-1mm larger than the inner diameter of the bottom flange; the inner skin is wound in a tension-reducing manner to ensure the uniformity and tightness of the winding layer, thereby improving the structural strength and dimensional accuracy of the inner skin.

[0025] Then assemble the bottom flange to the mast body and pre-cure the inner skin. In this step, after polishing the inner wall of the bottom flange assembly position with 200-300 mesh sandpaper, push the bottom flange along the top of the inner skin to a position 10-150mm away from the bottom of the inner skin and fix it. Pre-cure it at 80°C for 2h, and then pre-cure it at 100-120°C for 4h, and rotate it at a speed of 1-5 rpm during the curing process.

[0026] After assembling the mast body and the bottom flange, the outer dimensions of the inner skin are processed, and the honeycomb core is bonded to the surface of the inner skin; in this step, the outer dimensions of the inner skin after curing are machined, and the surface is cleaned and polished after machining, and the ring film is laid on the inner skin. After laying, the bubbles on the film are cut with a blade, and the honeycomb core is laid on the film, and the glass fiber yarn is wrapped around the surface of the honeycomb core to fix the honeycomb core.

[0027] Subsequently, the honeycomb core is stabilized and an outer skin is wound on the honeycomb core; in this step, the honeycomb core is heated at 80°C for 2h and then at 100°C for 2h for stabilization, the outer skin is immersed in the winding resin and pre-baked at 80°C for 2h, and then the outer skin is wound on the honeycomb core by circumferential winding and spiral winding, wherein the circumferential winding and spiral winding are performed alternately, the ratio of spiral winding to circumferential winding is 3:1-5:1, the spiral winding angle is 25-35°, and the tension is reduced during the winding process, and the tension is reduced by 1N for each layer of winding, and for each additional layer of spiral winding, the spiral winding position at the top of the mast retreats 100-300mm; the heating process of the honeycomb core ensures good bonding between the honeycomb core and the inner skin, enhances the overall rigidity of the mast, and facilitates the installation of other parts. At the same time, the winding process of the outer skin also adopts a tension reduction method, which ensures the uniformity and tightness of the outer skin and improves the structural strength and dimensional accuracy of the outer skin.

[0028] In this embodiment, the mast body is wound in a "layer-by-layer backward" manner, which can significantly improve the thickness uniformity of the tapered mast winding layer, and a honeycomb core is added in the middle of the mast body to form an inner skin-honeycomb core-outer skin sandwich structure, which significantly improves the rigidity of the mast. At the same time, a pad can be pre-embedded at the sandwich position to facilitate the installation of other parts of the mast. It is worth noting that the mass ratio of E51A resin and curing agent E51B used in the winding resin of the inner skin and outer skin is 100:50-100:100, and the resin is stirred for 10-20 minutes after mixing.

[0029] Then the whole is cured, and the outer skin is processed and trimmed after curing; in step f, it is cured at 80°C for 0.5h, and then cured at 130-150°C for 6h, and rotated at a speed of 1-5 rpm during the curing process. After the curing is completed, the outer skin is processed and trimmed, and a layer of epoxy resin is brushed on its surface, and finally cured at 80°C for 0.5h, and then cured at 100°C for 1h; through precise temperature and time control, as well as rotation measures, the overall structural stability and mechanical properties of the mast are ensured, and the reliability and service life of the mast are improved.

[0030] Finally, demolding is performed; in this step, after the product returns to room temperature, the product is placed on the demolding machine, the demolding tooling is installed on the product surface, the demolding machine is started to eject the mold core, and the demolding is completed. This is performed after the product returns to room temperature, avoiding stress concentration and deformation caused by temperature changes, and ensuring the final dimensional accuracy and appearance quality of the product.

[0031] The above are only preferred embodiments of the present invention, and are not intended to limit the patent scope of the present invention. All equivalent structural changes made using the contents of the present invention's specification and drawings, or directly / indirectly applied in other related technical fields, are included in the patent protection scope of the present invention.

Claims

1. A method for preparing a fully composite mast, characterized in that: The following steps are involved: a. Prepare the bottom flange; b. Prepare the mast body and wrap the inner skin around the mast body; c. Assemble the bottom flange to the mast body and pre-cure the inner skin; d. Process the outer dimensions of the inner skin and bond the honeycomb core to the surface of the inner skin; e. Stabilizing the honeycomb core and wrapping the outer skin around the honeycomb core; f. Overall curing treatment, and external dimension processing and trimming of the cured outer skin; g. Demoulding.

2. The method for preparing a fully composite mast according to claim 1, characterized in that: In step a, the bottom flange is formed by laying the carbon fiber prepreg by splicing, wherein the splicing seams of different layers are staggered by more than 20 mm, and after the laying is completed, the prepreg is bagged and vacuumized, and finally cured in an autoclave.

3. The method for preparing a fully composite mast according to claim 2, characterized in that: The autoclave was pressurized at 0.5 MPa during curing and cured at 80°C for 1 h, followed by curing at 120°C for 4 h.

4. The method for preparing a fully composite mast according to claim 1, characterized in that: In step b, the inner skin is immersed in the winding resin and pre-baked at 80°C for 2 hours, and then the inner skin is wrapped around the mast body by circumferential winding and spiral winding, wherein the circumferential winding and spiral winding are performed alternately, the ratio of spiral winding to circumferential winding is 3:1-5:1, the spiral winding angle is 25-35°, and the tension is reduced during the winding process, and the tension decreases by 1N for each layer of winding. For each additional layer of spiral winding, the spiral winding position at the top of the mast retreats 100-300mm. After the inner skin is wrapped, the outer diameter of the bottom of the mast body assembly position is 0.5-1mm larger than the inner diameter of the bottom flange.

5. The method for preparing a fully composite mast according to claim 1, characterized in that: After grinding the inner wall of the bottom flange assembly position with 200-300 mesh sandpaper in step c, push the bottom flange along the top of the inner skin to a position 10-150 mm away from the bottom of the inner skin and fix it, and pre-cure it at 80°C for 2 hours, and then pre-cure it at 100-120°C for 4 hours, and rotate it at a speed of 1-5 rpm during the curing process.

6. The method for preparing a fully composite mast according to claim 1, characterized in that: In step d, the outer dimensions of the inner skin after curing are machined, the surface is cleaned and polished after machining, the ring film is laid on the inner skin, the bubbles on the film are cut with a blade after laying, the honeycomb core is laid on the film, and the glass fiber yarn is wrapped around the surface of the honeycomb core to fix the honeycomb core.

7. The method for preparing a fully composite mast according to claim 1, characterized in that: In step e, the honeycomb core is heated at 80°C for 2h and then at 100°C for 2h for stabilization. The outer skin is impregnated with winding resin and pre-baked at 80°C for 2h. The outer skin is then wound onto the honeycomb core by circumferential winding and spiral winding. The circumferential winding and spiral winding are performed alternately. The ratio of spiral winding to circumferential winding is 3:1-5:

1. The spiral winding angle is 25-35°. Tension is reduced during the winding process. The tension is reduced by 1N for each layer of winding. For each additional layer of spiral winding, the spiral winding position at the top of the mast retreats 100-300mm.

8. The method for preparing a fully composite mast according to claim 1, characterized in that: In step b and step e, the winding resin adopts E51A resin and curing agent E51B in a mass ratio of 100:50-100:100, and the resin is stirred for 10-20 minutes after the resin is prepared.

9. The method for preparing a fully composite mast according to claim 1, characterized in that: In step f, the material is cured at 80°C for 0.5h, and then cured at 130-150°C for 6h, and rotated at a speed of 1-5 rpm during the curing process. After the curing is completed, the outer skin is processed and trimmed, and a layer of epoxy resin is applied on the surface. Finally, the material is cured at 80°C for 0.5h, and then cured at 100°C for 1h.

10. The method for preparing a fully composite mast according to claim 1, characterized in that: In step g, after the product returns to room temperature, the product is placed on a demoulding machine, the demoulding tooling is installed on the surface of the product, and the demoulding machine is started to eject the mold core to complete the demoulding.

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