Carbon fiber product forming process capable of achieving accurate forming of internal structure

Abstract

The invention discloses a carbon fiber product forming process capable of realizing accurate forming of an internal structure, which comprises the following steps: a core mold is designed according to the structure of a carbon fiber product, the core mold comprises a plastic core and an iron core, and an internal forming structure area for forming the internal structure of the carbon fiber product is designed on the iron core; assembling the iron core and the plastic core to form a core mold; wrapping the foaming core material with the carbon fiber prepreg to form an internal structure forming part, assembling the internal structure forming part on the internal forming structure area of the iron core, and wrapping and paving the carbon fiber prepreg outside a core mold; carbon fiber prepreg is laid on a mold cavity, and then the core mold is placed in a mold cavity of a forming mold; closing the mold; forming is conducted; and demolding. By means of the process, complex appearance structure forming can be achieved, the internal structure forming precision can be improved, the mold manufacturing cost can be reduced, the production cost can be reduced, the production efficiency can be improved, and the subsequent CNC machining time and the bonding time of the bonding section can be greatly shortened.

Description

Technical Field

[0001] The present invention relates to the technical field of carbon fiber products, and in particular to a carbon fiber product molding process capable of realizing precise molding of internal structures. Background Art

[0002] Carbon fiber products are composite materials made from carbon fiber prepreg through compression molding, stamping, pultrusion, injection molding, etc. Compression molding is a process in which carbon fiber prepreg is placed in a mold, and after the mold is closed, it is molded under a certain time, temperature, and pressure to prepare carbon fiber products.

[0003] At present, some carbon fiber products have a high structural complexity, and have some structures that are difficult to form. The conventional compression molding process using a hard core mold is inefficient, requires a complex mold, and has a high production cost. The conventional blow molding process using a plastic core mold cannot achieve precise positioning and molding of the internal structure, and the structure after molding cannot meet the design standards. In addition, the existing compression molding process also requires complex CNC post-processing after molding, and for products that require embedded metal parts for the internal structure, complex metal parts pasting work is also required after molding. Summary of the invention

[0004] In order to solve the above technical problems, the purpose of the present invention is to provide a carbon fiber product molding process that can achieve precise internal structure molding. The molding process uses a core mold composed of an iron core and a plastic core, and cooperates with the designed internal structure molding parts to form a carbon fiber product with a precise internal structure through a combination of blow molding and hard molding, which improves the internal structure molding accuracy, reduces production costs, improves production efficiency, and can greatly reduce the subsequent CNC processing time and the bonding time of the bonding section.

[0005] In order to achieve the above technical objectives and the above technical effects, the present invention is implemented through the following technical solutions:

[0006] A carbon fiber product molding process capable of realizing precise positioning of internal structures comprises the following steps:

[0007] (1) Designing and assembling a core mold: designing a core mold according to the structure of the carbon fiber product, the core mold comprising a plastic core and an iron core, the iron core being designed with an internal molding structure area for molding the internal structure of the carbon fiber product; assembling the iron core and the plastic core to form the core mold;

[0008] (2) Laying carbon fiber prepreg: Wrapping the designed and cut carbon fiber prepreg with the foam core material to form an internal structure molded part, assembling the internal structure molded part on the internal molding structure area of ​​the iron core, and then wrapping and paving the carbon fiber prepreg on the outside of the core mold;

[0009] (3) Mold insertion: fix the inserts required for molding in the cavity of the molding mold, then lay the carbon fiber prepreg on the cavity surface of the mold cavity, and then place the core mold wrapped with the carbon fiber prepreg in the cavity of the molding mold;

[0010] (4) Mold closing: closing the upper mold and the lower mold of the molding mold;

[0011] (5) Molding: Preheat the molding mold, and after the carbon fiber prepreg softens, start the press. After the press reaches the set molding pressure, pump air into the plastic core. After the inflation is completed, the molding mold automatically completes pressure maintenance and curing;

[0012] (6) Demolding: After curing is completed, remove the molded product from the molding mold, and then remove the core mold in the molded product.

[0013] Furthermore, the carbon fiber prepreg is formed by impregnating carbon fiber braid with a resin matrix.

[0014] Furthermore, the foam core material is PU foam core material.

[0015] Furthermore, in step (2), when metal parts need to be embedded in the internal structure of the carbon fiber product, the metal parts are placed in the foam core material in advance, and then the carbon fiber prepreg is wrapped around the foam core material to form an internal structure molded part with embedded metal parts.

[0016] Furthermore, in step (2), multiple layers of carbon fiber prepreg are laid on the outside of the core mold.

[0017] Furthermore, in step (5), the preheating temperature is 150-180°C.

[0018] Furthermore, in step (5), the set molding pressure of the press is 100-200 kg / cm 2 .

[0019] Furthermore, in step (5), the process of pumping air into the plastic core is divided into three stages.

[0020] Furthermore, in step (6), an opening is first cut in the molded product, and the core mold is removed through the opening.

[0021] The beneficial effects of the present invention are:

[0022] The molding process uses a core mold formed by an iron core and a plastic core, utilizes the plastic core in combination with blow molding to mold the main structure of the carbon fiber product, utilizes the iron core in combination with hard molding to mold the part with a complex internal structure of the carbon fiber product, and utilizes the internal structure molding parts assembled on the iron core to accurately position the internal structure of the molded carbon fiber product; in addition, when metal parts need to be embedded in the internal structure of the carbon fiber product, the metal parts can be embedded in the internal structure molding parts in advance, thereby reducing the bonding time of the subsequent bonding section; the process of the present invention can realize the molding of complex appearance structures, and can improve the molding accuracy of the internal structure, can reduce the mold manufacturing cost, reduce the production cost, improve the production efficiency, and can also greatly reduce the subsequent CNC processing time and the bonding time of the bonding section. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is a flow chart of the carbon fiber product molding process of the present invention;

[0024] Figure 2 A partial structural diagram of a carbon fiber intelligent bionic leg product according to an embodiment of the present invention;

[0025] Figure 3 A schematic structural diagram of a plastic core according to an embodiment of the present invention;

[0026] Figure 4 is a schematic structural diagram of an iron core according to an embodiment of the present invention;

[0027] Figure 5 This is a schematic diagram of the internal structure of a carbon fiber intelligent bionic leg product according to an embodiment of the present invention;

[0028] Figure 6 It is a schematic structural diagram of a forming mold according to an embodiment of the present invention. DETAILED DESCRIPTION

[0029] The technical solutions in the present invention will be described clearly and completely below in conjunction with specific embodiments. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. 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.

[0030] like Figure 1 As shown, the present invention provides a carbon fiber product molding process that can achieve precise positioning of the internal structure, comprising the following steps:

[0031] (1) Designing and assembling a core mold: designing a core mold according to the structure of the carbon fiber product, the core mold comprising a plastic core and an iron core, the iron core being designed with an internal molding structure area for molding the internal structure of the carbon fiber product; assembling the iron core and the plastic core to form the core mold;

[0032] (2) Laying carbon fiber prepreg: Wrapping the designed and cut carbon fiber prepreg with the foam core material to form an internal structure molded part, assembling the internal structure molded part on the internal molding structure area of ​​the iron core, and then wrapping and paving multiple layers of carbon fiber prepreg on the outside of the core mold;

[0033] Wherein, the carbon fiber prepreg is formed by impregnating a carbon fiber braid with a resin matrix;

[0034] The foam core material is PU foam core material;

[0035] When metal parts need to be embedded in the internal structure of the carbon fiber product, the metal parts are placed in the foam core material in advance, and then the carbon fiber prepreg is wrapped around the foam core material to form an internal structure molded part with embedded metal parts;

[0036] (3) Mold insertion: fix the inserts required for molding in the cavity of the molding mold, then lay the carbon fiber prepreg on the cavity surface of the mold cavity, and then place the core mold wrapped with the carbon fiber prepreg in the cavity of the molding mold;

[0037] (4) Mold closing: closing the upper mold and the lower mold of the molding mold;

[0038] (5) Molding: Preheat the molding mold to a temperature of 150-180°C. After the carbon fiber prepreg softens, turn on the press. After the press reaches the set molding pressure, pump air into the plastic core. After the inflation is completed, the molding mold automatically completes pressure-maintaining curing. The set molding pressure of the press is 100-200kg / cm 2 ; The process of pumping air into the plastic core is divided into three stages.

[0039] (6) Demolding: After curing is completed, the molded product is removed from the molding mold, and then the core mold in the molded product is removed. Specifically, in this step (6), an opening is first cut in the molded product, and the core mold is removed through the opening.

[0040] Example

[0041] like Figures 1 to 6 As shown, this embodiment provides a Figure 2 The molding process of the carbon fiber intelligent bionic leg product 4 shown in the figure. The intelligent bionic leg is a new type of intelligent lower limb that integrates brain-computer interface technology and artificial intelligence algorithms. When the wearer walks, the gait can be adjusted in real time according to the environment and muscle conditions to achieve a high bionic experience. As shown in the figure, the inner wall of the carbon fiber intelligent bionic leg product 4 of this embodiment has a boss structure 41, and a metal part 42 is buried in part of the boss structure 41.

[0042] The molding process of the carbon fiber intelligent bionic leg product includes the following steps:

[0043] (1) Design and assemble the core mold: Design the core mold according to the structure of the carbon fiber product, such as Figure 3 and Figure 4 As shown, the core mold includes a plastic core 1 and an iron core 2, and the iron core 1 is designed with an internal molding structure area 21 for molding the internal structure of the carbon fiber product; the iron core and the plastic core are assembled to form the core mold (specifically, the iron core 2 is assembled on the notch position 11 of the plastic core 1);

[0044] (2) Laying carbon fiber prepreg: Wrap the designed and cut carbon fiber prepreg with the foam core material to form an internal structure molded part. For the internal molded structure area 21 where metal parts need to be embedded, the foam core material is also wrapped with metal parts; the internal structure molded parts are assembled correspondingly on each internal molded structure area 21 of the iron core 2 (the step area in the figure, the step position accuracy and the horizontal and vertical dimension accuracy must be ensured during assembly), and then wrap and lay 4 layers of the designed and cut carbon fiber prepreg on the outside of the core mold;

[0045] (3) Inserting into the mold: Fix the insert 32 required for molding in the mold cavity 31 of the molding mold 3, then lay a layer of carbon fiber prepreg on the cavity surface of the molding mold, and then place the core mold wrapped with carbon fiber prepreg in the mold cavity 31 of the molding mold 3; for the insert area with complex shape, lay 2-3 layers of carbon fiber prepreg in advance to ensure the complete molding of the product appearance;

[0046] (4) Mold closing: the upper mold and the lower mold of the molding mold 3 are closed;

[0047] (5) Molding: Move the molding mold 3 to the hot table of a 200T press (table temperature 150°C), connect the air nozzle of the plastic core 1 to the air pipe of a vacuum pump, preheat the molding mold 3 for 3 minutes, ensure that the carbon fiber prepreg wrapped in the core mold of the molding mold cavity is softened, turn on the press, and use the fixed table of the upper and lower presses to compact the mold, with a molding pressure of 100kg / cm 2 After the press reaches the set pressure, the equipment pressurization is manually stopped. At this time, the plastic core is inflated in three stages. After 5 minutes of molding in the first stage, the air pressure is increased to 5 kg and maintained for 5 minutes. In the second stage, the air pressure is increased to 10 kg and maintained for 5 minutes. In the third stage, the air pressure is increased to 15 kg and maintained until the end. After the three stages of air pressure are completed, the molding mold 3 automatically completes pressure holding and curing on the hot table of the press, and the curing time is 80 minutes.

[0048] (6) Demolding: After curing is completed, the molding mold 3 is transferred to the work surface, the molding mold 3 is opened, the carbon fiber intelligent bionic leg product is taken out, and the flash at the parting line of the product is polished off with a file; an opening is cut at the desired opening position of the product, and the edge of the plastic core 1 is clamped by a vise through the opening, and the core mold can be taken out by pulling it outward with force;

[0049] The positions of the boss structures on both sides of the product after molding by the molding process of this embodiment are relatively stable, and the lateral and longitudinal dimensions between the boss structures are stable, which greatly reduces the subsequent CNC processing time. There is no need to stick metal parts in the corresponding boss structure area, which greatly shortens the bonding time of the subsequent bonding process.

[0050] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above and that the present invention can be implemented in other specific forms without departing from the spirit or essential features of the present invention. Therefore, the embodiments should be considered exemplary and non-restrictive in all respects, and the scope of the present invention is defined by the appended claims rather than the above description, and it is intended that all changes falling within the meaning and scope of the equivalent elements of the claims be included in the present invention.

[0051] In addition, it should be understood that although the present specification is described according to implementation modes, not every implementation mode contains only one independent technical solution. This description of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment may also be appropriately combined to form other implementation modes that can be understood by those skilled in the art.

Claims

1. A carbon fiber product molding process capable of realizing precise molding of internal structure, characterized in that: The steps include: (1) Designing and assembling a core mold: designing a core mold according to the structure of the carbon fiber product, the core mold comprising a plastic core and an iron core, the iron core being designed with an internal molding structure area for molding the internal structure of the carbon fiber product; assembling the iron core and the plastic core to form the core mold; (2) Laying carbon fiber prepreg: Wrapping the designed and cut carbon fiber prepreg with the foam core material to form an internal structure molded part, assembling the internal structure molded part on the internal molding structure area of ​​the iron core, and then wrapping and paving the carbon fiber prepreg on the outside of the core mold; (3) Mold insertion: fix the inserts required for molding in the cavity of the molding mold, then lay the carbon fiber prepreg on the cavity surface of the mold cavity, and then place the core mold wrapped with the carbon fiber prepreg in the cavity of the molding mold; (4) Mold closing: closing the upper mold and the lower mold of the molding mold; (5) Molding: Preheat the molding mold, and after the carbon fiber prepreg softens, start the press. After the press reaches the set molding pressure, pump air into the plastic core. After the inflation is completed, the molding mold automatically completes pressure maintenance and curing; (6) Demolding: After curing is completed, remove the molded product from the molding mold, and then remove the core mold in the molded product.

2. A carbon fiber product molding process capable of realizing precise molding of internal structure according to claim 1, characterized in that: The carbon fiber prepreg is formed by impregnating carbon fiber braids with a resin matrix.

3. A carbon fiber product molding process capable of realizing precise molding of internal structure according to claim 1, characterized in that: The foaming core material is PU foaming core material.

4. A carbon fiber product molding process capable of realizing precise molding of internal structure according to claim 1, characterized in that: In step (2), when metal parts need to be embedded in the internal structure of the carbon fiber product, the metal parts are placed in the foam core material in advance, and then the carbon fiber prepreg is wrapped around the foam core material to form an internal structure molded part with embedded metal parts.

5. A carbon fiber product molding process capable of realizing precise molding of internal structure according to claim 1, characterized in that: In step (2), multiple layers of carbon fiber prepreg are laid on the outside of the core mold.

6. A carbon fiber product molding process capable of realizing precise molding of internal structure according to claim 1, characterized in that: In step (5), the preheating temperature is 150-180°C.

7. A carbon fiber product molding process capable of realizing precise molding of internal structure according to claim 1, characterized in that: In step (5), the set molding pressure of the press is 100-200kg / cm 2 .

8. The carbon fiber product molding process capable of realizing precise molding of internal structure according to claim 1, characterized in that: In step (5), the process of pumping air into the plastic core is divided into three stages.

9. A carbon fiber product molding process capable of realizing precise molding of internal structure according to claim 1, characterized in that: In step (6), an opening is first cut in the molded product, and the core mold is removed through the opening.

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