A carbon fiber product forming process capable of realizing accurate forming of internal structure

Abstract

The application discloses a carbon fiber product forming process capable of realizing accurate forming of internal structures, and comprises the following steps: designing a core mold according to the structure of a carbon fiber product, wherein the core mold comprises a plastic core and an iron core, and the iron core is provided with an internal forming structure area for forming the internal structure of the carbon fiber product; assembling the iron core and the plastic core to form the core mold; wrapping a carbon fiber prepreg around a foamed core material to form an internal structure forming piece, and assembling the internal structure forming piece on the internal forming structure area of the iron core; wrapping and laying carbon fiber prepregs outside the core mold; laying carbon fiber prepregs on a mold cavity, and then placing the core mold in the cavity of a forming mold; closing the mold; forming; and demolding. The process can realize forming of a complex appearance structure, can improve the forming precision of the internal structure, can reduce the cost of mold manufacturing and production, can improve production efficiency, and can greatly reduce the CNC processing time and the bonding time of a bonding section.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of carbon fiber product, in particular to a carbon fiber product forming process capable of realizing precise forming of internal structure. BACKGROUND

[0002] The carbon fiber product is a composite material product made of carbon fiber prepreg through molding processes such as molding forming process, stamping forming process, pultrusion forming process, injection forming process, etc. Among them, the molding forming process is a process of placing carbon fiber prepreg in a mold, closing the mold, and molding and preparing carbon fiber products under certain time, temperature and pressure.

[0003] At present, some carbon fiber products have high structural complexity, and have some structures that are not easy to form inside. The conventional molding forming process using a hard core mold has low efficiency, complex mold is required, and the production cost is high. The conventional blow molding process using a plastic core mold cannot achieve precise positioning of the internal structure, and the structure after forming cannot meet the design standard. In addition, the existing molding forming process also needs complex CNC post-processing after forming, and for products that need to pre-bury metal parts inside the structure, complex metal part pasting work is also needed after forming. SUMMARY

[0004] To solve the above technical problems, the purpose of the present application is to provide a carbon fiber product forming process capable of realizing precise forming of internal structure. The core mold formed by the cooperation of the iron core and the plastic core is used in the forming process, and the internal structure forming part is designed. The carbon fiber product with precise internal structure is formed by combining blow molding and hard molding, which improves the internal structure forming precision, reduces the production cost, improves the production efficiency, and greatly reduces the CNC processing time and the bonding time of the bonding section.

[0005] To achieve the above technical purposes and effects, the present application realizes the following technical scheme:

[0006] A carbon fiber product forming process capable of realizing precise positioning of internal structure, comprising the following steps:

[0007] (1) Design and assemble the core mold: design the core mold according to the structure of the carbon fiber product, the core mold includes a plastic core and an iron core, the iron core is designed with an internal forming structure area for forming the internal structure of the carbon fiber product; assemble the iron core and the plastic core to form the core mold;

[0008] (2) Laying and pasting carbon fiber prepreg: wrapping the foamed core material with the designed and cut 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 then wrapping and pasting the carbon fiber prepreg outside the core mold;

[0009] (3) Molding: fixing the insert required for molding in the cavity of the molding die, then laying the carbon fiber prepreg on the cavity surface of the die cavity, and then placing the core mold wrapped with the carbon fiber prepreg in the cavity of the molding die;

[0010] (4) Clamping: clamping the upper die and the lower die of the molding die;

[0011] (5) Molding: preheating the molding die, after the carbon fiber prepreg softens, opening the press, and after the press reaches the set molding pressure, inflating the plastic core, and after the inflation is completed, the molding die automatically completes the pressure holding and curing;

[0012] (6) Demolding: taking out the molded product from the molding die, and then taking out the core mold in the molded product.

[0013] Further, the carbon fiber prepreg is formed by impregnating the carbon fiber woven fabric with a resin matrix.

[0014] Further, the foamed core material is a PU foamed core material.

[0015] Further, in step (2), when a metal part needs to be embedded in the internal structure of the carbon fiber product, the metal part is placed in the foamed core material in advance, and the carbon fiber prepreg is wrapped around the foamed core material to form an internal structure molding part with the metal part embedded.

[0016] Further, in step (2), the core mold is externally wrapped with multiple layers of carbon fiber prepreg.

[0017] Further, in step (5), the preheating temperature is 150-180℃.

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

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

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

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

[0022] The molding process adopts a core mold formed by cooperation of an iron core and a plastic core, uses the plastic core to cooperate with a blowing mold to form a main structure of the carbon fiber product, uses the iron core to cooperate with a hard mold to form a part of the carbon fiber product with a complex internal structure, and uses an internal structure forming piece assembled on the iron core to accurately position and form the internal structure of the carbon fiber product; in addition, when a metal piece needs to be pre-buried in the internal structure of the carbon fiber product, the metal piece can be pre-buried in the internal structure forming piece, so that the bonding time of a subsequent bonding section can be reduced; the process of the application can realize forming of a complex appearance structure, can improve the internal structure forming precision, can reduce the mold manufacturing cost, can reduce the production cost, can improve the production efficiency, can greatly reduce the CNC processing time and the bonding time of the subsequent bonding section. BRIEF DESCRIPTION OF DRAWINGS

[0023] Figure 1 A flow chart of the carbon fiber product forming process of the application;

[0024] Figure 2 A partial structure diagram of the carbon fiber intelligent bionic leg product of the embodiment of the application;

[0025] Figure 3 A structure schematic diagram of the plastic core of the embodiment of the application;

[0026] Figure 4 A structure schematic diagram of the iron core of the embodiment of the application;

[0027] Figure 5 An internal structure partial schematic diagram of the carbon fiber intelligent bionic leg product of the embodiment of the application;

[0028] Figure 6 A structure schematic diagram of the forming mold of the embodiment of the application. DETAILED DESCRIPTION

[0029] The technical solutions in the application will be clearly and completely described below with specific embodiments. Obviously, the described embodiments are only part of the embodiments of the application, rather than all the embodiments of the application. Based on the embodiments of the application, all other embodiments obtained by those skilled in the art without creative work fall within the protection scope of the application.

[0030] As shown in Figure 1 , the application provides a carbon fiber product forming process capable of accurately positioning an internal structure, including the following steps:

[0031] (1) Design and assemble a core mold: design the core mold according to the structure of the carbon fiber product, the core mold includes a plastic core and an iron core, the iron core is designed with an internal forming structure area for forming the internal structure of the carbon fiber product; assemble the iron core and the plastic core to form the core mold;

[0032] (2) Laying carbon fiber prepreg: Wrap the foamed core material with the designed and cut carbon fiber prepreg to form an internal structure molding part. Assemble the internal structure molding part on the internal molding structure area of ​​the iron core. Then wrap and lay multiple layers of carbon fiber prepreg on the outside of the core mold.

[0033] The carbon fiber prepreg is formed by impregnating carbon fiber woven fabric with a resin matrix.

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

[0035] When metal parts need to be embedded in the internal structure of carbon fiber products, 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 make an internal structure molded part with embedded metal parts.

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

[0037] (4) Mold closing: The upper and lower molds of the forming mold are closed;

[0038] (5) Molding: Preheat the molding die to 150-180℃. After the carbon fiber prepreg softens, turn on the press. Once the press reaches the set molding pressure, pump air into the plastic core. After pumping, the molding die automatically completes pressure holding and curing. The set molding pressure of the press is 100-200 kg / cm². 2 The process of inflating the plastic core is divided into three stages.

[0039] (6) Demolding: After curing, the molded article is removed from the mold, and then the core mold in the molded article is removed. Specifically, in this step (6), an opening is first cut in the molded article, 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 is shown. 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, it can adjust its gait in real time according to the environment and muscle conditions, achieving a highly bionic experience. As shown in the figure, the inner wall of the carbon fiber intelligent bionic leg product 4 in this embodiment has a boss structure 41, and a metal part 42 is embedded in part of the boss structure 41.

[0042] The molding process of this 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, as shown in FIGS. 1 and 2, the core mold comprises a plastic core 1 and an iron core 2, the iron core 1 is designed with an internal forming structure area 21 for forming the internal structure of the carbon fiber product; assemble the iron core and the plastic core to form the core mold (specifically, the iron core 2 is assembled on the notch position 11 of the plastic core 1); Figure 3 Figure 4

[0044] (2) Lay the carbon fiber prepreg: wrap the designed and cut carbon fiber prepreg around the foamed core material to form the internal structure forming piece, for the internal forming structure area 21 that needs to be embedded with metal parts, the metal parts are also wrapped in the foamed core material; then assemble the internal structure forming piece on each internal forming structure area 21 (step area in the figure, the step position accuracy and the horizontal and vertical size accuracy need to be ensured during assembly) of the iron core 2, and then wrap and lay 4 layers of designed and cut carbon fiber prepreg on the outside of the core mold;

[0045] (3) Molding: fix the inserts 32 needed for forming in the cavity 31 of the forming mold 3, then lay 1 layer of carbon fiber prepreg on the cavity surface of the cavity of the forming mold, and then place the core mold wrapped with carbon fiber prepreg in the cavity 31 of the forming mold 3; for the area of the inserts with complex shape, 2-3 layers of carbon fiber prepreg are laid in advance to ensure the complete formation of the appearance and shape of the product;

[0046] (4) Clamping: clamp the upper mold and the lower mold of the forming mold 3;

[0047] (5) Forming: move the forming mold 3 to the hot table surface (the table surface temperature is 150°C) of the 200T press, connect the vacuum pump air pipe at the air nozzle of the plastic core 1, preheat the forming mold 3 for 3 minutes, ensure that the carbon fiber prepreg wrapped around the core mold in the cavity of the forming mold softens, then start the press, use the fixed table surface of the upper and lower press to compact the mold, the forming pressure is 100 kg / cm 2 , when the press reaches the set pressure, stop the equipment manually, at this time, start to inflate the plastic core, in three stages, the first stage is to press for 5 minutes, the air pressure is increased to 5 kg, maintained for 5 minutes, the second stage is to increase the air pressure to 10 kg, maintained for 5 minutes, the third stage is to increase the air pressure to 15 kg, maintained until the end, after the three-stage air pressure is finished, the forming mold 3 automatically completes the pressure holding and curing on the hot table surface of the press, the curing time is 80 minutes;

[0048] (6) Demolding: after the curing is completed, transfer the forming mold 3 to the working table surface, open the forming mold 3, take out the carbon fiber intelligent bionic leg product, use a file to polish off the flash at the clamping line of the product; cut an opening at the required opening position of the product, use the vise to clamp the edge position of the plastic core 1 through the opening, and pull it out forcibly to take out the core mold;

[0049] ​​The position of the boss structure on both sides of the product after the forming process of the embodiment is relatively stable, the transverse and longitudinal dimensions between the boss structures are stable, which greatly reduces the subsequent CNC processing time, and there is no need to paste metal parts in the area corresponding to the boss structure, which greatly shortens the bonding time of the subsequent bonding section.

[0050] It is apparent to a person skilled in the art that the present application is not limited to the details of the above-described exemplary embodiments, but can be implemented in other specific forms without departing from the spirit or essential characteristics of the present application. Therefore, the embodiments should be considered in all respects as illustrative and not restrictive, the scope of the present application being defined by the appended claims rather than the above description, and it is intended that all changes falling within the meaning and range of equivalency of the claims are embraced therein.

[0051] Furthermore, it should be understood that although the present specification is described in terms of embodiments, not every embodiment contains only one independent technical solution, and the description of the specification is only for the sake of clarity, and a person skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by a person skilled in the art.

Claims

1. A carbon fiber product molding process that enables accurate molding of internal structures, characterized by, The method comprises the following steps: (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 forming structure area for forming the internal structure of the carbon fiber product; assembling the iron core and the plastic core to form the core mold; (2) laying and pasting carbon fiber prepreg: wrapping the designed and cut carbon fiber prepreg around the foamed core material to form an internal structure forming piece, assembling the internal structure forming piece on the internal forming structure area of the iron core, and then wrapping and laying carbon fiber prepreg outside the core mold; (3) molding: fixing the required inserts in the cavity of the forming mold, then laying and pasting carbon fiber prepreg on the cavity surface of the mold cavity, and then placing the core mold wrapped with carbon fiber prepreg in the cavity of the forming mold; (4) closing the mold: closing the upper mold and the lower mold of the forming mold; (5) molding: preheating the forming mold, after the carbon fiber prepreg softens, opening the press, and after the press reaches the set molding pressure, inflating the plastic core, and after the inflation is completed, the forming mold automatically completes the pressure holding and curing; (6) demolding: taking out the molded product from the forming mold, and then taking out the core mold in the molded product.

2. The carbon fiber product forming process capable of precisely forming an internal structure according to claim 1, wherein The carbon fiber prepreg is formed by impregnating carbon fiber woven fabric with a resin matrix.

3. The carbon fiber product forming process capable of precisely forming an internal structure according to claim 1, wherein The foamed core material is a PU foamed core material.

4. The carbon fiber product forming process capable of precisely forming an internal structure according to claim 1, wherein In step (2), when metal parts need to be pre-embedded in the internal structure of the carbon fiber product, the metal parts are pre-placed in the foamed core material, and then the carbon fiber prepreg is wrapped around the foamed core material to form an internal structure forming piece with pre-embedded metal parts.

5. The carbon fiber product forming process enabling precise forming of internal structures according to claim 1, wherein, In step (2), multiple layers of carbon fiber prepreg are laid and pasted outside the core mold.

6. The carbon fiber product forming process enabling precise forming of internal structures according to claim 1, wherein, In step (5), the preheating temperature is 150-180°C.

7. The carbon fiber product forming process enabling precise forming of internal structures according to claim 1, wherein, In step (5), the molding press is set to a molding pressure of 100 to 200 kg / cm 2 .

8. The carbon fiber product forming process enabling precise forming of internal structures according to claim 1, wherein, In step (5), the process of inflating the plastic core is divided into three stages.

9. The carbon fiber product forming process enabling precise forming of internal structures according to claim 1, wherein, In step (6), an opening is first cut in the molded product, and the core mold is taken out through the opening.

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