A tooling and method for integrated forming of composite components

Abstract

The present application relates to a kind of tooling and method for the integrated forming of composite component, belong to the field of bonding process equipment, solve the uneven pressure transmission of existing bonding equipment / tooling, insufficient conductive pressure, interface contact is not close, bonding effect is not good, the problem of one of easily damaging material to be handled.The present application discloses a kind of tooling for the integrated forming of composite component, the tooling is made of upper die, buffer pad, bottom die, the buffer pad is made of flexible buffer material;The flexible buffer material has three-layer structure of sequentially laminated flexible rubber layer, fiber-reinforced composite sandwich core, wear-resistant rubber layer;The bottom die is provided with positioning device.High-quality pressurized bonding for easily damaged material is realized, on the premise of ensuring uniform pressure transmission, interface contact is close, conductive pressure is up to standard, bonding effect is good, certain protective effect is played to the material to be handled, can be widely applied to the bonding and integrated forming of composite component.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of bonding process equipment, in particular to a tool and method for integrated forming of composite material components. BACKGROUND

[0002] With the rapid development of the aerospace industry, there is an urgent need for lightweight, high-temperature-resistant, and high-load materials. In order to achieve maximum weight reduction and meet the requirements of high-temperature-resistant and load-integrated service environments, an outer heat-resistant material and a load-bearing structural material are generally used to form a load-resistant and heat-resistant integrated composite material component to protect internal parts of the aircraft. Due to their different functions, the outer heat-resistant layer and the load-bearing layer have different material characteristics. The outer heat-resistant layer uses lightweight thermal insulation materials with low density, soft and brittle, poor impact compression performance. The load-bearing layer uses high-temperature-resistant resin-based composite materials with high specific strength and stiffness, and is prone to deformation. Therefore, the forming pressure action mode and transmission effect during the composite forming process of the two are crucial to the forming quality of the component.

[0003] Common laminating processes and devices are generally suitable for the preparation process of flat materials of the same material, and require regular shapes, specific sizes and thicknesses, which are difficult to apply to the preparation process of specific special-shaped load-resistant and heat-resistant integrated components. In order to protect the outer heat-resistant layer material, the cushioning material is also a protective measure, but the commonly used cushioning material cannot meet the characteristics of the outer heat-resistant layer special material, which can easily lead to uneven pressure transmission effect, affecting the internal forming quality of the component and even damaging the material itself. In practical applications, vacuum bag laminating is also a co-curing forming method, which uses atmospheric pressure to fix the laminated parts in place, but it also has many limitations. The vacuum pressure is limited, and there is a lack of bonding positioning reference, which leads to the fact that the inner and outer layer bonding profiles cannot be completely matched, and it is easy to cause large-area debonding of the composite material shell and the outer heat-resistant layer. At the same time, the operation process is complex and the production efficiency is low. SUMMARY

[0004] In view of the above analysis, the present application aims to provide a tool and method for integrated forming of composite material components to solve one of the problems of uneven pressure transmission, insufficient conduction pressure, loose contact between the pressing interface and the material to be processed, poor bonding effect, and damage to the material to be processed in the existing composite forming process.

[0005] The present application discloses a tool for integrated forming of composite material components, which is composed of an upper die 12, a buffer pad 11 and a bottom die 6.

[0006] The upper die 12 and the bottom die 6 form a forming cavity of the composite material component; the buffer pad 11 is made of flexible cushioning material and is fixed to the lower surface of the upper die 12.

[0007] The flexible cushioning material has a three-layer structure of sequentially laminated flexible rubber layer 1, fiber-reinforced composite sandwich core and wear-resistant rubber layer 5;

[0008] The fiber-reinforced composite sandwich core is made of a fiber preform and a resin and has a density gradient.

[0009] The bottom die 6 is provided with a positioning device composed of an edge stop limiting block 7 and a middle wedge-shaped positioning block 8.

[0010] Specifically, the cushion pad 11 is fixed to the lower surface of the upper die 12 in an adhesive form.

[0011] Specifically, the thickness of the cushion pad 11 is 0.6-1.0 mm.

[0012] Specifically, the upper die 12 and the bottom die 6 are matched in shape and are flat, a specific arc or a variable curvature shape, and the bottom die 6 is provided with a recess.

[0013] Specifically, the bottom surface profile of the edge stop limiting block 7 is matched with the bottom die 6 and is designed to be flat, a specific arc or a variable curvature shape.

[0014] Specifically, the middle wedge-shaped positioning block 8 is provided with a threaded hole in communication with the bottom die 6.

[0015] The application also discloses an integrated forming method of a composite material component, which adopts the above tooling and comprises the following steps:

[0016] S21: preparing a bearing layer 9 and an outer heat-proof layer 10;

[0017] S22: roughening the bonding surfaces of the bearing layer 9 and the outer heat-proof layer 10;

[0018] S23: placing the bearing layer 9 on the bottom die 6 of the tooling and performing pre-positioning and fixing;

[0019] S24: coating an adhesive on the bonding surfaces of the bearing layer 9 and the outer heat-proof layer 10, placing the outer heat-proof layer 10 above the bearing layer 9, performing positioning and fixing, and closing the upper die 12 with the cushion pad bonded to the lower surface;

[0020] S25: placing the tooling on a press, setting the parameters of the press, and pressurizing and curing;

[0021] S26: taking out the tooling, demolding and obtaining the composite material component.

[0022] Specifically, the step S22 adopts surface polishing and sand blasting to roughen the bonding surfaces.

[0023] Specifically, step S23 is specifically operated as follows: the bearing layer 9 is placed on the bottom die 6 of the tooling, the inner surface is attached to the profile of the bottom die 6, and the edge pressure limiting block 7 is used for fixation, then the outer heat protection layer 10 is assembled, the edge pressure limiting block 7 is used as a positioning reference to determine the circumferential edge position, and alignment, positioning and adjustment are performed.

[0024] Specifically, step S24 is specifically operated as follows: the outer heat protection layer 10 is placed above the bearing layer 9, the middle wedge-shaped positioning block 8 is used for positioning, the positions of the bearing layer 9 and the outer heat protection layer 10 are matched, and the position of the outer heat protection layer 10 is fixed after assembly.

[0025] Compared with the prior art, the present application can at least achieve one of the following beneficial effects:

[0026] 1. The tooling disclosed in the present application is provided with a cushion pad prepared from the flexible cushion material, so that the bonding pressure is uniformly and sufficiently transmitted, and the material is not easily damaged. The cushion pad provided in the present application adopts a sandwich structure of a flexible rubber layer, a gradient fiber reinforced composite sandwich core and a wear-resistant rubber layer. A better pressure transmission effect is provided through a plurality of gradient density units, and when the system is affected by external pressure changes, the changed pressure can be transmitted to the fiber reinforced composite sandwich core through the flexible rubber layer, the preform sandwich layer is deformed to a certain extent, and part of the impact energy is absorbed, so that the pressure in the system is reasonably dispersed, and a pressure buffering effect is achieved. If the pressure in the system suddenly changes or there is pulsation, and the mutation reaches the upper limit of damage to the outer heat protection layer, since the density gradient fiber reinforced composite sandwich core adopts the same fiber weaving structure as the outer heat protection layer, the low-density unit is preferentially destroyed, and the material body is well protected. For example, when the material quality (fiber and resin type) of the sandwich core and the material to be processed are the same, when the density gradient distribution of the sandwich core is 0.4-1.0 g / cm 3 , the outer heat protection layer material (material to be processed) with a density greater than 0.4 g / cm 3 can be protected; if the density of the outer heat protection layer is 0.4-1.0 g / cm 3 , the protection effect is good, and the pressure can be fully transmitted, and the buffering effect is better.

[0027] 2. The cushion pad provided in the present application is arranged between the tooling and the material to be processed, fully ensures that the tooling interface and the material to be processed are in full contact, compensates for the profile and thickness tolerance of the outer heat protection layer and the bearing layer itself, controls the thickness of the cavity, ensures that the bonding surface is in full contact and uniformly stressed, and solves the problem of poor bonding effect caused by insufficient contact and air gap of the bonding surface

[0028] 3. The cushioning pad provided by the present invention adopts a sandwich structure consisting of a flexible rubber layer, a gradient fiber-reinforced composite sandwich core, and a wear-resistant rubber layer. It has high elasticity, large deformation, wear resistance, and a certain degree of fragility (providing good protection for the material itself). Therefore, it has high safety, applicability, and durability.

[0029] 4. The tooling disclosed in the present invention has a simple structure, simple application method, mild conditions, good pressurized bonding effect, and is not easy to damage the material to be processed. It is suitable for large-scale batch production of related composite materials, especially heat-resistant and load-bearing composite materials (integrated molding).

[0030] In the present invention, the above-mentioned technical solutions can be combined with each other to achieve more preferred combinations. Other features and advantages of the present invention will be described in the following description, and some advantages will become apparent from the description or be learned through practice of the present invention. The objectives and other advantages of the present invention can be realized and obtained through the contents particularly pointed out in the description and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The accompanying drawings are only for the purpose of illustrating particular embodiments and are not to be considered limiting of the present invention. Like reference symbols denote like parts throughout the drawings.

[0032] Figure 1 Schematic diagram of the flexible cushioning material structure (3-layer fiber preform);

[0033] Figure 2 A schematic diagram of a tooling structure for integrally forming composite components;

[0034] Figure 3 The present invention is a flow chart of a method for integrally forming a heat-resistant load-bearing composite material component.

[0035] Reference numerals:

[0036] 1-Flexible rubber layer; 2-First density unit (first layer of fiber preform); 3-Second density unit (second layer of fiber preform); 4-Third density unit (third layer of fiber preform); 5-Wear-resistant rubber layer; 6-Bottom mold; 7-Edge pressure limit block; 8-Wedge-shaped positioning block; 9-Bearing layer; 10-Outer heat protection layer; 11-Buffer pad; 12-Upper mold; 13-Positioning screw. DETAILED DESCRIPTION

[0037] The preferred embodiments of the present invention will be described in detail below in conjunction with the accompanying drawings, wherein the accompanying drawings constitute a part of this application and are used together with the embodiments of the present invention to illustrate the principles of the present invention, and are not used to limit the scope of the present invention.

[0038] The application discloses a tool for integrally forming a composite component, the composite component being a heat-proof load-bearing integrated composite component formed by bonding an outer heat-proof layer and a load-bearing layer; the tool is composed of an upper mold, a buffer pad and a bottom mold, wherein the buffer pad is made of a flexible buffer material. The flexible buffer material has a three-layer structure sequentially laminated by a flexible rubber layer, a fiber-reinforced composite interlayer core and a wear-resistant rubber layer; and the fiber-reinforced composite interlayer core comprises multiple gradient density units.

[0039] Specifically, the bottom mold is provided with a positioning device composed of an edge pressing stop limiting block and a middle wedge-shaped positioning block. A screw structure is arranged on the lower surface of the edge pressing stop limiting block and is matched with a screw hole in the corresponding position of the bottom mold, so that the edge pressing stop limiting block is connected and fixed to the bottom mold.

[0040] The tool realizes accurate positioning and assembly of the outer heat-proof layer and the load-bearing layer through cooperation of the edge pressing stop limiting block and the middle wedge-shaped positioning block, and realizes overall high-precision and high-quality bonding forming. More importantly, based on the dual-function design of cavity thickness control and stress buffering, a flexible buffer layer (i.e. the buffer pad) is introduced between the composite component and the tool, which on the one hand compensates for the shape and thickness tolerances of the outer heat-proof layer and the load-bearing layer, controls the cavity thickness, and ensures that the bonding surface is in close contact and uniformly stressed; and on the other hand, provides better stress buffering effect between the upper mold of the tool and the outer heat-proof layer, has good wear resistance, avoids the problem of damage to the outer heat-proof layer caused by excessive local stress, effectively protects the product, and improves the product quality and the qualification rate.

[0041] Specifically, the buffer pad is fixed to the lower surface of the upper mold in a bonding form.

[0042] Specifically, the thickness of the buffer pad is 0.6-1.0 mm. The total thickness tolerance of the load-bearing layer and the outer heat-proof layer (to-be-processed material) is generally not more than 0.6 mm, so as to ensure the uniformity of pressure transmission and the sufficient adhesion between the equipment interface and the material interface, the thickness of the buffer material should be not less than the size of the total thickness tolerance of the to-be-processed material, i.e. 0.6 mm. In addition, the thickness of the buffer material should not be too thick, and according to actual experience, the thickness is preferably not more than 1 mm.

[0043] Specifically, the upper mold and the bottom mold are matched in shape and are planar, a specific arc or a variable curvature shape, and the bottom mold is provided with a concave cavity. The concave cavity is matched with the load-bearing layer, the inner side wall of the concave cavity is matched with the side edge of the load-bearing layer, and is used for fixing the load-bearing layer. That is to say, the concave cavity is closely related to the size and thickness of the to-be-processed material, and after the size of the concave cavity is determined, the size and thickness of the material that can be processed by the tool are also fixed.

[0044] Specifically, the positioning device is composed of edge pressing limiting blocks and middle wedge-shaped positioning blocks. On the one hand, the edge pressing limiting blocks are used to fix the material to be processed, effectively preventing the material from being deformed due to warping and thus being inaccurate in position, and at the same time, the limiting blocks are used to determine the position of the edges of the material, and the position of the material to be processed is coarsely adjusted as a positioning reference; and the middle wedge-shaped positioning blocks are used as a second positioning reference to more accurately adjust the relative positions of the multiple layers (two or more) of the material to be processed, so as to ensure that the multiple layers of the material to be processed are fixed at the theoretical bonding positions.

[0045] Specifically, the bottom surface profile of the edge pressing limiting block matches the bottom die, and is designed as a plane, a specific arc or a variable curvature shape. The bottom die is provided with a threaded hole at a corresponding position, and the limiting block is connected with the bottom die through a fastening screw. Optionally, according to the specific size and shape of the material to be processed, the number of limiting blocks can be 2 or more.

[0046] Specifically, the middle wedge-shaped positioning block is provided with a threaded hole in communication with the bottom die, and the threaded hole is used to fix the wedge-shaped positioning block in the positioning groove of the bottom die, and the positioning block is aligned with the threaded hole of the bottom die when the position of the wedge-shaped block completely matches the product.

[0047] Preferably, the thickness / height of the edge pressing limiting block and the middle wedge-shaped positioning block should not be too large, and the specific size is adjusted according to the thickness of the material to be processed, so as to avoid that the top of the positioning device is too high and thus interferes with the bottom surface of the upper die, resulting in uneven pressure.

[0048] The application also discloses a flexible cushioning material, which has a three-layer structure of sequentially laminated flexible rubber layer, fiber-reinforced composite sandwich core and wear-resistant rubber layer; wherein the fiber-reinforced composite sandwich core comprises multiple gradient density units.

[0049] Specifically, the fiber-reinforced composite sandwich core is made of a fiber preform and a resin, and is a pre-solidified material with a density gradient gradually changing.

[0050] In use, the flexible rubber layer of the flexible cushioning material of the application is in contact with a bonding device (such as a pressing device or a tool), and is used to transmit the pressure of the device to the fiber-reinforced composite sandwich core with a density gradient and then to the product, thereby playing a role of preliminary pressure buffering and transmission.

[0051] The fiber-reinforced composite sandwich core with a density gradient comprises multiple gradient density units, thus providing a better pressure transmission effect. When affected by external pressure changes, the composite sandwich core deforms to a certain extent, absorbs part of the impact energy, so that the pressure in the system is reasonably dispersed, thereby playing a role of pressure buffering.

[0052] In actual use, the cushioning material can be made of a fiber reinforced composite sandwich core body with the same or similar weaving structure and material (fiber type and resin type) as the material to be treated. Since the two have similar composition and structure, the structural strength and density are positively correlated. When the external pressure exceeds a certain limit, the low-density unit of the fiber reinforced composite sandwich core body will be damaged first, thereby providing better protection to the material body.

[0053] For example, when the fiber reinforced composite sandwich core body has the same or similar structure and material (fiber and resin type) as the material to be treated, the density gradient distribution of the fiber reinforced composite sandwich core body is 0.4-1.0 g / cm 3 . If the three-layer density unit structure has three layers of density units with increasing or decreasing density, the density of the three layers can be 0.4, 0.7, and 1.0 g / cm 3 , respectively. In this case, the outer heat protection layer material (material to be treated) with a density greater than 0.4 g / cm 3 can be protected. If the density of the outer heat protection layer is 0.4-1.0 g / cm 3 , the protection can be provided while the pressure can be fully transmitted, and the cushioning effect is better. If the pressure in the system suddenly changes or has pulsation and suddenly changes to the upper limit of the damage of the outer heat protection layer, since the fiber reinforced composite sandwich core body with a density gradient has the same weaving structure as the outer heat protection layer, the low-density unit is damaged first, thereby providing better protection to the material body, and thus having high safety, applicability, and durability.

[0054] The wear-resistant rubber layer has excellent wear resistance and long service life, and can withstand long-time friction without being easily worn.

[0055] Specifically, the fiber preform is composed of one or more of inorganic glass fiber, quartz fiber, carbon fiber, phenolic fiber, glass fiber, mullite fiber, or alumina fiber. The above fibers are commonly used fibers in the field of special materials for space thermal protection.

[0056] Specifically, the resin is one or more of thermoplastic phenolic resin, thermosetting phenolic resin, silicone-modified phenolic resin, boron phenolic resin, and polyarylacetylene resin. The above resins are commonly used resins in the field of special materials for space thermal protection.

[0057] The combination of the fiber preform and the resin can cover most of the composition systems of aerospace special outer heat protection materials, the fiber reinforced composite interlayer core formed by the combination has a similar structure to most of the aerospace special outer heat protection materials, and thus has similar force transmission performance and similar structural strength in a similar density range, thereby playing a better stress buffering role between the bonding equipment and the outer heat protection layer, avoiding the problem of damage to the outer heat protection layer due to excessive local stress, fully playing a pressure transmission and product protection role, and improving product quality and qualification rate.

[0058] Specifically, the density of the fiber reinforced composite interlayer core is the lowest at the interface with the flexible rubber layer, and the density of the fiber reinforced composite interlayer core is the highest at the interface with the wear-resistant rubber layer. The flexible buffer material described below is in the order from top to bottom, the flexible rubber layer, the fiber reinforced composite interlayer core, and the wear-resistant rubber layer.

[0059] The fiber reinforced composite interlayer core has a density decreasing gradient in the thickness direction (i.e., the lowest density unit is at the interface between the flexible rubber layer and the fiber reinforced composite interlayer core), which is realized by the multiple density units of the fiber preform. The fiber preform includes n density units in the thickness direction, where n≥3. The density difference between adjacent density units can be determined according to actual needs, and is preferably uniformly distributed within the selected density range, such as a density difference Δρ=0.3 g / cm 3 In an ideal case, i.e., n is infinite, the density difference between adjacent density units is infinitely small, and the technical effect is best. However, this is not possible in actual implementation. Therefore, the density difference between adjacent density units should be determined comprehensively according to the thickness of the fiber reinforced composite interlayer core and the thickness of the selected single-layer density unit. In general, the larger n is, the better the buffering performance and pressure transmission performance are.

[0060] Through the density gradient design, on the one hand, the pressure transmission process is gradually buffered layer by layer, thereby achieving better pressure transmission effect. On the other hand, the low-density unit has certain damage protection characteristics. If the pressure in the system suddenly changes or has pulsation and suddenly changes to the upper limit of damage to the outer heat protection layer, the low-density unit is preferentially destroyed due to the density gradient fiber reinforced composite interlayer core adopting the same fiber weaving structure as the outer heat protection layer, thereby playing a protection role.

[0061] In fact, the fiber reinforced composite interlayer core also has a certain buffering function in the thickness direction with a density increasing gradient (i.e., the highest density unit is at the interface between the flexible rubber layer and the fiber reinforced composite interlayer core), but the buffering effect is slightly worse.

[0062] Specifically, the total thickness of the flexible buffer material is 0.6-1.0 mm, the thickness of the flexible rubber layer and the wear-resistant rubber layer is 0.15-0.25 mm respectively, and the thickness of the fiber reinforced composite interlayer core is 0.3-0.5 mm.

[0063] An important application scenario of the flexible cushioning material disclosed in the present application is the preparation of aerospace special composite components. By pressure bonding of the outer heat-proof layer and the load-bearing layer, a heat-proof load-bearing integrated composite component is prepared. The total thickness tolerance of the component is generally not more than 0.6 mm. In order to ensure the uniformity of pressure transmission and the full adhesion of the equipment interface and the material interface, the thickness of the cushioning material should be not less than the size of the total tolerance of the material to be processed, i.e. 0.6 mm. In addition, the thickness of the cushioning material should not be too thick. According to actual experience, it is appropriate to be not more than 1 mm.

[0064] Preferably, in order to fully ensure the sufficiency of pressure conduction and take into account the protection of the material to be processed, the thickness of the fiber-reinforced composite sandwich core should be not less than twice the thickness of the flexible rubber layer or the wear-resistant rubber layer. Since the fiber-reinforced composite sandwich core can be damaged in advance when the pressure approaches or exceeds the tolerance limit of the material to be processed, a thicker fiber-reinforced composite sandwich core is beneficial to leave more safety protection margin. According to actual experience, considering factors such as pressure transmission and cost, the thickness of the fiber-reinforced composite sandwich core should not be thickened unlimitedly, i.e. it is appropriate to be 0.3-0.5 mm.

[0065] Specifically, the flexible rubber layer is one or more of natural rubber, styrene-butadiene rubber, nitrile rubber, silicone rubber, thermoplastic polyurethane flexible body, styrene thermoplastic flexible body, and ethylene-propylene-diene rubber. The flexible rubber layer composed of the above materials can meet the requirements of strength ≥ 2.0 MPa, elongation ≥ 300%, and elasticity ≥ 60%, has good deformation performance and coating effect, and is beneficial to the full contact and pressure conduction between interfaces.

[0066] Specifically, the wear-resistant rubber layer is made of one or more of natural rubber, styrene-butadiene rubber, nitrile rubber, silicone rubber, thermoplastic polyurethane flexible body, styrene thermoplastic flexible body, and ethylene-propylene-diene rubber, and adds wear-resistant fillers; the wear-resistant fillers are one or more of carbon fibers, graphite, polytetrafluoroethylene particles, and molybdenum disulfide.

[0067] Preferably, the addition amount of the wear-resistant filler is 3%-10% by mass based on the total mass of the wear-resistant rubber layer. If the addition amount is too small, the wear-resistant effect cannot be good, and if the addition amount is too high, the adhesion and uniformity of the rubber body are affected, and the vulcanization molding of the rubber layer is affected.

[0068] The present application also discloses a preparation method of the flexible cushioning material, comprising the following steps:

[0069] S1: preparing a flexible rubber sheet;

[0070] S2: Fiber preforms of different volume densities are prepared, cut to appropriate sizes, and stacked in order of volume density to form a gradient reinforcement; resin is diluted with a solvent, injected into the gradient reinforcement, and dried to obtain a fiber-reinforced composite sandwich core;

[0071] S3: Prepare wear-resistant rubber sheet;

[0072] S4: placing the cut flexible rubber sheet, the fiber-reinforced composite sandwich core, and the wear-resistant rubber sheet in a vulcanization mold in sequence, and obtaining a flexible cushioning material after vulcanization and demoulding.

[0073] Specifically, the flexible rubber sheet can be purchased or prepared by oneself.

[0074] The present invention provides a method for preparing a rubber sheet, wherein the raw materials for the preparation include a rubber base material, a softener, an anti-aging agent, a toughening agent, and a processing aid, and the method comprises the following steps:

[0075] The raw materials are mixed in proportion and then put into a mixer for mixing to obtain rubber agglomerates.

[0076] The mixed rubber mass is calendered to obtain a flexible rubber sheet of specific thickness and width.

[0077] For example, the raw materials for the preparation mentioned above include, by mass fraction, 70-80% rubber base material, 5-10% softener, 0.5-2% anti-aging agent, 10-20% toughening agent, and 1-3% processing aid, and the calendering molding temperature is 60-95°C.

[0078] Preferably, the rubber substrate of the flexible rubber sheet is one or more of natural rubber, styrene-butadiene rubber, nitrile rubber, silicone rubber, butadiene rubber, thermoplastic polyurethane flexible body, styrene thermoplastic flexible body, and EPDM rubber.

[0079] The flexible rubber layer prepared from the above materials can meet the requirements of strength ≥2.0MPa, elongation ≥300%, and elasticity ≥60%, has good deformation performance and coating effect, and is conducive to sufficient contact and pressure conduction between interfaces.

[0080] Specifically, in step S2, the number of fiber preform layers stacked is no less than three. Using a greater number of layers can achieve a smoother density gradient, which is beneficial for pressure conduction and stabilizes the internal structure of the fiber-reinforced composite sandwich core. However, considering that the total thickness of the fiber-reinforced composite sandwich core should not exceed 0.5 mm, the number of fiber preform layers should not be increased indefinitely.

[0081] For example, along the direction from the wear-resistant rubber layer to the flexible rubber layer, the volume density difference between adjacent fiber preforms (taking a total of 3 layers as an example) is 0.1 to 0.2 g / cm3 The uniform distribution of the volume density difference between adjacent fiber preforms within the density upper and lower limit range is conducive to improving the structural stability of the flexible cushioning material, and is also conducive to obtaining a better pressure transmission effect.

[0082] Specifically, the fiber preform is prepared by a fiber net tire, needle punching, composite needle punching or sewing, etc., and is a three-dimensional multi-layer grid structure, and the volume density is 0.12-0.4 g / cm 3 The core density of the fiber-reinforced composite sandwich core prepared in the volume density range covers the density range of common thermal protection layer materials, thereby playing a more sufficient pressure transmission effect and protection effect.

[0083] The porosity of the fiber preform is greater than 65%, and the higher porosity meets the density requirement, is conducive to resin impregnation during subsequent pre-solidification, and on the other hand, when subjected to external pressure impact in actual application, the porous network structure can effectively absorb external energy, so that it has a higher stress absorption and buffering effect.

[0084] Specifically, the step S2 is specifically operated as follows: the resin is diluted to a mass concentration of 10-50% by a solvent, and the injection pressure is controlled to be 0.01-0.15 MPa to inject the gradient reinforcement. The solvent is one or a mixture of several of ethanol, isopropanol, water, ethylene glycol or glycerol. When the mass concentration is too high, the resin cannot be uniformly dispersed, which affects the molding effect, and when the concentration is too low, the sandwich core of a specific density cannot be prepared, which affects the final material buffering effect.

[0085] The application further discloses a composite material component integrated forming method, namely, an integrated forming method of a heat-proof load-bearing integrated composite material component, which utilizes the above tooling to realize integrated forming of the composite component through steps of material surface treatment, adhesive coating, pressure curing, demolding and the like.

[0086] The specific steps include:

[0087] S21: preparing a load-bearing layer and an outer heat-proof layer;

[0088] S22: roughening the bonding surfaces of the load-bearing layer and the outer heat-proof layer;

[0089] S23: placing the load-bearing layer on the tooling bottom die and performing pre-positioning and fixing;

[0090] S24: coating the bonding surfaces of the load-bearing layer and the outer heat-proof layer with an adhesive, and placing the outer heat-proof layer above the load-bearing layer, and performing positioning and fixing, and closing the upper die with the cushion pad bonded to the lower surface;

[0091] S25: placing the tooling on a press, setting the press parameters, and performing pressure curing;

[0092] S26: taking out the tooling, demolding, and obtaining the composite component.

[0093] Specifically, the bearing layer is a high-temperature resistant resin such as bismaleimide resin or polyimide, and a corresponding prepreg is prepared by a hot melting method or a wet method, and a composite bearing layer is prepared by using a molding process or a autoclave molding process.

[0094] Specifically, the outer heat protection layer is a composite material prepared by impregnating a fiber preform with a resin glue solution. The fiber preform is combined in a forming mold, a resin precursor glue solution is injected under pressure, and after sufficient composite impregnation, curing and drying are performed to obtain the outer ablation layer. The above materials are disclosed in the prior art and can be purchased or prepared according to actual needs.

[0095] Specifically, the fiber preform of the outer heat protection layer is composed of one or more of inorganic glass fiber, quartz fiber, carbon fiber, phenolic fiber, glass fiber, mullite fiber or alumina fiber. The above fibers are commonly used fibers in the field of aerospace thermal protection.

[0096] Specifically, the resin used in the outer heat protection layer is one or more of thermoplastic phenolic resin, thermosetting phenolic resin, silicone-modified phenolic resin, boron phenolic resin, and polyarylacetylene resin. The above resins are commonly used resins in the field of aerospace thermal protection.

[0097] Specifically, step S22 can use surface polishing, sandblasting and other processes to roughen the bonding surface, thereby increasing the roughness of the bonding surface, making it more fully contact with the adhesive and having a larger contact area, which is conducive to obtaining better bonding effect.

[0098] Preferably, the bonding surface of the bearing layer is sandblasted with corundum sand of 50 mesh or less, and the bonding surface of the outer heat protection layer is polished with sandpaper of 50 mesh or less. When the mesh number of sandblasting and polishing is too high, the surface roughness is too low and cannot roughen the surface. When the mesh number is too low, the surface quality will be more rough and uneven, and the material properties will be damaged.

[0099] Specifically, step S23 is specifically operated by placing the bearing layer on the tooling bottom mold, making the inner surface adhere to the bottom mold surface, and fixing it by using the edge stop limiting block. Then, the outer heat protection layer is trial assembled, the edge stop limiting block is used as a predetermined positioning reference to determine the circumferential edge position, and alignment, positioning and adjustment are performed. This step only prepositions and fixes the bearing layer, and trial assembly of the outer heat protection layer is only to assist in verifying whether the prepositioning effect of the bearing layer is ideal.

[0100] Specifically, step S24 is specifically operated as follows: the outer heat protection layer is placed above the bearing layer, the wedge-shaped positioning block is used for positioning, the positions of the bearing layer and the outer heat protection layer are matched, and the outer heat protection layer is fixed after assembly.

[0101] Specifically, the adhesive in step S24 is a silicone rubber, a silicone-oxygen-nitrogen adhesive, or other adhesives with good heat resistance and adhesion. Such adhesives have a temperature resistance level of 300°C or higher, meeting the temperature requirement for use, and the coating thickness is 0.5-1 mm. If the adhesive layer is too thin, it cannot infiltrate both sides of the bonded object, or even only one side has adhesive, which negatively affects the internal bonding quality. If the adhesive layer is too thick, the probability of defects in the adhesive layer increases, and stress concentration occurs around these defects when subjected to external force, leading to adhesive layer damage in subsequent products under high heat flow service environment.

[0102] Specifically, the press parameters are 1.5 MPa-3 MPa. If the bonding pressure is too high, the outer heat protection material is easily damaged, leading to irreversible structural damage such as delamination and fracture. If the bonding pressure is too low, the adhesive cannot effectively flow inside the material, affecting the infiltration effect on the bonding surface and adversely affecting the bonding effect.

[0103] Specifically, the curing temperature is room temperature-60°C. If the temperature is too high, the outer heat protection layer is easily chemically reacted after being affected by the temperature, which destroys the bulk structure and affects the subsequent service performance.

[0104] Specifically, the specific operation of step S25 is as follows: after curing at room temperature for 72 hours, the upper mold is opened, the fastening screws of the edge stop limit block and the middle wedge-shaped positioning block are loosened respectively, the positioning blocks are removed, the residual adhesive is cleaned and locally trimmed, and the bonded and formed product is obtained.

[0105] Examples and comparative examples:

[0106] Example 1

[0107] Step one: preparation of flexible rubber layer

[0108] The mass fractions of 78% nitrile rubber, 8% softening agent, 1% anti-aging agent, 10% toughening agent, and 3% processing aid are mixed according to the proportion, then put into a mixer for mixing treatment, and uniformly mixed to obtain a rubber mass. The rubber mass obtained by mixing is formed by calendering at a temperature of 70°C, and a flexible rubber sheet with fixed thickness and width is obtained.

[0109] Step two: preparation of fiber-reinforced composite sandwich core

[0110] The low-density fiber preform adopts a phenolic fiber web composite needling process, the first density unit volume density is 0.14 g / cm 3 , the second density unit volume density is 0.25 g / cm 3 , and the third density unit volume density is 0.30 g / cm 3 . The gradient fiber preform is used as a reinforcing body, a resin is diluted by ethanol solvent, the mass concentration is controlled to be 25%, the resin is injected into the reinforcing body to perform a sol-gel reaction, the injection pressure is controlled to be 0.10 MPa, and after normal pressure drying, a fiber-reinforced composite sandwich core body is obtained, and the fiber-reinforced composite sandwich core body density range is 0.50-0.80 g / cm 3 .

[0111] Step three: preparation of the wear-resistant rubber layer

[0112] 75% of nitrile rubber, 8% of softening agent, 1% of anti-aging agent, 10% of toughening agent, 2% of processing aid, and 4% of polytetrafluoroethylene particle wear-resistant filler are mixed according to the proportion, and then are put into a mixer for mixing treatment, so that a rubber rubber mass is obtained. The rubber rubber mass obtained by mixing is calendered, the calendering temperature is 70 DEG C, and a flexible rubber sheet with a fixed thickness and width is obtained.

[0113] Step four: preparation of the flexible buffer layer

[0114] First, the vulcanization mold is preheated to 150-180 DEG C, a layer of flexible rubber sheet is laid on the mold, then the fiber-reinforced composite sandwich core body is laid, the volume density of the fiber-reinforced composite sandwich core body is 0.14 g / cm 3 , the third density unit of the fiber-reinforced composite sandwich core body is connected with the flexible rubber sheet, and finally the surface wear-resistant rubber sheet is laid, the mold is covered, and the vulcanization stage is entered, the vulcanization temperature is 180 DEG C, the vulcanization is kept for 4 h, and after demolding, a 1 mm thick flexible buffer layer is obtained.

[0115] The above flexible buffer material is used for bonding the outer heat protection layer and the bearing layer.

[0116] The tooling is prepared, including the upper mold, the buffer pad and the bottom mold;

[0117] The tooling is used for bonding the outer heat protection layer and the bearing layer, and a composite component is prepared, and the steps are as follows:

[0118] First step: preparation of the bearing layer and the outer heat protection layer

[0119] The bearing layer adopts carbon fiber reinforced polyimide resin, and the bearing layer is prepared by a molding process;

[0120] The outer heat protection layer is a composite material prepared by impregnating uniform phenolic fiber preform with phenolic resin glue, and the density is 0.60 g / cm 3 .

[0121] Second step: roughening treatment:

[0122] The outer surface of the bearing layer is sandblasted with 50-mesh diamond abrasive, and the outer heat protection layer is polished with 50-mesh sandpaper. After cleaning, the product is ready for use.

[0123] Third step: placing the bearing layer on the tooling bottom mold and pre-positioning and fixing:

[0124] The bearing layer is placed in the concave cavity of the tooling bottom mold, with the inner surface adhering to the bottom mold surface. The edge stop limit block is used for fixing, and then the outer heat protection layer is assembled. The edge stop limit block is used as a pre-positioning reference to determine the circumferential edge position. Alignment, positioning, and adjustment are performed.

[0125] Fourth step: bonding and forming:

[0126] Apply a total thickness of 0.5mm of KH-RTV-400 silicone adhesive to the bonding surface of the bearing layer and the outer heat protection layer. Place the outer heat protection layer above the bearing layer and use the second positioning reference for positioning. After assembly, fix the position of the outer heat protection layer. Close the tooling upper mold and mount it on the press.

[0127] Fifth step: pressure curing, bonding pressure 2MPa, complete the bonding and forming of the heat protection bearing integrated composite component.

[0128] Sixth step: demolding:

[0129] After curing at room temperature for 72h, open the upper mold, loosen the fastening screws of the edge stop limit block and the middle wedge-shaped positioning block, remove the positioning blocks, clean the remaining adhesive, and perform local trimming to obtain the bonded and formed product.

[0130] Implementation effect

[0131] The prepared flexible cushioning material has a strength of 3.0MPa, an elongation of 350%, and an elasticity of 75%.

[0132] The product is detected by CT, the bonding quality of the bearing layer and the outer heat protection layer is good, there is no debonding area, the effective bonding area ratio is 100%, the structure of the outer heat protection layer and the bearing layer is intact, and there is no internal damage.

[0133] Example 2

[0134] Step one: preparation of flexible rubber layer

[0135] The mass fraction of 80% cis-butadiene rubber, 6% softener, 2% antioxidant, 10% toughening agent, 2% processing aid, and the like are mixed in proportion, and then put into a mixer for mixing treatment. After uniform mixing, a rubber rubber mass is obtained. The rubber mass obtained by mixing is calendered to form a flexible rubber sheet with a fixed thickness and width.

[0136] Step two: preparation of fiber-reinforced composite sandwich core

[0137] The low-density fiber preform adopts a glass fiber web composite needling process. The first density unit has a volume density of 0.10 g / cm 3 , the second density unit has a volume density of 0.22 g / cm 3 , and the third density unit has a volume density of 0.30 g / cm 3 . The resin is diluted by ethanol solvent to control its mass concentration to 25%, and is injected into the reinforcing body for sol-gel reaction, with the injection pressure controlled to 0.10 MPa. After drying at normal pressure, a fiber-reinforced composite sandwich core is obtained, with a density range of 0.40-0.80 g / cm 3 .

[0138] Step three: preparation of wear-resistant rubber layer

[0139] The mass fraction of 78% cis-butadiene rubber, 6% softener, 2% antioxidant, 8% toughening agent, 2% processing aid, and 4% polytetrafluoroethylene particle wear-resistant filler are mixed in proportion, and then put into a mixer for mixing treatment. After uniform mixing, a rubber rubber mass is obtained. The rubber mass obtained by mixing is calendered to form a flexible rubber sheet with a fixed thickness and width.

[0140] Step four: preparation of flexible buffer layer

[0141] First, the vulcanization mold is preheated to 150-160°C. A layer of flexible rubber sheet is first laid on the mold, then the fiber-reinforced composite sandwich core is laid on, the volume density of the third density unit of the fiber-reinforced composite sandwich core is 0.10 g / cm 3 , and the flexible rubber sheet is in contact with the flexible rubber sheet, and finally the surface wear-resistant rubber sheet is laid on, and the mold is covered, and the vulcanization stage is entered, with the vulcanization temperature being 160°C and the holding time being 4h. After demolding, a flexible buffer layer with a thickness of 1mm is obtained.

[0142] The above flexible buffer material is used for bonding the outer heat protection layer and the bearing layer.

[0143] Prepare the tooling, including the upper mold, the buffer pad, and the bottom mold;

[0144] The above tooling is used for bonding the outer heat protection layer and the bearing layer to prepare a composite component, with the following steps:

[0145] First step: preparation of the bearing layer and the outer heat protection layer:

[0146] The bearing layer is made of carbon fiber reinforced bismaleimide resin, and the bearing layer is prepared by molding process;

[0147] The outer heat protection layer is a composite material made of glass fiber preform impregnated with phenolic resin glue, with a density of 0.70 g / cm 3 .

[0148] Second step: roughening treatment:

[0149] The outer surface of the bearing layer is sandblasted with 50 mesh diamond sand, and the outer heat protection layer is polished with 50 mesh sandpaper. After cleaning, it is ready for use.

[0150] Third step: placing the bearing layer on the tooling bottom die and pre-positioning and fixing:

[0151] Place the bearing layer in the concave cavity of the tooling bottom die, so that the inner surface is in contact with the bottom die surface. Use the edge stop limit block to fix it. Then assemble the outer heat protection layer. Use the edge stop limit block as the pre-positioning reference to determine the circumferential edge position. Align, position and adjust.

[0152] Fourth step: bonding and forming:

[0153] Apply a total thickness of 0.5 mm of KH-RTV-400 silicone rubber adhesive to the bonding surface of the bearing layer and the outer heat protection layer. Place the outer heat protection layer on top of the bearing layer and position it using the second positioning reference. After assembly, fix the position of the outer heat protection layer. Close the tooling upper die and mount it on the press.

[0154] Fifth step: pressure curing, bonding pressure 2 MPa, complete the bonding and forming of the heat protection bearing integrated composite component.

[0155] Sixth step: demolding:

[0156] After curing at room temperature for 72 hours, open the upper die, loosen the fastening screws of the edge stop limit block and the middle wedge-shaped positioning block, remove the positioning blocks, clean the remaining adhesive and perform local finishing to obtain the bonded and formed product.

[0157] Implementation effect

[0158] The prepared flexible cushioning material has a strength of 3.5 MPa, an elongation of 340%, and an elasticity of 82%.

[0159] The product is detected by CT, the bonding quality of the bearing layer and the outer heat protection layer is good, there is no debonding area, the effective bonding area ratio is 100%, the structure of the outer heat protection layer and the bearing layer is intact, and there is no internal damage.

[0160] Example 3

[0161] Step 1: Preparation of flexible rubber layer

[0162] The mass fraction of 78% silicone rubber, 8% softener, 1% antioxidant, 10% toughening agent, 3% processing aid, were mixed in proportion, then put into a mixer for mixing treatment, and uniformly mixed to obtain a rubber mass. The rubber mass obtained by mixing was calendered to form a flexible rubber sheet with fixed thickness and width.

[0163] Step 2: Preparation of fiber-reinforced composite sandwich core

[0164] The low-density fiber preform was prepared by a phenolic fiber web composite needling process. The volume density of the first density unit was 0.12 g / cm 3 , the volume density of the second density unit was 0.26 g / cm 3 , and the volume density of the third density unit was 0.36 g / cm 3 . The resin was diluted by ethanol solvent to control the mass concentration to 25%, and then injected into the reinforcing body for sol-gel reaction, with the injection pressure controlled at 0.10 MPa. After drying at normal pressure, the fiber-reinforced composite sandwich core was obtained, with a density range of 0.44-0.85 g / cm 3 .

[0165] Step 3: Preparation of wear-resistant rubber layer

[0166] The mass fraction of 75% silicone rubber, 8% softener, 1% antioxidant, 10% toughening agent, 2% processing aid, and 4% molybdenum disulfide wear-resistant filler were mixed in proportion, then put into a mixer for mixing treatment, and uniformly mixed to obtain a rubber mass. The rubber mass obtained by mixing was calendered to form a flexible rubber sheet with fixed thickness and width.

[0167] Step 4: Preparation of flexible cushion layer

[0168] First, the vulcanization mold was preheated to 150-180℃, and a layer of flexible rubber sheet was laid on the mold, then the fiber-reinforced composite sandwich core was laid on it, with the volume density of the third density unit of the fiber-reinforced composite sandwich core being 0.12 g / cm 3 , and the flexible rubber sheet being in contact with the third density unit. Finally, the surface wear-resistant rubber sheet was laid on, and the mold was covered, and the vulcanization stage was entered, with the vulcanization temperature being 180℃ and the holding time being 4 h. After demolding, a flexible cushion layer with a thickness of 1 mm was obtained.

[0169] The above flexible cushion material was used for bonding the outer heat protection layer and the load-bearing layer.

[0170] Prepare a tooling, including an upper mold, a buffer pad and a bottom mold;

[0171] Use the tooling for bonding the outer heat protection layer and the load bearing layer to prepare a composite component, the steps are as follows:

[0172] First step: prepare the load bearing layer and the outer heat protection layer:

[0173] The load bearing layer is prepared by using carbon fiber reinforced polyimide resin through a molding process.

[0174] The outer heat protection layer is a composite material prepared by impregnating phenolic resin glue solution into a uniform phenolic fiber preform, with a density of 0.68 g / cm 3 .

[0175] Second step: roughening treatment:

[0176] The outer surface of the load bearing layer is sandblasted with 50 mesh diamond abrasive, and the inner surface of the outer heat protection layer is polished with 50 mesh sandpaper. After cleaning, it is ready for use.

[0177] Third step: place the load bearing layer on the tooling bottom mold and pre-position and fix it:

[0178] Place the load bearing layer in the concave cavity of the tooling bottom mold, so that the inner surface is in contact with the bottom mold surface. Then, use the edge stop limit block to fix it. Then, assemble the outer heat protection layer, use the edge stop limit block as the pre-positioning reference to determine the circumferential edge position, and align, position and adjust it.

[0179] Fourth step: bonding and forming:

[0180] Apply a total thickness of 0.5 mm of KH~CP silicone rubber adhesive to the bonding surface of the load bearing layer and the outer heat protection layer. Place the outer heat protection layer above the load bearing layer and use the second positioning reference to position it. After assembling in place, fix the position of the outer heat protection layer. Close the tooling upper mold and mount it on the press.

[0181] Fifth step: pressurize and cure, bonding pressure 2 MPa, complete the bonding and forming of the heat protection and load bearing integrated composite component.

[0182] Sixth step: demolding:

[0183] After curing at room temperature for 72 hours, open the upper mold, loosen the fastening screws of the edge stop limit block and the middle wedge-shaped positioning block, remove the positioning blocks, clean the remaining adhesive and perform local finishing to obtain the bonded and formed product.

[0184] Implementation effect

[0185] The prepared flexible cushioning material has a strength of 3.2 MPa, an elongation of 340%, and an elasticity of 80%.

[0186] Adopt CT to detect product, the bonding quality of the bearing layer and the outer heatproof layer is good, no debonding area appears, the proportion of effective bonding area is 100%, the outer heatproof layer and the bearing layer structure are perfect, and no internal damage.

[0187] Comparative Example 1

[0188] Adopt commercially available low-elasticity polyurethane rubber layer as the flexible buffer material, the strength is 1.2 MPa, the elongation is 100%, and the elasticity is 40%.

[0189] The preparation process of the flexible buffer material is omitted, and the commercially available low-elasticity polyurethane rubber layer is used to replace the flexible buffer material disclosed in the application to make the tool buffer pad. Other operations and parameter settings are completely same as those in Example 1.

[0190] Implementation effect

[0191] Adopt CT to detect product, the bonding quality of the bearing layer and the outer heatproof layer is poor, large-area debonding area appears, and the proportion of effective bonding area is only 80%.

[0192] Comparative Example 2

[0193] Adopt commercially available high-elasticity rubber layer as the flexible buffer material, the strength is 2.2 MPa, the elongation is 240%, and the elasticity is 60%.

[0194] The preparation process of the flexible buffer material is omitted, and the commercially available high-elasticity rubber layer is used to replace the flexible buffer material disclosed in the application to make the tool buffer pad. Other operations and parameter settings are completely same as those in Example 1.

[0195] Implementation effect

[0196] Adopt CT to detect product, the bonding quality of the bearing layer and the outer heatproof layer is good, the proportion of effective bonding area is 94%, but the outer heatproof layer appears local delamination fracture, and the internal structure is damaged.

[0197] The above only describes the preferred embodiments of the application, but the protection scope of the application is not limited to this. Any changes or replacements within the technical range disclosed in the application can be easily thought by those skilled in the art, and should be covered in the protection scope of the application.

Claims

1. A tool for integrally forming composite components, characterized by: The tooling is composed of an upper mold (12), a buffer pad (11), and a bottom mold (6); The upper mold (12) and the bottom mold (6) are combined to form a molding cavity of the composite material component; the buffer pad (11) is made of a flexible buffer material and is fixed to the lower surface of the upper mold (12); The flexible buffer material has a three-layer structure stacked in the order of a flexible rubber layer (1), a fiber-reinforced composite sandwich core, and a wear-resistant rubber layer (5); wherein the fiber-reinforced composite sandwich core is made of a fiber preform and a resin, and the fiber-reinforced composite sandwich core presents a density increasing gradient or a density decreasing gradient in the thickness direction; The bottom mold (6) is provided with a positioning device, which is composed of an edge pressure-stopping block (7) and a middle wedge-shaped positioning block (8).

2. The tooling according to claim 1, characterized in that: The buffer pad (11) is fixed to the lower surface of the upper mold (12) in an adhesive manner.

3. The tooling according to claim 1, characterized in that: The thickness of the buffer pad (11) is 0.6-1.0 mm.

4. The tooling according to claim 1, characterized in that: The shapes of the upper mold (12) and the bottom mold (6) match each other and are a plane, a specific arc shape or a variable curvature shape, and the bottom mold (6) is provided with a concave cavity.

5. The tooling according to claim 1, characterized in that: The bottom surface profile of the edge pressure stop block (7) matches the bottom mold (6) and is designed to be a plane, a specific arc shape, or a variable curvature shape.

6. The tooling according to claim 1, characterized in that: The middle wedge-shaped positioning block (8) is provided with a threaded hole connected to the bottom mold (6).

7. A method for integrally forming a composite material component, characterized in that: Using the tooling according to any one of claims 1 to 6, the one-piece molding method comprises the following steps: S21: preparing a bearing layer (9) and an outer heat protection layer (10); S22: roughening the bonding surface of the bearing layer (9) and the outer heat protection layer (10); S23: placing the bearing layer (9) on the bottom mold (6) of the tooling, and pre-positioning and fixing it; S24: applying adhesive to the bonding surface of the bearing layer (9) and the outer heat-proof layer (10), placing the outer heat-proof layer (10) on the bearing layer (9), positioning and fixing it, and closing the upper mold (12) with the buffer pad bonded to the upper and lower surfaces; S25: placing the tooling on the press, setting press parameters, and pressurizing and curing; S26: Remove the tooling, demould, and obtain the composite material component.

8. The one-piece molding method according to claim 7, wherein: In step S22, the bonding surface is roughened by surface grinding and sandblasting.

9. The integral molding method according to claim 7, wherein: The specific operation of step S23 is to place the bearing layer (9) on the bottom mold (6) of the tooling, so that the inner surface fits the surface of the bottom mold (6), and fix it with the edge pressure limit block (7), and then try to assemble the outer heat protection layer (10), using the edge pressure limit block (7) as a pre-positioning reference to determine the circumferential edge position, and perform alignment, positioning, and adjustment.

10. The integral molding method according to claim 7, wherein: The specific operation of step S24 is to place the outer heat protection layer (10) above the bearing layer (9), use the middle wedge-shaped positioning block (8) to position it so that the positions of the bearing layer (9) and the outer heat protection layer (10) match, and fix the position of the outer heat protection layer (10) after assembling them in place.

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