Special-shaped large-size quartz hood integral forming preparation tool and use method thereof
Through the split-flap tooling and vacuum exhaust glue injection technology, the dimensional accuracy and material uniformity problems in the molding process of large-size quartz hoods are solved, and high-precision molding and continuous production of special-shaped products are achieved.
Patent Information
- Application Number
- CN202510666156.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-05-22
- Publication Date
- 2025-08-15
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Figure CN120483498A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of aircraft dielectric material forming, and in particular to a tool for integrally forming and preparing a special-shaped large-size quartz head cover and a method for using the tool. Background Art
[0002] Modern aircraft, especially missiles and other supersonic vehicles, require nose covers that protect the internal payload from harmful environmental influences such as aerodynamic forces, aerodynamic heat, and acoustic vibrations. They also ensure excellent aerodynamic properties and reduce flight resistance. A nose cover typically consists of a cap and a body. The cap bears various loads, provides thermal insulation, and noise isolation, and provides a good operating environment for onboard equipment. The body is also wave-transmitting and heat-resistant. Quartz-reinforced quartz, due to its excellent wave-transmitting properties, thermal protection, and high-temperature strength stability, has been widely used in the manufacture of aircraft nose covers. Combining the cap and body into one, the cover achieves high overall wave-transmitting properties, thermal protection, and excellent strength stability at high temperatures.
[0003] However, the traditional quartz head cover molding process presents several technical challenges, particularly when it comes to large-scale structures, where ensuring dimensional accuracy and material uniformity is particularly challenging. Existing technical solutions struggle to simultaneously address both precision control and material consistency for large structures. Therefore, a new tooling and method are urgently needed to address this issue. Summary of the Invention
[0004] The purpose of the present invention is to provide a tooling for integrally forming and preparing a large-sized quartz head cover of a special shape and a method for using the same. By adopting a petal-type tooling, vacuum pumping and glue injection technology, the dimensional accuracy and density uniformity of the quartz head cover during the forming process can be effectively guaranteed, thereby solving the forming accuracy problems and material uniformity problems existing in the prior art.
[0005] According to one purpose of the present invention, the present invention provides a tool for integrally forming a special-shaped large-size quartz hood, wherein the inner profile of the tool is consistent with the pneumatic outer profile of the quartz hood, and a margin of 2 to 5 mm is left. The tool includes multiple petal outer molds in the axial direction of the quartz hood, and the multiple petal outer molds are assembled by locating pins and screws; at least one glue injection interface is provided at the bottom of the tool, and a valve is provided on the glue injection interface; a core mold is provided inside the tool, and the core mold is consistent with the inner cavity profile of the quartz hood, and the precision of the core mold is higher than the precision of the inner cavity profile of the quartz hood, and the tool is provided with transverse and longitudinal flanges.
[0006] Furthermore, the core mold surface accuracy of the tooling is better than 1 mm rms.
[0007] According to another object of the present invention, the present invention provides a method for using the above-mentioned tooling for integrally forming and preparing a large-sized quartz head cover, comprising the following steps:
[0008] S1. Design and manufacture tooling, and control the tightness of the injection interface through valves;
[0009] S2. Place the quartz fiber preform on the tooling core mold. The size of the preform should be consistent with the size of the tooling cavity.
[0010] S3, drying the tooling core mold and the quartz fiber preform as a whole at high temperature;
[0011] S4, assembling the petaled tooling together with the quartz fiber preform to form an overall sealed cavity;
[0012] S5. Evacuate the sealed cavity to negative pressure through the vacuum nozzle;
[0013] S6. Injecting the quartz solution into the inner space of the quartz fiber preform through the glue injection interface and applying positive pressure;
[0014] S7, heating the entire tooling, the quartz fiber preform, and the sealed cavity of the quartz solution to gel;
[0015] S8. Open the tooling to allow the blank to fully contact with the air and complete the curing and drying;
[0016] S9, grinding the inner and outer surfaces of the blank to expose the internal pores;
[0017] S10, cleaning the surface of the blank with a solution;
[0018] S11, repeat S4 to S10 five to ten times until the density of the blank meets the requirements;
[0019] S12. Process the outer surface of the blank to the designed size.
[0020] Furthermore, in S3, the temperature range of the high-temperature drying of the preform is 400-500°C, and the time range of the high-temperature drying of the preform is 1-3 hours.
[0021] Furthermore, in S4, the preform is a low-density three-dimensional grid structure with a porosity of 40% to 65%;
[0022] In S4, the specific process of constructing the overall sealed cavity is as follows:
[0023] S401, covering the outer surface of the quartz fiber preform with an isolation and diversion material, avoiding the glue injection interface; the isolation and diversion material includes a diversion net and a breathable felt;
[0024] S402, assembling the split molding tooling with the core mold in sequence, so that the tooling and the preform form an integral sealed cavity.
[0025] Furthermore, in S5, the vacuum negative pressure range is 0.008 to 0.015 MPa, and the pressure holding time of the vacuum sealing cavity is not less than 0.5 h;
[0026] In S5, the method for evacuating the sealed cavity to a negative pressure is:
[0027] S501. Connect at least one vacuum air nozzle to the upper flange of the molding tool:
[0028] S502, evacuating the sealed cavity into a vacuum through a vacuum nozzle.
[0029] Furthermore, in S6, the positive pressure range is 1-1.5 MPa; the mass ratio of the quartz solution is 10%-50%;
[0030] In S6, the sealed cavity is injected with quartz solution through the injection interface, the quartz solution completely fills the interior space of the preform, and a positive pressure is applied as follows:
[0031] S601, connecting at least one glue injection channel at the lower flange of the molding tool;
[0032] S602: Inject the quartz solution into the inner space of the preform through the injection channel and pressurize it.
[0033] Furthermore, in S7, the temperature range of the entire heating gel is 50 to 70° C., and the heating time is 2 to 3 hours.
[0034] Furthermore, in S8, the temperature range of the overall curing and drying is 90-120° C., and the time range of the overall curing and drying is 3-5 hours.
[0035] Furthermore, in S10, the solution is alcohol or acetone.
[0036] The technical solution of the present invention solves the problem of difficulty in assembling and demolding special-shaped products through a split-flap molding tool, thereby realizing the integral molding of large-sized quartz head cover products; through the coordinated use of inner and outer molds, the same set of molds realizes the drying molding of the preform and the molding of the product, thereby ensuring the continuity of the product realization process and improving the process molding accuracy of the quartz head cover products; by improving the dimensional accuracy requirements of the inner surface of the tooling, the optimized control of the product surface accuracy is achieved, thereby solving the problem of structural dimensional accuracy control in the integral molding process of large-sized quartz head covers. BRIEF DESCRIPTION OF THE DRAWINGS
[0037] In order to more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the specific embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.
[0038] Figure 1 This is a schematic structural diagram of a molding tool for a special-shaped quartz head cover according to an embodiment of the present invention;
[0039] Figure 2 A top view of a molding tool for a special-shaped quartz head cover according to an embodiment of the present invention;
[0040] Figure 3 This is a cross-sectional view of the molding tool AA for a special-shaped quartz head cover according to an embodiment of the present invention:
[0041] Figure 4 This is a schematic structural diagram of a quartz head cover according to an embodiment of the present invention;
[0042] Figure 5 is a cross-sectional view of a quartz head cover according to an embodiment of the present invention;
[0043] Figure 6 This is a flow chart of a method for integrally forming a large-sized, special-shaped quartz head cover according to an embodiment of the present invention.
[0044] In the figure: 1. Split outer mold of the molding tool; 2. Core mold; 3. Preform; 4. Quartz solution; 5. Vacuum air nozzle; 6. Glue injection interface; 7. Conical rotation structure; 8. Airfoil structure. DETAILED DESCRIPTION
[0045] The following will clearly and completely describe the technical solutions of the present invention in conjunction with the embodiments. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.
[0046] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise" and the like to indicate directions or positional relationships based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operate in a specific direction, and therefore should not be understood as limiting the present invention.
[0047] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the said features. In the description of the present invention, "multiple" means two or more, unless otherwise clearly and specifically defined. In addition, the terms "installed", "connected", and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be an indirect connection through an intermediate medium, or it can be a communication between the two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to the specific circumstances.
[0048] Example 1
[0049] This embodiment provides a tool for integrally forming and preparing a special-shaped large-size quartz hood. The inner surface of the tool is basically consistent with the aerodynamic outer surface of the quartz hood, leaving a margin of 2 to 5 mm; the tool is divided into petals in the axial direction of the hood and assembled with a combination of positioning pins and screws; at least one glue injection interface is provided at the bottom of the tool, and the tightness of each glue injection interface is controlled by a valve; the internal core mold of the tool is consistent with the inner cavity surface of the quartz hood, and the accuracy is higher than the accuracy of the inner cavity surface; the tool is provided with transverse and longitudinal flanges to maintain overall rigidity.
[0050] In this embodiment, the tooling is made of a rigid material such as aluminum alloy, cast iron, 45# steel, or Invar. The axial length of the integrally formed quartz head cover is greater than 1.8 m. The core mold surface accuracy of the tooling is better than 1 mm rms.
[0051] The present invention relates to a tooling and a method for integrally forming a special-shaped large-sized quartz head cover, in particular to a method for integrally forming a special-shaped large-sized quartz head cover with a fiber three-dimensional structure as a reinforcement phase and having certain load-bearing performance, belonging to the technical field of aircraft dielectric material forming.
[0052] Example 2
[0053] This embodiment designs and manufactures a molding tool whose inner surface is consistent with the pneumatic outer surface of the quartz head cover, uses vacuum pressurization technology to solidify the preform, and injects quartz solution into the preform through the glue injection interface to form a high-density, rigid molded product.
[0054] The method for preparing the tooling for integrally forming a large-sized quartz head cover of this embodiment includes the following steps:
[0055] Tooling design and manufacturing:
[0056] The inner surface of the molding tool is essentially identical to the aerodynamic profile of the quartz hood, with a 2-5mm margin. The tool's split-petal design allows for assembly along the hood's axis, with locating pins and screws ensuring assembly stability. The tool's bottom features at least one glue injection port, each controlled by a valve to ensure airtightness and sealing during the molding process.
[0057] Preform preparation:
[0058] A quartz fiber preform is placed on the tooling core mold. The preform's dimensions should match those of the tooling cavity. This preform has a low-density, three-dimensional grid structure with a porosity of 40% to 65%. The tooling and preform are then dried at a high temperature of 400-500°C for 1-3 hours to remove moisture from the preform.
[0059] Vacuum extraction and glue injection:
[0060] The assembled tooling and preform form a sealed cavity, which is then evacuated to a negative pressure using a vacuum nozzle. The vacuum pressure range is 0.008-0.015 MPa, and the pressure is maintained for at least 0.5 hours. Next, a quartz solution is injected into the preform's interior through the injection port, with a mass ratio of 10% to 50%. After injection, a positive pressure of 1-1.5 MPa is applied to ensure that the quartz solution completely fills the preform's voids.
[0061] Gel and heat curing:
[0062] The sealed cavity is heated to a temperature of 50-70°C for 2-3 hours to promote the solidification and formation of the quartz solution. Finally, the blank is demolded, polished, and cleaned to ensure the required density. Finally, the final surface processing is performed to obtain a quartz head cover that meets the design requirements.
[0063] Example 3
[0064] This example uses a large, shaped, integrally formed quartz hood with a quartz solution matrix and a three-dimensional quartz fiber structure as the reinforcement to illustrate the present invention in detail. The term "shaped" refers to a non-axisymmetric, variable-cross-section, winged configuration, and "large" refers to a maximum dimension of 1.8 m for the integrally formed quartz hood.
[0065] like Figure 4 and Figure 5As shown, the aerodynamic shape of the quartz hood primarily comprises a conical rotating structure 7 and an airfoil structure 8. The hood's aerodynamic profile is a non-axisymmetric variable-section airfoil configuration. Therefore, the internal profile of the molding tool is designed to be non-axisymmetric. To achieve a net-size product, the core mold surface accuracy of the molding tool should be better than 1mm / s.
[0066] In order to realize the integral molding of a large-sized quartz head cover with a special shape, the present invention provides a molding tool for the integral molding of a large-sized quartz head cover.
[0067] like Figure 1 As shown, the inner surface of the tooling of this embodiment is basically consistent with the aerodynamic outer surface of the quartz hood, leaving a margin of 2 to 5 mm; the tooling is divided into petals in the axial direction of the hood, including multiple molding tooling petal outer molds 1, and the multiple molding tooling petal outer molds 1 are assembled with positioning pins and screws; at least one injection interface 6 is provided at the bottom of the tooling, and the tightness of each injection interface 6 is controlled by a valve, and can be opened at the same time to improve the injection efficiency; the internal core mold 2 of the tooling is consistent with the inner cavity surface of the quartz hood, and the accuracy is higher than the accuracy of the inner cavity surface; the tooling is provided with transverse and longitudinal flanges to maintain overall rigidity.
[0068] The forming tooling is made of rigid materials, such as aluminum alloy, cast iron, 45# steel or Invar, etc.
[0069] like Figure 1-Figure 3 As shown, in order to ensure the airtightness of the molding tooling, sealing grooves are provided on all the joint surfaces and sealing strips are installed inside. Based on the above molding tooling, the present invention provides a molding method for integrally molding a special-shaped large-size quartz head cover.
[0070] like Figure 1-3 and Figure 6 As shown, this embodiment provides a method for integrally forming a large-sized quartz head cover, specifically comprising the following steps:
[0071] Step (1) designing and manufacturing a tool, wherein the inner profile of the tool is substantially consistent with the pneumatic outer profile of the quartz hood, with a margin of 2 to 5 mm; the tool is divided into petals in the axial direction of the hood, including a plurality of molding tool petal outer molds 1, and the plurality of molding tool petal outer molds 1 are assembled by a combination of positioning pins and screws; at least one glue injection interface 6 is provided at the bottom of the tool, and the tightness of each glue injection interface 6 is controlled by a valve; the internal core mold 2 of the tool is consistent with the inner cavity profile of the quartz hood, and the accuracy is higher than the accuracy of the inner cavity profile; the tool is provided with transverse and longitudinal flanges to maintain overall rigidity;
[0072] Step (2) placing a quartz fiber preform 3 on the tooling core mold 2, wherein the size of the preform 3 is consistent with the size of the tooling inner mold cavity;
[0073] Step (3) drying the tooling core mold 2 together with the quartz fiber preform 3 as a whole at high temperature; the temperature range of the high-temperature drying of the preform 3 is 400-500° C.; the time range of the high-temperature drying of the preform 3 is 1-3 hours.
[0074] Step (4) assembles the petaled tooling together with the quartz fiber preform 3 to form an integral sealed cavity; the preform 3 is a low-density three-dimensional grid structure with a porosity of 40% to 65%.
[0075] Step (5) evacuates the sealed cavity to a negative pressure through the vacuum air nozzle 5; the vacuum negative pressure range is 0.008 to 0.015 MPa, and the pressure holding time of the vacuum sealed cavity is not less than 0.5 h.
[0076] Step (6) Inject the quartz solution 4 into the inner space of the quartz fiber preform 3 through the glue injection interface 6 and apply positive pressure; the positive pressure range is 1 to 1.5 MPa. The mass ratio of the quartz solution 3 is 10% to 50%.
[0077] Step (7) heating the tooling together with the sealed cavity of the quartz fiber preform 3 and the quartz solution to form a gel; the temperature range of the overall heated gel is 50 to 70° C., and the heating time is 2 to 3 hours.
[0078] Step (8) opens the tooling to allow the blank to fully contact with the air and complete curing and drying; the overall curing and drying temperature range is 90 to 120° C., and the overall curing and drying time range is 3 to 5 hours.
[0079] Step (9) grinding the inner and outer surfaces of the blank to expose the internal pores;
[0080] Step (10) cleaning the surface of the blank with a solution; the solution is alcohol or acetone.
[0081] Step (11) repeating steps (4) to (10) 5 to 10 times until the density of the blank meets the requirements;
[0082] Step (12) machining the outer surface of the blank to the designed size.
[0083] In step (4), the specific process of constructing the integral sealed cavity is as follows:
[0084] Step 4.1: Lay isolation and diversion materials on the outer surface of the quartz fiber preform, avoiding the glue injection interface; the isolation and diversion materials include diversion nets and breathable felt.
[0085] Step 4.2: Assemble the split molding tooling with the core mold in sequence, so that the tooling and the preform form an integral sealed cavity.
[0086] In step (5), the method for evacuating the sealed cavity to a negative pressure is:
[0087] Step S5.1, connect at least one vacuum air nozzle to the upper flange of the molding tool:
[0088] Step S5.2: evacuate the sealed cavity through a vacuum nozzle.
[0089] In step (6), the quartz solution is injected into the sealed cavity through the glue injection interface, the quartz solution completely fills the internal space of the preform, and a positive pressure is applied as follows:
[0090] Step S6.1, connecting at least one glue injection channel to the flange at the bottom of the molding tool;
[0091] Step S6.2: injecting the quartz solution into the interior space of the preform through the glue injection channel and pressing it.
[0092] In this embodiment, the glue injection interface and vacuum nozzle are located at the upper and lower flanges of the molding tool, respectively. The glue injection interface is sealed by multiple valves to improve glue injection efficiency. In this embodiment, the internal molding surface of the tooling is substantially consistent with the aerodynamic outer surface of the quartz head cover, and its precision is higher than that of the internal cavity molding surface.
[0093] The present invention solves the problem of difficulty in assembling and demolding special-shaped products by using a split-flap molding tool, thereby realizing the integral molding of large-sized quartz head covers. By using the inner and outer molds in combination, the same set of molds realizes both preform drying and product molding, thereby ensuring the continuity of the product manufacturing process and improving the process molding accuracy of the quartz head covers. By improving the dimensional accuracy requirements of the inner mold surface of the tool, the product surface accuracy is optimized and controlled, thereby solving the problem of structural dimensional accuracy control in the integral molding process of large-sized quartz head covers.
[0094] The present invention combines vacuum negative pressure with a flow-guiding material to achieve uniform infiltration of the entire product, ensuring uniform density and infiltration efficiency. RTM pressurization is used to increase product density and achieve compactness. The inner contour of the product produced using the method of the present invention is better than 1 mm rms, and the product density deviation is ±0.05.
[0095] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the above embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.
Claims
1. A tool for integrally forming and preparing a large-sized quartz head cover, characterized in that: The inner profile of the tooling is consistent with the pneumatic outer profile of the quartz head cover, with a margin of 2 to 5 mm. The tooling includes multiple petal outer molds in the axial direction of the quartz head cover, and the multiple petal outer molds are assembled by locating pins and screws; at least one glue injection interface is provided at the bottom of the tooling, and a valve is provided on the glue injection interface; a core mold is provided inside the tooling, and the core mold is consistent with the inner cavity profile of the quartz head cover, and the accuracy of the core mold is higher than the accuracy of the inner cavity profile of the quartz head cover, and the tooling is provided with transverse and longitudinal flanges.
2. The tooling for integrally forming and preparing a large-sized special-shaped quartz head cover according to claim 1 is characterized in that: The core mold surface accuracy of the tooling is better than 1 mm rms.
3. The method for using the tooling for integrally forming and preparing a special-shaped large-size quartz head cover according to claim 1 is characterized in that: The following steps are involved: S1. Design and manufacture tooling, and control the tightness of the injection interface through valves; S2. Place the quartz fiber preform on the tooling core mold. The size of the preform should be consistent with the size of the tooling cavity. S3, drying the tooling core mold and the quartz fiber preform as a whole at high temperature; S4, assembling the petaled tooling together with the quartz fiber preform to form an overall sealed cavity; S5. Evacuate the sealed cavity to negative pressure through the vacuum nozzle; S6. Injecting the quartz solution into the inner space of the quartz fiber preform through the glue injection interface and applying positive pressure; S7, heating the entire tooling, the quartz fiber preform, and the sealed cavity of the quartz solution to gel; S8. Open the tooling to allow the blank to fully contact with the air and complete the curing and drying; S9, grinding the inner and outer surfaces of the blank to expose the internal pores; S10, cleaning the surface of the blank with a solution; S11, repeat S4 to S10 five to ten times until the density of the blank meets the requirements; S12. Process the outer surface of the blank to the designed size.
4. The method for using the tooling for integrally forming and preparing a large-sized quartz head cover according to claim 3 is characterized in that: In S3, the temperature range of the high-temperature drying of the preform is 400-500° C.: the time range of the high-temperature drying of the preform is 1-3 hours.
5. The method for using the tooling for integrally forming and preparing a special-shaped large-size quartz head cover according to claim 3 is characterized in that: In S4, the preform is a low-density three-dimensional grid structure with a porosity of 40% to 65%; In S4, the specific process of constructing the overall sealed cavity is as follows: S401, covering the outer surface of the quartz fiber preform with an isolation and diversion material, avoiding the glue injection interface; the isolation and diversion material includes a diversion net and a breathable felt; S402, assembling the split molding tooling and the core mold in sequence, so that the tooling and the preform form an integral sealed cavity.
6. The method for using the tooling for integrally forming and preparing a special-shaped large-size quartz head cover according to claim 3 is characterized in that: In S5, the vacuum negative pressure range is 0.008-0.015 MPa, and the pressure holding time of the vacuum sealing cavity is not less than 0.5 h; In S5, the method for evacuating the sealed cavity to a negative pressure is: S501. Connect at least one vacuum air nozzle to the upper flange of the molding tool: S502, evacuating the sealed cavity into a vacuum through a vacuum nozzle.
7. The method for using the tooling for integrally forming and preparing a large-sized quartz head cover according to claim 3, characterized in that: In S6, the positive pressure range is 1-1.5 MPa; the mass ratio of the quartz solution is 10%-50%; In S6, the sealed cavity is injected with quartz solution through the injection interface, the quartz solution completely fills the interior space of the preform, and a positive pressure is applied as follows: S601, connecting at least one glue injection channel at the lower flange of the molding tool; S602: Inject the quartz solution into the inner space of the preform through the injection channel and pressurize it.
8. The method for using the tooling for integrally forming and preparing a large-sized quartz head cover according to claim 3, characterized in that: In S7, the temperature range of the entire gel heating is 50 to 70° C., and the heating time is 2 to 3 hours.
9. The method for using the tooling for integrally forming and preparing a special-shaped large-size quartz head cover according to claim 3, characterized in that: In S8, the temperature range of the overall curing and drying is 90 to 120° C., and the time range of the overall curing and drying is 3 to 5 hours.
10. The method for using the tooling for integrally forming and preparing a special-shaped large-size quartz head cover according to claim 3, characterized in that: In S10, the solution is alcohol or acetone.
Citation Information
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