Ultrathin lightweight VR light sealing element and process thereof

Abstract

The invention discloses an ultrathin light-weight VR light sealing element and a process thereof, relates to the technical field of VR equipment and optical detection instruments, and aims to solve the problem that traditional steel amp; the PC composite light sealing piece is heavy, the carbon fiber replacement stress is unstable, and 360-degree surrounding back-off is difficult to machine. The light sealing piece takes high-modulus CFRP as a core, adopts five layers, ensures fiber continuity by means of a Fibersim technology, optimizes a nose bridge area to prevent stress concentration, and is provided with a multi-component mold containing a sliding block; the weight is less than or equal to 15g, the thickness is 1.2 mm, and the rigidity is superior to that of a traditional structure; the device is remarkable in light weight, high in rigidity, high in processing qualification rate, good in reliability, capable of being popularized in technology and capable of meeting the requirements of VR equipment.

Description

Technical Field

[0001] This invention relates to the field of VR devices and optical inspection instruments, and in particular to an ultra-thin, lightweight VR light sealing component and its manufacturing process. Background Technology

[0002] In existing technologies, the mainstream solution for optical sealing components is a steel and polycarbonate (PC) composite structure. The specific material composition and parameters are: a 1.25mm thick PC layer + a 0.5mm thick stainless steel layer + a 1.25mm thick PC layer, resulting in an overall structure thickness of 3mm and a weight of 45g. This composite structure achieves basic performance through the "toughness supplementation of PC material + rigid support of stainless steel material," but it suffers from two major limitations in practical applications: First, the weight is too large; 45g is insufficient for the lightweight requirements of VR devices and other scenarios, easily leading to head fatigue and discomfort after prolonged wear. Second, the thickness is too large; the 3mm structure occupies a significant amount of internal space, severely limiting the possibility of miniaturization and thinning in VR devices and optical testing instruments, contradicting the current development trend of "miniaturization and portability" in consumer electronics and precision instruments.

[0003] To address the insufficient lightweighting of traditional steel & PC composite structures, the industry has begun to explore the use of carbon fiber reinforced polymer (CFRP) composites to replace steel & PC structures, leveraging the low density and high strength of CFRP to achieve weight reduction. However, the anisotropy and unique molding characteristics of CFRP itself have led to new technical bottlenecks in this replacement process. Specifically, existing carbon fiber replacement solutions mostly retain the original dimensions of the steel & PC structure, employing traditional lamination processes for 0° unidirectional carbon fiber lay-up, using ordinary standard modulus carbon fibers (such as T300), with a single layer thickness of 0.3mm, and a total of 4 layers (total thickness 1.2mm). Pre-forming is achieved locally through butt bonding. Furthermore, for the critical 360° surrounding inverted waterproof step structure of the light-sealing component, traditional CNC milling is still being used, without systematic computer-aided engineering (CAE) simulation verification, relying solely on physical testing to determine rigidity.

[0004] The existing carbon fiber alternatives have significant drawbacks: First, the layup design is unreasonable. 0° unidirectional layups are prone to fiber breakage in curved structures (such as the area corresponding to the nose bridge of VR light seals), resulting in a lack of continuous fiber support and a decrease in overall rigidity. CAE simulations have verified that under static pressure, the maximum displacement reaches 2.91mm, the torsion angle reaches 5.22°, and the rigidity is even lower than the original steel & PC structure. Second, the problem of localized stress concentration is prominent. The nose bridge area of ​​the light seal is slender (width ≤ 5mm), and the traditional "butt bonding" method results in discontinuous fibers at the bonding points, leading to a stress concentration factor as high as 1 under stress. 8. It is prone to cracks or even breakage, which seriously affects the service life of the structure; third, the molding quality is poor. On the one hand, the bonding area between carbon fiber and the green auxiliary parts of the equipment is only 8mm², and the bonding strength is less than 15MPa. It is easy to fall off during use. On the other hand, the resin filling at the sharp corners (angle ≤30°) of the product is incomplete, which easily produces defects such as bubbles and missing glue, and damages the optical sealing performance; fourth, the processing bottleneck has not been broken. The 360° surrounding inverted buckle is a recessed waterproof step structure. When traditional CNC milling is performed, the tool cannot be inserted into the recessed area. After processing, it is easy to have missing material and burrs, which cannot meet the requirements of waterproofing and structural accuracy.

[0005] In summary, existing optical sealing component technologies are inadequate in terms of balancing lightweight and high rigidity, structural stability, molding quality, and processing feasibility. There is an urgent need for a technical solution that can simultaneously address these issues to meet the core requirements of VR devices and optical testing instruments for optical sealing components that are "ultra-thin, lightweight, highly rigid, and highly reliable." Summary of the Invention

[0006] To address the technical problems existing in the background art, this invention proposes an ultra-thin, lightweight VR light sealing component and its manufacturing process.

[0007] In the first aspect, the present invention proposes an ultra-thin and lightweight VR light sealing component, comprising a VR light sealing component body and a nose bridge area. The VR light sealing component body uses high-modulus carbon fiber reinforced composite material as the core material, adopts a five-layer symmetrical layup structure, with a single layer thickness of 0.24 mm, a total thickness of 1.2 mm, and a weight of ≤15 g. The fiber layup path is optimized by reverse unfolding technology of the Fibersim platform, so that the 0° fibers in the arc area are continuously distributed in a circumferential manner. The bridge of the nose adopts a composite structure with one-piece molding and continuous fiber coverage, with a width of 6mm, a stress concentration factor of ≤1.2, and is provided with a 360° surrounding inverted waterproof step, the depth of which is 1.5mm.

[0008] Furthermore, the high-modulus carbon fiber reinforced composite material has a density of 1.55 g / cm³, a specific strength of ≥1216 MPa・cm³ / g, a specific modulus of ≥112.9 GPa・cm³ / g, a resin content of 38%±2%, and a surface density of 200 g / m².

[0009] Secondly, the present invention also proposes a process for an ultra-thin, lightweight VR light-sealing component, comprising the following steps: a. Prepreg cutting and layup: In a Class 10000 cleanroom at 23℃±2℃ and 45%±5% relative humidity, the high modulus CFRP prepreg is thawed for ≥4h. It is then cut into 5 layers of a specific shape using a CNC laser cutter according to the layup path file output by the Fibersim platform. The dimensional error of each layer is ≤±0.05mm. The layers are then laid manually on a special layup fixture. The layers are rolled 3 times with a rubber roller with a pressure of 0.2MPa to remove interlayer air bubbles. The bubble diameter is ≤0.5mm and the bubble rate is ≤1%. The interlayer bonding strength is ≥25MPa. b. Core mold preforming: After cleaning the 6061 aluminum alloy core mold with a surface roughness Ra≤0.8μm, spray a 5μm±1μm thick release agent and dry at 60℃ for 15min. Place the prepreg layers onto the core mold, ensuring that the 0° fiber direction deviates from the core mold axis by ≤±0.5°. Wrap it in a high-temperature resistant vacuum bag and evacuate to a vacuum degree ≤-0.095MPa. Maintain pre-compression and shaping for 10min, with a shape fit ≥98%. c. Core mold fixing and mold closing: Preheat the mold containing the bottom mold, slider, top mold and core mold to 80℃±5℃. Place the pre-formed core mold and slider into the positioning groove of the bottom mold and fix them with positioning pins. The positioning error is ≤±0.03mm. First close the top mold and bottom mold with a mold closing pressure of 50kN. Then drive the four circumferentially distributed sliders to move inward until they are in contact with the laminated surface. The contact gap is ≤0.02mm. d. Hot-press curing: A three-stage hot-press curing process is adopted. In the heating stage, the temperature is increased from room temperature to 120℃ and the pressure is increased from 0.2MPa to 0.8MPa, which takes 10-30 minutes. In the curing stage, the temperature and pressure are maintained at 120℃ and 0.8MPa for 20-40 minutes, and the resin curing degree is ≥95%. In the cooling stage, the temperature is reduced from 120℃ to 25℃ and the pressure is reduced from 0.8MPa to 0.2MPa, which takes 10-30 minutes, and the residual stress is ≤50MPa. e. Core mold removal and product demolding: When the mold cools to 25℃±2℃ and the product surface temperature is ≤30℃, release the mold closing pressure and use a special core pulling mechanism to separate and pull out the core mold. The pulling force is 10kN and the speed is 5mm / s. Then drive the slider to move outward synchronously along the slide groove at a speed of 3mm / s and a synchronization error of ≤±0.05mm. Finally, remove the product through the ejection mechanism with an ejection force of 20kN and an ejection speed of 2mm / s. f. CNC finishing: Fix the product on a special fixture of the CNC machining center, and clamp it with 3-point positioning. The clamping error is ≤±0.02mm. Use TiAIN coated carbide end mills with a diameter of 3mm and 4 cutting edges. Machining is carried out at a speed of 15000r / min, a feed rate of 500mm / min, and a depth of cut of 0.1-0.2mm. The critical dimension tolerance is ±0.05mm, and the surface roughness Ra≤1.6μm. g. Grinding and defect filling: Grind with 400-grit alumina sandpaper at a speed of 1500 r / min and a pressure of 0.1 MPa. Blow away dust with compressed air. After inspection with an industrial endoscope, fill defects ≤0.3 mm with epoxy resin glue, cure at 60℃ for 30 min, and grind with 600-grit sandpaper until the flatness of the filled area is ≤0.02 mm. h. Waterproof coating spraying: Clean the product with anhydrous ethanol for 10 min using an ultrasonic cleaner, dry at 80℃ for 20 min, spray polytetrafluoroethylene coating using electrostatic spraying equipment, pressure 0.3MPa, distance 200mm, thickness 50μm±5μm, cure at 200℃ for 60 min, coating adhesion ≥15MPa.

[0010] Furthermore, in step a, the CNC laser cutting machine has a cutting speed of 500mm / s and a laser power of 80W, and a polytetrafluoroethylene anti-stick film is applied to the surface of the special layup tooling.

[0011] Furthermore, in step c, the bottom mold of the multi-component mold is made of H13 hot work die steel with a carbon content of 0.32%-0.45% and a chromium content of 4.75%-5.50%. It is quenched and tempered, with a surface hardness of 50-52HRC and a tensile strength of ≥1800MPa. The diameter tolerance of the center positioning groove of the bottom mold is H7, the fitting clearance is 0.015-0.035mm, the inner wall roughness of the slide is Ra≤0.4μm, and high-temperature grease is applied. The diameter of the guide post holes at the four corners is 20mm.

[0012] Furthermore, in step c, the slider is made of S136 stainless steel, which is electrically processed and mirror polished. The inner wall roughness Ra≤0.2μm, the individual size is 80mm×50mm×30mm, the outer oblique guide post hole axis makes an angle of 20° with the direction of movement, the tolerance H8, the fit clearance 0.02-0.04mm, the inner protrusion height is 1.5mm and the width is 2mm, the edge radius is R0.1mm, and the bottom is provided with two 5mm diameter locating pins.

[0013] Furthermore, in step c, the top mold is made of H13 hot work die steel, with four sets of 500W / 220V heating tubes embedded inside, spaced 30mm apart, and the surface temperature uniformity error ≤±2℃; the four corner guide pillars are 20mm in diameter with a tolerance of H6, the flatness of the bottom pressure transmission surface is ≤0.01mm / 100mm, and four venting grooves, each 0.5mm wide and 0.2mm deep, are provided around the molding cavity.

[0014] Furthermore, in step c, the core mold is a split 6061-T6 aluminum alloy structure with an upper section diameter of 30mm and a lower section diameter of 28mm. It is connected by an M10 thread with a precision of 5g. The surface is hard anodized with a film thickness of 15-20μm and a hardness of HV300. A release agent is applied, and an 8mm diameter positioning hole is provided at the top of the upper section with a tolerance of H7.

[0015] Furthermore, in step d, the hot pressing curing is performed using an autoclave; In step h, the drying temperature after ultrasonic cleaning is 80℃ and the time is 20 minutes.

[0016] Furthermore, in step e, the slider demolding is driven by the inclined guide post driving system, the clearance between the inclined guide post and the slider is 0.01-0.02mm, the core pulling mechanism is driven by a servo motor, and the demolding process takes ≤30s.

[0017] The beneficial effects of this invention are: By using high-modulus CFRP as the core material, employing a five-layer layup and Fibersim fiber optimized design, creating multi-component molds with sliders, and combining precise manufacturing processes, this technology achieves extreme lightweighting of light-sealing components, with a weight of ≤15g (66% weight reduction compared to traditional methods) and a thickness of 1.2mm (60% thinner than traditional methods). It also surpasses traditional steel & PC structures in rigidity (maximum displacement ≤2.5mm under 10N force, torsion angle ≤4.8° under 100N·mm torque). Furthermore, it solves the problem of 360° surround undercut processing (increasing the pass rate to over 95%), enhances bonding and sealing performance (bonding strength ≥25MPa, waterproof to IPX7 level), reduces the defect rate (≤0.1%), and the technical solution can be replicated and promoted to other curved CFRP structural components. This multi-dimensional breakthrough overcomes traditional technical pain points, adapts to the needs of VR devices, and has high application value. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the VR light-sealing component in this invention; Figure 2 This is a schematic diagram of the disassembled structure of the mold in this invention.

[0019] In the diagram: 1. VR light-sealing component body; 2. Nose bridge area; 3. Waterproof step; 4. Bottom mold; 5. Slider; 6. Top mold; 7. Core mold. Detailed Implementation

[0020] Reference Figure 1-2 The present invention proposes an ultrathin, lightweight VR light-sealing component and its manufacturing process, the specific implementation of which is as follows: I. Implementation of Ultra-thin Lightweight VR Light Sealing Component Structure The core structure of this VR optical sealing component includes the VR optical sealing component body 1 and the nose bridge area 2, which are integrally molded structures. Together, they realize the optical sealing and structural support functions of VR equipment and optical testing instruments. VR light-sealing component body 1: High-modulus carbon fiber reinforced composite (CFRP) is used as the core material. This material has a density of 1.55 g / cm³, a specific strength ≥1216 MPa・cm³ / g, a specific modulus ≥112.9 GPa・cm³ / g, a resin content controlled at 38%±2%, and a surface density of 200 g / m², ensuring both lightweight construction and high rigidity. The body adopts a five-layer symmetrical layup structure, with a single layer thickness precisely controlled at 0.24 mm, a total thickness of only 1.2 mm, and an overall weight ≤15 g. Compared to traditional steel & PC composite structures, this represents a 66% weight reduction and a 60% thinner profile. During the layup design phase, the fiber layup path is optimized using the reverse unfolding technology of the Fibersim platform. The 0° fibers in the arc region are adjusted to a continuous, circling distribution, which completely avoids the fiber breakage problem in traditional layups and significantly improves the rigidity of the main structure. Tests show that the maximum displacement under a 10N external force is ≤2.5mm and the maximum torsion angle under a 100N·mm torque is ≤4.8°, meeting the stringent requirements of optical equipment for structural stability.

[0021] Nose Bridge Area 2: As a key area for the VR light-sealing component to fit the human face, it adopts a composite structure of "one-piece molding + continuous fiber coverage". The width is optimized to 6mm (20% wider than the traditional slender structure). The continuous fiber completely wraps around this area, eliminating the fiber discontinuity defects caused by traditional "butt bonding", reducing the stress concentration coefficient to below 1.2, and effectively preventing cracks or breakage under stress. At the same time, the outer side of the Nose Bridge Area 2 is equipped with a 360° surrounding inverted waterproof step 3. The recessed depth of the waterproof step 3 is 1.5mm (25% less than the traditional design). It retains the waterproof sealing function and is compatible with the slider molding process of special molds, solving the technical bottleneck of traditional CNC machining, and ensuring that the waterproof sealing reaches IPX7 level (no water leakage after immersion in 1m water for 30 minutes).

[0022] II. Implementation of the Fabrication Process for Ultra-Thin and Lightweight VR Optical Sealing Components This light-sealing component achieves mass production through a process of "prepreg treatment, preforming, mold closing, hot pressing and curing, and post-demolding treatment." The specific implementation details of each step are as follows: Step 1: Prepreg cutting and layup The operation is carried out in a Class 10000 cleanroom, with the environment controlled at a temperature of 23℃±2℃ and a relative humidity of 45%±5% to avoid the impact of dust and temperature and humidity fluctuations on the performance of the prepreg. First, the high-modulus CFRP prepreg is thawed in the workshop for ≥4 hours to ensure that the resin inside the prepreg is fully softened and free of stress residue. Then, a TrumpfTruLaser3030 CNC laser cutting machine is used to cut the prepreg according to the layup path file output by the Fibersim platform. The cutting speed is set to 500mm / s and the laser power to 80W, and the prepreg is precisely cut into 5 layers of a specific shape, with the dimensional error of each layer ≤±0.05mm. After cutting, the layers are manually laid on a special layup fixture with a PTFE anti-stick film on the surface. The layup sequence strictly follows the symmetrical principle of "0° / 45° / 90° / -45° / 0°". After each layer is laid, it is rolled 3 times with a rubber roller with a pressure of 0.2MPa to completely remove interlayer air bubbles (the air bubble diameter should be ≤0.5mm and the air bubble rate should be ≤1%). Finally, the interlayer bonding force is guaranteed to be ≥25MPa, which lays the foundation for the stability of the subsequent molded structure.

[0023] Step 2: Core mold preforming The core mold 7 is made of 6061-T6 aluminum alloy. The surface of the core mold 7 is precision ground to a roughness Ra≤0.8μm. First, the surface oil is wiped clean with alcohol, and then MoldReleaseAgent738 is evenly sprayed on. The spraying thickness is controlled to be 5μm±1μm. Then, it is placed in a 60℃ oven to dry for 15 minutes to ensure that the release agent forms a uniform film on the surface of the core mold 7. The prepreg stack laid in step 1 is placed on the core mold 7. The stack position is adjusted so that the deviation between the 0° fiber direction and the axis of the core mold 7 is ≤±0.5°. Then, the core mold-stack assembly is wrapped with a high-temperature resistant vacuum bag with a temperature resistance of ≥200℃. The vacuum system is connected and the vacuum degree is evacuated to ≤-0.095MPa. This vacuum state is maintained for 10 minutes for pre-pressing and shaping. Finally, the stack is made to fit the contour of the core mold 7 tightly with a shape fit of ≥98%, so as to avoid structural displacement during subsequent hot pressing.

[0024] Step 3: Core mold fixing and mold closing This process uses a four-component mold: bottom mold 4, slider 5, top mold 6, and core mold 7. The specific implementation of each component is as follows: Mold preheating: Place the entire mold into the hot press equipment and preheat it to 80℃±5℃ to eliminate the temperature difference between the mold and the prepreg layers and prevent the resin from flowing unevenly in the early stage of hot pressing due to excessive temperature difference. Core mold fixing: Place the pre-formed core mold 7 and the stacked components into the positioning groove in the center of the bottom mold 4. The bottom mold 4 is made of H13 hot work die steel (carbon content 0.32%-0.45%, chromium content 4.75%-5.50%, quenched and tempered, surface hardness 50-52HRC, tensile strength ≥1800MPa). The diameter tolerance of the positioning groove is H7, and the clearance between the positioning groove and the core mold 7 is 0.015-0.035mm. The core mold 7 is fixed by two positioning pins with a diameter of 10mm at the bottom of the groove to ensure that the positioning error is ≤±0.03mm. Slider and top mold closing: The hydraulic system is activated, first driving the top mold 6 and bottom mold 4 to close, with a closing pressure of 50kN (the top mold 6 also uses H13 hot work die steel, with four sets of 500W / 220V heating tubes embedded inside, spaced 30mm apart, surface temperature uniformity error ≤±2℃, four corner guide pillars with a diameter of 20mm and tolerance H6, matching the guide pillar holes of the bottom mold 4 to ensure coaxiality ≤0.02mm); then driving four ring-arrayed sliders 5 (made of S136 stainless steel, EDM and mirror polished, inner wall roughness Ra≤0.2μm, individual size 80mm×50mm×30mm) along the bottom... The T-shaped groove of mold 4 (groove width 25mm, groove depth 15mm, inner wall roughness Ra≤0.4μm, coated with KluberPlusOG33-220 high temperature grease) moves inward until the inner side of slider 5 is in contact with the laminated surface, with a contact gap ≤0.02mm. At this time, the protruding structure on the inner side of slider 5 (height 1.5mm, width 2mm, edge radius R0.1mm) forms a 360° surrounding the inverted waterproof step 3 molding cavity. The four venting grooves with a width of 0.5mm and a depth of 0.2mm opened around the molding cavity at the bottom of the top mold 6 can ensure that the resin volatilized gas is smoothly discharged during subsequent hot pressing.

[0025] Step 4: Hot pressing and curing After mold assembly, the entire mold is transferred into an ASC Process Systems 36-48 autoclave for a three-stage thermosetting curing process: Heating stage: Slowly raise the temperature from room temperature to 120℃, while simultaneously increasing the pressure from 0.2MPa to 0.8MPa, with the time controlled between 10-30 minutes. Slow heating and pressurization can prevent the resin in the prepreg from flowing rapidly and causing fiber displacement. Curing stage: Maintain temperature at 120℃ and pressure at 0.8MPa for 20-40 minutes to allow the resin to fully cross-link and cure, with a degree of curing ≥95%, forming a stable carbon fiber and resin composite structure. Cooling stage: The temperature is reduced from 120℃ to 25℃, and the pressure is simultaneously reduced from 0.8MPa to 0.2MPa, which takes 10-30 minutes. Slow cooling and pressure reduction can reduce the residual stress generated by curing shrinkage, and ultimately make the residual stress ≤50MPa, so as to avoid warping and deformation of the product after cooling.

[0026] Step 5: Core mold removal and product demolding Once the mold temperature drops to 25℃±2℃ and the product surface temperature is ≤30℃, initiate the demolding process. Core mold removal: First, loosen the mold closing pressure between the top mold 6 and the bottom mold 4. Use a dedicated core pulling mechanism driven by a Panasonic A6 series servo motor to pull the core mold 7 out at a uniform speed of 5mm / s with a pulling force of 10kN. The core mold 7 is a split structure (the upper section has a diameter of 30mm and the lower section has a diameter of 28mm, connected by an M10 thread with a thread precision of 5g). Before pulling the core, separate the threaded connection between the two sections of the core mold, and then pull out the upper and lower sections in sequence. During the extraction process, strictly control the speed and direction to avoid scratching the core mold 7 against the inner wall of the product. The depth of the scratch marks should be ≤0.01mm. Demolding of the slider and the product: Activate the inclined guide post drive system of the mold (the clearance between the inclined guide post and the slider 5 is 0.01-0.02mm), drive the four sliders 5 to move outward synchronously along the sliding groove of the bottom mold 4 at a speed of 3mm / s and a synchronization error of ≤±0.05mm, until the sliders 5 are completely disengaged from the 360° surrounding inverted waterproof step 3; finally, through the ejection mechanism (4 ejector rods with a diameter of 10mm) at the bottom of the bottom mold 4, the product is ejected from the bottom mold 4 with an ejection force of 20kN and an ejection speed of 2mm / s. Remove the product with clean gloves (to avoid contamination from hand oil). The entire demolding process takes ≤30s, without manual intervention, ensuring that the product is undamaged.

[0027] Step 6: CNC finishing After demolding, the product is fixed on a special fixture of the DMG MORIC MX50U CNC machining center. Precise clamping is achieved through a 3-point positioning method (the positioning reference is the reference holes at both ends of the product), with a clamping error of ≤±0.02mm. A 3mm diameter, 4-cut, TiAIN-coated carbide end mill is used, with a machining speed of 15000r / min, a feed rate of 500mm / min, and a cutting depth of 0.1-0.2mm. The edges and reference holes of the product are precision machined to ensure that the tolerance of key dimensions (such as the total length of 216.55mm) is controlled within ±0.05mm, and the surface roughness Ra≤1.6μm, meeting the assembly accuracy requirements of subsequent equipment.

[0028] Step 7: Grinding and Defect Filling Grinding process: Use 400-grit alumina sandpaper to grind the burrs and processing marks on the product surface at a speed of 1500 r / min and a pressure of 0.1 MPa. After grinding, use compressed air with a pressure of 0.5 MPa to blow away the surface dust to avoid dust residue affecting the subsequent coating adhesion. Defect detection and filling: An industrial endoscope with a resolution of 1920×1080 is used to inspect the surface and internal defects of the product. For defects such as bubbles and dents with a diameter ≤0.3mm, epoxy Resin E-51 epoxy resin is used for filling. After filling, the product is placed in a 60℃ oven for curing for 30 minutes. Then, the filled area is sanded with 600-grit sandpaper until the flatness is ≤0.02mm to ensure that the product surface is smooth and free of defects.

[0029] Step 8: Waterproof coating spraying Surface pretreatment: Place the product in an ultrasonic cleaner with a frequency of 40kHz and a power of 500W, and clean it with anhydrous ethanol for 10 minutes to thoroughly remove surface oil stains. Then place it in an 80℃ oven to dry for 20 minutes to ensure that the product surface is dry. Coating spraying: Electrostatic spraying equipment is used, with a spraying pressure of 0.3MPa and a spraying distance of 200mm. A polytetrafluoroethylene (PTFE) coating with a solid content of 60% is sprayed, and the coating thickness is controlled at 50μm±5μm. After spraying, the product is placed in a 200℃ oven for 60 minutes to cure, so that the coating forms a strong bond with the product surface. The final coating adhesion is ≥15MPa, and the waterproof performance reaches IPX7 level, ensuring that the light seal can maintain good sealing performance in humid environments.

[0030] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. An ultra-thin, lightweight VR optical seal, characterized by, The VR light seal body (1) is made of high modulus carbon fiber reinforced composite material as core material, adopts five-layer symmetric layup structure, single layer thickness is 0.24mm, total thickness is 1.2mm, weight is less than or equal to 15g, and the fiber layup path is optimized by Fibersim platform reverse unfolding technology, so that the 0° fiber in the arc area is distributed in a continuous ring shape; The nose bridge area (2) adopts an integrated and continuous fiber covered composite structure, the width is 6mm, the stress concentration coefficient is less than or equal to 1.2, and a 360° ring-shaped reverse waterproof step (3) is arranged, and the reverse waterproof step (3) has a recess depth of 1.5mm.

2. The ultra-thin, lightweight VR light seal of claim 1, wherein, The high modulus carbon fiber reinforced composite material has a density of 1.55g / cm³, a specific strength of greater than or equal to 1216MPa·cm³ / g, a specific modulus of greater than or equal to 112.9GPa·cm³ / g, a resin content of 38%±2%, and a surface density of 200g / m².

3. A process for preparing the ultra-thin, lightweight VR optical seal of claim 1, wherein, The method comprises the following steps: a. Prepreg cutting and layup: in a Class10000 clean workshop with a temperature of 23℃±2℃ and a relative humidity of 45%±5%, the high modulus CFRP prepreg is thawed for more than or equal to 4 hours, a numerical control laser cutting machine is used to cut the prepreg into five layers of specific shapes according to the layup path file output by the Fibersim platform, the size error of each layer is less than or equal to ±0.05mm, the prepreg is manually laid on a special layup tool, and a rubber roller with a pressure of 0.2MPa is used to roll three times to remove air bubbles between the layers, the air bubble diameter is less than or equal to 0.5mm, the air bubble rate is less than or equal to 1%, and the interlayer bonding strength is greater than or equal to 25MPa; b. Core mold preforming: after the 6061 aluminum alloy core mold with a surface roughness Ra of less than or equal to 0.8μm is cleaned, 5μm±1μm thick release agent is sprayed and dried at 60℃ for 15 minutes, the laid prepreg stack is sleeved on the core mold, the 0° fiber direction is deviated from the core mold axis by less than or equal to ±0.5°, the vacuum bag is wrapped after being heated to a high temperature, and then vacuumizing is performed to a vacuum degree of less than or equal to -0.095MPa, and the shape fitting degree is greater than or equal to 98%; c. Core mold fixing and mold closing: the mold containing the bottom mold (4), the slider (5), the top mold (6) and the core mold (7) is preheated to 80℃±5℃, the preformed core mold (7) and the slider (5) are put into the positioning groove of the bottom mold (4) and fixed by the positioning pin, the positioning error is less than or equal to ±0.03mm, the top mold (6) and the bottom mold (4) are closed first, the closing pressure is 50kN, and then the four circumferentially distributed sliders (5) are driven to move inward to the surface of the stack, and the fitting gap is less than or equal to 0.02mm; d. Hot pressing and curing: a three-stage hot pressing and curing process is adopted, the temperature is raised from room temperature to 120℃, the pressure is raised from 0.2MPa to 0.8MPa, and the time consumption is 10-30min, the curing stage is at 120℃ and 0.8MPa for 20-40min, the resin curing degree is greater than or equal to 95%, the temperature is lowered from 120℃ to 25℃, the pressure is lowered from 0.8MPa to 0.2MPa, and the time consumption is 10-30min, and the residual stress is less than or equal to 50MPa. e. Core mold extraction and product demolding: when the mold is cooled to 25℃±2℃ and the surface temperature of the product is ≤30℃, loosen the clamping pressure, use the special core extraction mechanism to extract the core mold, the pulling force is 10kN, the speed is 5mm / s, then drive the slider (5) to move outward along the sliding groove at a speed of 3mm / s, the synchronization error is ≤±0.05mm, finally take out the product through the ejection mechanism, the ejection force is 20kN, the ejection speed is 2mm / s; f. CNC finishing: fix the product on the special fixture of the CNC machining center, clamp it through 3-point positioning, the clamping error is ≤±0.02mm, use TiAIN coated carbide end mill with a diameter of 3mm and 4 blades, process at a speed of 15000r / min, a feed speed of 500mm / min, and a cutting depth of 0.1-0.2mm, the key dimension tolerance is ±0.05mm, and the surface roughness Ra is ≤1.6μm; g. Polishing and defect filling: polish with 400 mesh aluminum oxide sandpaper at a speed of 1500r / min and a pressure of 0.1MPa, blow away the dust with compressed air, fill ≤0.3mm defects with epoxy resin glue after industrial endoscope detection, solidify at 60℃ for 30min, and polish with 600 mesh sandpaper until the flatness of the filled area is ≤0.02mm; h. Waterproof coating spraying: use an ultrasonic cleaner to clean the product with anhydrous ethanol for 10min, dry at 80℃ for 20min, use electrostatic spraying equipment to spray polytetrafluoroethylene coating, the pressure is 0.3MPa, the distance is 200mm, the thickness is 50μm±5μm, solidify at 200℃ for 60min, and the coating bonding force is ≥15MPa.

4. The ultra-thin, lightweight VR optical seal process of claim 3, wherein, In step a, the numerical control laser cutting machine cuts at a speed of 500mm / s and a laser power of 80W, and the special layering tooling surface is attached with polytetrafluoroethylene release film.

5. The ultra-thin, lightweight VR optical seal process of claim 3, wherein, In step c, the bottom mold of the multi-component mold is made of H13 hot work die steel with a carbon content of 0.32%-0.45% and a chromium content of 4.75%-5.50%, after quenching and tempering treatment, the surface hardness is 50-52HRC, and the tensile strength is ≥1800MPa; the center positioning groove of the bottom mold has a diameter tolerance of H7 and a fit clearance of 0.015-0.035mm, the inner wall roughness of the sliding groove is Ra≤0.4μm, high-temperature lubricating grease is applied, and the four corner guide pillar holes have a diameter of 20mm.

6. The ultra-thin, lightweight VR optical seal process of claim 3, wherein, In step c, the slider is made of S136 stainless steel, processed by electric spark and mirror polished, the inner wall roughness is Ra≤0.2μm, the single size is 80mm×50mm×30mm, the angle between the outer side inclined guide pillar hole axis and the movement direction is 20°, the tolerance is H8, the fit clearance is 0.02-0.04mm, the inner side protrusion height is 1.5mm, the width is 2mm, the edge R0.1mm round corner, and the bottom is provided with two positioning pins with a diameter of 5mm.

7. The ultra-thin, lightweight VR optical seal process of claim 3, wherein, In step c, the top mold is made of H13 hot work die steel, with 4 groups of 500W / 220V heating pipes embedded inside, the spacing is 30mm, the surface temperature uniformity error is ≤±2℃; the four corner guide pillars have a diameter of 20mm, the tolerance is H6, the bottom pressure transmission surface flatness is ≤0.01mm / 100mm, and 4 exhaust grooves with a width of 0.5mm and a depth of 0.2mm are arranged around the forming cavity.

8. The ultra-thin, lightweight VR optical seal process of claim 3, wherein, The mandrel in step c is a split 6061-T6 aluminum alloy structure, with an upper section having a diameter of 30 mm and a lower section having a diameter of 28 mm, connected by an M10 thread, with a precision of 5 g, a surface hard anodic oxidation, a film thickness of 15-20 μm, a hardness of HV300, and a coating release agent. The upper section has a diameter of 8 mm positioning hole at the top, with a tolerance of H7.

9. The ultra-thin, lightweight VR optical seal process of claim 3, wherein, The hot pressing and curing in step d uses a hot press tank. The drying temperature after ultrasonic cleaning in step h is 80°C, and the time is 20 min.

10. The ultra-thin, lightweight VR optical seal process of claim 3, wherein, The sliding block demolding in step e is driven by an inclined guide pillar driving system, with a clearance of 0.01-0.02 mm between the inclined guide pillar and the sliding block. The core pulling mechanism is driven by a servo motor, and the demolding process takes ≤30 s.

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