Method of manufacturing a flap bond

Abstract

The application discloses a manufacturing method of aileron bonding parts in the technical field of aerial unmanned planes, and comprises the following steps: S1, preparing laminated plate parts and edge strip parts; S2, pretreating a bonding tool; S3, pretreating bonding surfaces of the laminated plate parts and the edge strip parts; S4, preparing a honeycomb core and a foam core, laying a rubber film or foaming rubber on a preset bonding surface, positioning a lower skin on the bonding tool, and sequentially assembling a preformed framework to be subjected to pre-foaming treatment. By adopting a carbon fiber composite laminated structure, a composite layout of a foam sandwich and a honeycomb sandwich, and an integrated structure design of a single beam and multiple ribs, the application greatly reduces the number of independent parts and standard parts, significantly reduces the overall weight of the aileron bonding parts, effectively improves the flight maneuvering flexibility and endurance of the unmanned plane, and simultaneously reduces flight energy consumption and manufacturing cost.

Description

Technical Field

[0001] This invention relates to the field of aviation unmanned aerial vehicle (UAV) technology, and in particular to a method for manufacturing an aileron adhesive bonding component. Background Technology

[0002] As a crucial piece of equipment in the aviation field, the flight performance of unmanned aerial vehicles (UAVs) is closely related to the lightweight, reliability, and environmental resistance of their wing structures. During UAV missions, the wings must withstand complex aerodynamic loads while meeting long-term service requirements. Therefore, the choice of materials and manufacturing processes for the wing structure directly impacts the UAV's endurance, maneuverability, and operating costs. Reasonable structural design and efficient manufacturing of the wing are key to improving the overall performance of UAVs.

[0003] Currently, the manufacturing of drone wings largely relies on traditional metal materials, which are formed through conventional machining, multi-part assembly, and fastener assembly. In existing technologies, metal materials are widely used in wing manufacturing due to their mature processing technology. The manufacturing process mainly revolves around the cutting, forging, welding, and subsequent assembly of metal blanks, forming a complete wing structure through the combination of multiple independent parts.

[0004] However, existing technologies have certain problems: On the one hand, the high density of metal materials results in a relatively high overall weight of the wing surface, which not only increases the energy consumption of the UAV but also reduces its flight maneuverability, making it difficult to meet the development requirements of lightweight UAVs. On the other hand, the manufacturing of metal wings relies on the processing and assembly of a large number of independent parts and standard components, which not only makes the manufacturing process cumbersome and increases production costs, but also affects the overall stability and corrosion resistance of the wing structure due to gaps and stress concentrations at the joints of multiple components. Long-term use can easily lead to loosening of components, corrosion and aging, and shorten the service life of the wing surface. In addition, traditional manufacturing processes are difficult to achieve integrated structural design and cannot fully utilize the performance advantages of new materials, thus restricting further improvement of UAV wing surface performance. Therefore, we urgently need a manufacturing method for aileron adhesive bonding components to solve the above problems. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a manufacturing method for aileron adhesive bonding components. By adopting an integrated design of composite materials and a stepped bonding process, the method achieves a balance between lightweight and high strength in the aileron, improves structural integrity and corrosion resistance, reduces manufacturing costs and maintenance difficulty, and meets the high-performance and long-life requirements of UAVs.

[0006] The objective of this invention is achieved by including the following steps:

[0007] S1: Fabrication of laminate parts and edge strip parts;

[0008] S2: Pre-treatment of the adhesive bonding fixture;

[0009] S3: Pre-treat the surfaces of the laminate parts and edge strip parts to be glued;

[0010] S4: Prepare honeycomb core and foam core, cover the pre-set bonding surface with adhesive film or foam, position the lower skin on the adhesive bonding fixture, assemble them in sequence to form a pre-formed skeleton, and then perform pre-foaming treatment.

[0011] S5: Lay an adhesive film on the bonding surface between the preformed skeleton and the upper skin, assemble the upper skin and seal it in a vacuum bag. After the air tightness test, transfer it to a hot autoclave for bonding and curing.

[0012] S6: After curing, demold the adhesive parts and perform non-destructive testing, excess cutting, edge sealing, and final inspection in sequence. After passing the inspection, the parts are put into storage.

[0013] Optionally, the laminated parts are formed by laying unidirectional prepreg in a preset layup ratio, and the edge strip parts are formed by laying plain prepreg in a preset layup ratio. During the laying process, vacuum compaction is performed at preset intervals. Both the laminated parts and the edge strip parts are cured in an autoclave and subjected to non-destructive testing before being put into use.

[0014] Optionally, the pretreatment in step S2 includes cleaning, heat treatment, coating with a release agent, and drying at room temperature; the cleaning of the tooling used to prepare the parts in step S1 is the same as the cleaning of the adhesive tooling in step S2, both of which are wiped with organic solvents and alcohol reagents at least twice in sequence, with an interval of not less than a preset time between each wipe.

[0015] Optionally, the pretreatment in step S3 includes roughening each surface to be bonded uniformly with sandpaper at opposite angles, then wiping it clean with a clean cloth moistened with an alcohol reagent and drying it.

[0016] Optionally, the pre-foaming treatment in step S4 includes room temperature vacuuming, heating, heat preservation and cooling operations in sequence. The heating rate and cooling rate are both controlled within a preset range, and the heat preservation temperature and heat preservation time are set according to the characteristics of the film and the foaming adhesive.

[0017] Optionally, in step S4, the preformed skeleton is positioned and fixed by the engraving lines, positioning pins and stop strips on the adhesive bonding fixture. After assembly, the gap between the mating surfaces is checked and the gap is filled with metal foil.

[0018] Optionally, the adhesive curing in step S5 includes room temperature pressurization, heating, heat preservation and cooling operations in sequence. The pressurization rate, heating rate and cooling rate are all controlled within a preset range. The pressurization pressure, heat preservation temperature and heat preservation time are set according to the characteristics of the adhesive film and the adhesive requirements.

[0019] Optionally, in step S5, the outer edge of the adhesive film extends beyond the preset width of the skin edge, and before sealing the vacuum bag, a non-porous isolation film, an alkali-free glass cloth, a breathable felt, and a vacuum nozzle are laid out in sequence.

[0020] Optionally, in step S6, the non-destructive testing adopts the method of detecting internal defects in non-metallic materials; the edge sealing treatment adopts the adhesive sealing method.

[0021] Optionally, the UAV aileron includes an inner elliptical aileron and an outer elliptical aileron, both of which adopt a single beam multi-rib composite structure. A foam core is provided on the upper side of the beam, and a honeycomb core is provided on the lower side of the beam. The joint is formed by machining aluminum alloy forgings.

[0022] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0023] 1. This invention, by adopting a composite layout of carbon fiber composite laminate structure, foam sandwich and honeycomb sandwich, combined with a single beam multi-rib integrated structural design, significantly reduces the number of independent parts and standard parts used, significantly reduces the overall weight of the aileron adhesive joint, effectively improves the flight maneuverability and endurance of the UAV, and at the same time reduces flight energy consumption and manufacturing costs.

[0024] 2. This invention uses a stepped bonding process, including standardized pretreatment of the bonding surfaces, pre-foaming gap filling, and autoclave pressurization and heating curing, to combine the components into an integral structure. This effectively avoids the stress concentration and gap defects problems of traditional spliced ​​ailerons, significantly improves the bonding strength and structural integrity, and enhances the aileron's load-bearing capacity and stability under complex aerodynamic loads.

[0025] 3. This invention, through a quality control system that includes standardized tooling pretreatment, precise assembly of engraving lines and positioning pins, copper foil gap filling, and full-process non-destructive testing, effectively ensures the forming accuracy of parts and the accuracy of adhesive bonding positioning, reduces manufacturing deviations and internal defects, improves product consistency and pass rate, simplifies operation procedures, and increases production efficiency.

[0026] 4. By adapting the mechanical properties of composite materials and metal joints, using adhesive edge sealing and protection, and employing an integrated structural design, this invention significantly improves the corrosion resistance, deformation resistance, and damage tolerance of the aileron adhesive joints, extending the product's service life, reducing the later maintenance costs and replacement frequency of UAVs, and better meeting the usage requirements of UAVs for long life and high reliability. Attached Figure Description

[0027] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0028] Figure 1 This is a schematic diagram of the structure provided by the present invention.

[0029] Figure 2 This is a schematic diagram of the inner aileron structure provided by the present invention.

[0030] Figure 3 This is a schematic diagram of the outer aileron structure provided by the present invention.

[0031] Figure 4 This is a schematic diagram of the process route provided by the present invention.

[0032] Figure 5 This is a flow chart of the laminate forming process provided by the present invention.

[0033] Figure 6 This is a flow chart of the edge strip forming process provided by the present invention.

[0034] Figure 7 This is a flow chart of the adhesive bonding molding process provided by the present invention.

[0035] In the diagram: 1. Joint; 2. Foam; 3. Beam; 4. Rib; 5. Edge strip; 6. Honeycomb. Detailed Implementation

[0036] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0037] like Figure 1-7 As shown in the figure, an embodiment of the present invention provides a method for manufacturing an aileron adhesive component, comprising the following steps:

[0038] S1: Prepare laminate parts and edge strip parts.

[0039] In step S1, the laminate parts are formed by laying unidirectional prepreg according to a preset layup ratio, and the edge strip parts are formed by laying plain prepreg according to a preset layup ratio. During the laying process, vacuum compaction is performed at preset intervals. Both the laminate parts and the edge strip parts are cured in an autoclave and subjected to non-destructive testing before being put into use.

[0040] Here, the laminated parts specifically include the skin, beam 3, and rib 4, which adopt a carbon fiber composite laminate structure, using T700 / P-1 unidirectional prepreg with a layup ratio of 0° / ±45° / 90°=2:2:1 and a single layer thickness of 0.125mm. The edge strip 5 is a thick and complex-shaped laminated structure, using a composite material molding structure, using T300 / P-1 plain weave prepreg with a layup ratio of 0° / ±45°=1:1 and a single layer thickness of 0.2mm. When cutting the prepreg, the outer contour boundary line of the part is exported by software. According to the principle that "the seams of the same direction of layup should be staggered by at least 25mm", the cutting drawing is made by dividing, coding, and sorting by drawing software. It is then imported into an automatic cutting machine for precise cutting. The angle error of the material sheet is controlled within 0.5°. During the laying process, an allowance for machining or cutting is left. The material sheets are laid in a butt joint manner to ensure the accuracy of cutting and laying, providing a basis for the consistency of the mechanical properties of the part structure.

[0041] Furthermore, during the tiling process, the sheets are laid out according to the marked order and the direction of the mold coordinate system. After the first layer is laid, vacuum compaction is performed for 15 minutes. Subsequent layers are vacuum compacted for 15 minutes after every four layers are laid. When laying the parts, they are laid simultaneously with the furnace-filled sheets. During encapsulation, the peeling cloth, non-porous release film, breathable felt, vacuum nozzle, and vacuum bag film are laid out sequentially. After passing the airtightness test, the parts are transferred to an autoclave for curing. The curing parameters are: applied vacuum pressure ≤ -0.095 MPa, and temperature rise to 130±5℃ (heating rate 1.0℃). (Medium temperature 135℃). The fastest heating rate is 40℃ for the thermocouple, then pressurized to a constant pressure of 0.6±0.02MPa. The slowest heating rate is 125℃ for the thermocouple, then held at that temperature for 110-120 minutes. The thermocouple is then cooled to below 80℃ at a rate not exceeding 2.0℃ / min to release the pressure. The thermocouple is then opened at below 60℃. Through standardized laying, sealing and curing processes, interlayer air and excess resin are effectively removed, avoiding defects such as porosity and delamination, and ensuring the structural strength and molding quality of the parts.

[0042] Furthermore, after curing, the mold is allowed to cool to room temperature before demolding. Parts are removed using PTFE sheets. For complex splicing molds, bolts must be removed first before demolding. After non-destructive testing with an ultrasonic flaw detector, the parts are manually polished or machined to make allowances according to the part status table and the engraved lines on the inner surface. The edges are sealed with J-349-1 adhesive. After final inspection of the shape, size, weight, and performance of the parts in the furnace, the surface is cleaned, coded and marked, and packaged with bubble wrap for warehousing. This achieves full-process quality control of the parts, eliminates unqualified products, and ensures that the parts meet the requirements for subsequent bonding. At the same time, the use of carbon fiber composite materials significantly reduces the weight of the parts, laying the foundation for improving the flight flexibility of the UAV.

[0043] S2: Pre-treat the bonding fixture.

[0044] The pretreatment in step S2 includes cleaning, heat treatment, coating with release agent and drying at room temperature; the cleaning of the tooling used to prepare the parts in step S1 is the same as the cleaning of the bonding tooling in step S2, both of which are wiped with organic solvents and alcohol reagents at least twice in sequence, with an interval of not less than a preset time between each wipe.

[0045] Here, the organic solvent is acetone, and the alcohol reagent is anhydrous ethanol. The wiping is done three times, with an interval of at least 10 minutes between each wipe. During cleaning, first remove the tooling oil seal, wipe with acetone, and then place in an oven to heat at 180-200℃ for 3-4 hours. Then wipe with clean wiping paper or cloth moistened with anhydrous ethanol to remove dust, particles and other excess material from the mold surface. Ensure that the tooling surface is undamaged and the scribing lines are clearly visible. Avoid impurities on the tooling surface from affecting the molding accuracy or bonding of the parts and prevent defects from appearing on the surface of the parts.

[0046] Furthermore, after cleaning, a layer of release agent is applied to the working surface of the tooling. After application, it is dried at room temperature for at least 30 minutes to form a uniform release layer, reducing the risk of adhesion between the part and the tooling, ensuring a smooth demolding process, and preventing the part from being deformed or damaged due to improper demolding force.

[0047] Furthermore, whether it is the tooling for preparing laminate parts and edge strip 5 parts in S1, or the bonding tooling in S2, all follow the same cleaning, heating, mold release agent coating and drying standards to achieve standardization and normalization of tooling processing, ensure the consistency of tooling status in each process, provide reliable guarantee for the part forming accuracy and bonding positioning accuracy, simplify the operation process, improve production efficiency, and indirectly reduce manufacturing costs.

[0048] S3: Pre-treat the surfaces of laminate parts and edge strip parts to be glued.

[0049] The pretreatment in step S3 includes roughening each surface to be bonded evenly with sandpaper at opposite angles, then wiping it clean with a clean cloth moistened with an alcohol reagent and drying it.

[0050] Here, 180# sandpaper is selected, with opposite tilt angles of 45° and -45°. Anhydrous ethanol is used as the alcohol reagent. After the bonding surface is roughened, it is wiped clean with a clean cloth soaked in anhydrous ethanol, and then dried for 15 minutes. The roughening treatment increases the roughness of the bonding surface, expands the contact area between the adhesive film and the bonding surface, and thoroughly removes surface oil, dust and other impurities to avoid impurities affecting the bonding effect.

[0051] Furthermore, the roughening process is strictly controlled in terms of intensity and uniformity to ensure that the bonding surfaces are free of dead corners and excessive wear, and to prevent secondary contamination after drying. This ensures the consistency of cleanliness and roughness of the bonding surfaces, allowing the adhesive film to spread evenly and fully wet the interface, thereby improving the adhesion and sealing of the bonding interface.

[0052] Furthermore, standardized pretreatment of the bonding surface provides stable and reliable interface conditions for subsequent pre-foaming and bonding curing, effectively avoiding defects such as delamination and hollowing after bonding, enhancing the structural integrity and stability of the aileron bonding component, ensuring that it can stably transmit stress when subjected to complex aerodynamic loads, and extending its service life.

[0053] S4: Prepare the honeycomb core and foam core, cover the pre-set bonding surface with adhesive film or foam, position the lower skin on the bonding fixture, assemble them in sequence to form a pre-formed skeleton, and then perform pre-foaming treatment.

[0054] The pre-foaming process in step S4 includes vacuuming at room temperature, heating, heat preservation, and cooling operations. The heating rate and cooling rate are controlled within a preset range, and the heat preservation temperature and heat preservation time are set according to the characteristics of the film and the foaming adhesive.

[0055] Here, the honeycomb 6-core is a hexagonal honeycomb 6, and the foam 2-core is PMI foam 2. The pre-set mating surfaces are the contact surfaces between the edge strip 5 and the rib box and beam 3, and the contact surfaces between the honeycomb 6-core and beam 3, rear edge strip 5, and rib 4. The contact surfaces between the edge strip 5, rib box, and beam 3 are covered with adhesive film, and the contact surfaces of the honeycomb 6-core are covered with expanding foam. During assembly, the clean lower skin is first positioned and fixed by the glued tooling, markings, stop strips, and positioning pins. The surface is covered with a non-porous isolation film. Then, the left rib box and insert are installed (after installation, the position of the rib box and the markings are checked). The beam 3 is installed into the left rib box according to the mold markings. Then, the upper rib box of beam 3, foam 2-core, and insert are installed in sequence (the rib box and foam 2 are installed according to the markings, and the insert is installed according to the positioning pins). The right rib box is connected to beam 3. Then, the lower rib box of beam 3 and honeycomb 6-core are installed. Finally, the rear edge strip 5 is placed according to the markings to achieve precise assembly of each component, laying the foundation for a stable skeleton after pre-foaming.

[0056] Further, after assembly, check the gap between the rib box and the baffle, fill it with copper foil, and then cover the honeycomb 6, rib box and other components with a non-porous isolation film. Then, lay EW200A alkali-free glass cloth and the upper skin in sequence and stick them to prevent movement. After sealing the vacuum bag, perform pre-foaming. The pre-foaming parameters are: heating rate ≤2.0℃ / min, room temperature to 70℃ (medium temperature 80℃), slowest heating thermocouple to 70℃ and then hold for 60-70min, cooling rate ≤2.0℃ / min, open the can for inspection below 50℃, fill with copper foil to avoid loss of adhesive film or foam, fix the upper skin to prevent displacement, and use pre-foaming parameters that are adapted to the properties of adhesive film and foam to ensure sufficient foaming and initial bonding, and avoid deformation of the skeleton.

[0057] Furthermore, this process involves pre-assembling and pre-foaming the dispersed components to form a structurally stable pre-formed skeleton, reducing the risk of deformation during subsequent adhesive bonding and curing. At the same time, it achieves preliminary fixation of each component, improving the accuracy and efficiency of subsequent adhesive bonding and ensuring the overall structural strength of the aileron.

[0058] In step S4, the preformed skeleton is positioned and fixed by the engraving lines, positioning pins and stop strips on the adhesive bonding fixture. After assembly, the gap between the mating surfaces is checked and the gap is filled with metal foil.

[0059] Here, the metal foil is copper foil, and the engraving lines on the adhesive bonding fixture clearly define the assembly reference positions of each component. The positioning pins and stop bars work together to restrict the horizontal and vertical displacement of the components. The three work together to achieve precise positioning of each component of the preformed skeleton, ensuring that the skeleton size meets the design requirements after assembly, and avoiding component offset that would cause dimensional deviations in the subsequent adhesive bonding of the ailerons.

[0060] Furthermore, after assembly, check the gaps between key mating surfaces such as the rib box and the baffle, and the beam 3 and the rib box one by one. Fill the gaps with copper foil as needed to eliminate assembly errors, ensure that each component fits tightly, prevent the glue film and foam from accumulating or flowing away in the gaps during pre-foaming or adhesive curing, and ensure the uniformity of the adhesive interface.

[0061] Furthermore, precise positioning and gap filling significantly improve the stability of the pre-formed skeleton structure, resulting in a more uniform stress distribution during subsequent bonding and curing, reducing local stress concentration, improving the overall mechanical properties of the aileron bonding components, ensuring that they can stably withstand aerodynamic loads during the UAV's roll motion, and enhancing flight safety.

[0062] S5: Apply adhesive film to the bonding surface between the preformed skeleton and the upper skin, assemble the upper skin and seal it in a vacuum bag. After airtightness testing, transfer it to an autoclave for bonding and curing.

[0063] Step S5, the bonding and curing process, includes room temperature pressurization, heating, heat preservation, and cooling operations. The pressurization rate, heating rate, and cooling rate are all controlled within preset ranges. The pressurization pressure, heat preservation temperature, and heat preservation time are set according to the characteristics of the adhesive film and the bonding requirements.

[0064] Here, after pre-foaming and demolding, the foam and adhesive film protruding above the skeleton surface are sanded off. A layer of adhesive film is laid on the bonding surface of the upper and lower skins, with the outer edge of the adhesive film extending 1-2mm beyond the edge of the skin. After sealing in a vacuum bag, the skin is vacuum pre-extracted at room temperature for at least 15 minutes. After pre-extraction, the lower skin is placed in the fixture, and the non-porous release film, pre-formed skeleton, and non-porous release film are laid out in sequence. After positioning and fixing the upper skin, it is vacuum-sealed and placed in the tank for pre-compression. The adhesive film indentation is checked, and 1-2 layers of adhesive film are added to areas without indentation. Repeated checks are performed to ensure that the adhesive film compensation meets the bonding requirements. The adhesive film extends beyond the edge to ensure full coverage of the bonding surface. Pre-extraction and pre-compression effectively remove air. Check and add adhesive to avoid missing adhesive and ensure uniform bonding.

[0065] Furthermore, during the lower skin bonding process, the release liner is removed, and the pre-formed skeleton, non-porous release liner, EW200A alkali-free glass cloth, and upper skin are placed and fixed. A vacuum bag is then sealed (sealable synchronously with the furnace components; a non-porous release liner is placed between honeycomb 6 and the upper test plate of the furnace components). After airtightness testing and autoclave leak testing, curing is performed. The parameters are: room temperature, pressurized from 0.02 MPa / min to 0.05 MPa, heating rate ≤2.0℃ / min, medium temperature 130℃, slowest heating to 120℃ via thermocouple followed by holding for 120-130 min, cooling rate ≤2.5℃ / min, and pressure released and opened below 50℃. During the upper skin bonding process, the lower skin bonding component surface adhesive film is first demolded and cleaned. The upper skin is then fixed with pressure-sensitive tape and cured according to the same parameters. Step-by-step bonding and curing parameters adapted to the adhesive film characteristics ensure full curing of the adhesive film. The curing effect is verified synchronously with the furnace components to improve bonding strength and structural integrity.

[0066] Furthermore, the pressurized and heated environment of the autoclave allows the adhesive interface to bond tightly, achieving integral adhesive bonding of the aileron. This significantly reduces the number of parts and standard components, ensuring structural strength while reducing weight, and meeting the requirements of the UAV to withstand complex loads on the wing surface during flight.

[0067] In step S5, the outer edge of the adhesive film extends beyond the preset width of the skin edge. Before sealing the vacuum bag, a non-porous isolation film, an alkali-free glass cloth, a breathable felt, and a vacuum nozzle are laid out in sequence.

[0068] Here, the preset width is 1-2mm, and the alkali-free glass cloth is EW200A alkali-free glass cloth. The laying sequence when sealing the vacuum bag is as follows: first lay the non-porous release film on top of the assembled parts, then lay the EW200A alkali-free glass cloth, then lay the breathable felt, and finally install the vacuum nozzle and cover the vacuum bag film for sealing. The non-porous release film prevents the adhesive film or resin from sticking to other layup materials, the EW200A alkali-free glass cloth enhances the structural strength of the adhesive area, the breathable felt ensures that the air in the vacuum bag is discharged evenly, and the vacuum nozzle ensures a stable vacuuming effect.

[0069] Furthermore, after the packaging is completed, an airtightness test is performed first. Only after confirming that there is no air leakage will it be transferred to the autoclave for subsequent processes. This allows for the timely detection of vacuum bag damage and prevents the bonding quality from deteriorating due to air leakage during the curing process. It also ensures that the pressure and temperature inside the autoclave can be evenly transferred to the bonding interface.

[0070] Furthermore, this layup and encapsulation method ensures the stability of the adhesive curing process, allowing the adhesive film to fully wet the bonding surface and cure completely, significantly improving the sealing and strength of the adhesive, while avoiding adhesive film loss or product surface contamination, ensuring the appearance quality and internal performance of the aileron adhesive components, and giving them good corrosion resistance and fatigue resistance in complex flight environments.

[0071] S6: After curing, demold the adhesive parts and perform non-destructive testing, excess cutting, edge sealing, and final inspection in sequence. After passing the inspection, the parts are put into storage.

[0072] In step S6, non-destructive testing is performed using a non-metallic material internal defect detection method; edge sealing is performed using an adhesive sealing method.

[0073] Here, during demolding, after the mold has cooled to room temperature, the vacuum bag film, breathable felt, and isolation film on the outside of the bonded parts (including those in the furnace) are removed in sequence. Then, the peripheral baffles and inserts are removed, and the bonded parts are separated from the bonding mold. The part number is marked on the outer skin of the bonded parts with a marker. Non-destructive testing is performed using C-scan, ultrasonic testing, and X-ray photography to inspect the internal quality of the honeycomb 6-core bonded parts and those in the furnace. For unqualified products, an unqualified product review form is issued, and qualified products are stamped and marked. A comprehensive inspection is conducted to check for defects such as internal pores, delamination, and delamination to ensure that the internal quality of the products is qualified.

[0074] Furthermore, the excess material is cut by hand grinding or machine cutting. According to the part status table and the external dimensions, the excess material at the edges is removed. After cleaning the excess adhesive and surface dust, particles and other waste, the edges are sealed with J-349-1 adhesive. Precise cutting ensures that the external dimensions of the aileron meet the design requirements. The J-349-1 adhesive sealing can effectively seal the fiber ends of the cut surface, prevent moisture and corrosive media from entering, and improve corrosion resistance.

[0075] Furthermore, during the final inspection, the shape, size, weight, non-destructive testing results, and performance testing of the parts in the furnace are comprehensively examined. After passing the inspection, a certificate of conformity is issued. Before warehousing, the parts are cleaned, coded, and packaged with bubble wrap to form a closed-loop quality control system for post-processing. This ensures the consistency and reliability of the delivered products. The coding facilitates quality traceability, and the bubble wrap packaging avoids damage during transportation and storage, extends the product's lifespan, and reduces the maintenance costs of drones.

[0076] The drone's ailerons include an inner elliptical aileron and an outer elliptical aileron, both of which adopt a single-beam multi-rib composite structure. Foam cores are installed on the upper side of the beam, and honeycomb cores are installed on the lower side of the beam. The joints are machined from aluminum alloy forgings.

[0077] Here, the inner and outer elevons are distributed along the span, and each piece is equipped with two rotating joints 1 for connecting to the wing's rear spars hinge. The skin and ribs 4 of both are made of carbon fiber composite laminate structure, and the rear edge strip 5 is made of composite material molding structure. The joint 1 is specifically machined from 7050-T7451 aluminum alloy forging. Carbon fiber composite material has the characteristics of high specific strength, high specific stiffness and low coefficient of thermal expansion. 7050-T7451 aluminum alloy forging has excellent mechanical properties and processing performance. The combination of the two achieves a balance between lightweight and high strength of the aileron, meeting the load requirements of the UAV during flight.

[0078] Furthermore, the foam 2 core set on the upper side of beam 3 is PMI foam 2, and the honeycomb 6 core set on the lower side of beam 3 is hexagonal honeycomb 6. The foam 2 core and the honeycomb 6 core have both lightweight and buffer energy absorption characteristics, which can further reduce the overall weight of the aileron and improve the structure's resistance to deformation and damage tolerance, avoiding excessive local stress that could lead to structural damage.

[0079] Furthermore, the integrated structural design of the single beam 3 multi-rib 4 significantly reduces the number of independent parts and standard parts, lowers the assembly difficulty and manufacturing cost, while reducing splicing gaps, significantly improving the corrosion resistance and structural stability of the aileron, extending its service life, and the two rotating joints 1 ensure the flexible rotation of the aileron, realizing precise control of the UAV's roll motion, and comprehensively improving the UAV's flight performance and economic efficiency.

[0080] The working principle and usage process of this invention are as follows: A stepped process route is used to achieve precise molding and performance optimization of the aileron adhesive components: First, suitable unidirectional and plain-weave prepregs are selected, and through precise cutting, layering, and autoclaving, laminated parts and edge strip 5 parts that meet mechanical requirements are prepared, providing a structural foundation for subsequent adhesive bonding; then, through stepwise cleaning with organic solvents and alcohol reagents, heat treatment, and coating with a release agent, the tooling surface is ensured to be clean and flat, while the bonding surfaces of the parts are roughened and cleaned to improve the adhesion of the bonding interface; subsequently, the foam core, honeycomb core 6, beam 3, and rib 4 are assembled in a preset order. The components, including the edge strip 5, form a pre-formed skeleton. Pre-foaming treatment is used to achieve initial fixation and gap filling of each component. Then, through film coating, vacuum sealing, and pressurization and heating curing in an autoclave, the components are tightly integrated into a whole, giving full play to the synergistic load-bearing effect of composite materials and sandwich structures. Finally, non-destructive testing is used to check for internal defects. Through excess cutting, adhesive sealing, and comprehensive final inspection, the dimensional accuracy and reliability of the product are ensured. At the same time, by utilizing the mechanical adaptability of the single beam 3 multi-rib 4 combined structure and metal joint 1, the lightweight, high strength and corrosion resistance of the aileron are achieved, meeting the working conditions requirements of the UAV roll motion control.

[0081] The above description of the embodiments is only for the purpose of helping to understand the method and core ideas of the present invention. It should be noted that those skilled in the art can make several improvements and modifications to the present invention without departing from the principles of the present invention, and these improvements and modifications also fall within the protection scope of the claims of the present invention.

Claims

1. A method for manufacturing an aileron adhesive bonding component, characterized in that: Includes the following steps: S1: Fabrication of laminate parts and edge strip parts; S2: Pre-treatment of the adhesive bonding fixture; S3: Pre-treat the surfaces of the laminate parts and edge strip parts to be glued; S4: Prepare honeycomb core and foam core, cover the pre-set bonding surface with adhesive film or foam, position the lower skin on the adhesive bonding fixture, assemble them in sequence to form a pre-formed skeleton, and then perform pre-foaming treatment. S5: Lay an adhesive film on the bonding surface between the preformed skeleton and the upper skin, assemble the upper skin and seal it in a vacuum bag. After the air tightness test, transfer it to a hot autoclave for bonding and curing. S6: After curing, demold the adhesive parts and perform non-destructive testing, excess cutting, edge sealing, and final inspection in sequence. After passing the inspection, the parts are put into storage.

2. The manufacturing method of an aileron adhesive bonding component according to claim 1, characterized in that: In step S1, the laminated parts are formed by laying unidirectional prepreg according to a preset layup ratio, and the edge strip parts are formed by laying plain prepreg according to a preset layup ratio. During the laying process, vacuum compaction is performed at preset intervals. Both the laminated parts and the edge strip parts are cured in an autoclave and subjected to non-destructive testing before being put into use.

3. The manufacturing method of an aileron adhesive component according to claim 1, characterized in that: The pretreatment in step S2 includes cleaning, heat treatment, coating with release agent and drying at room temperature; the cleaning of the tooling used to prepare the parts in step S1 is the same as the cleaning of the bonding tooling in step S2, both of which are wiped with organic solvents and alcohol reagents at least twice in sequence, with an interval of not less than a preset time between each wipe.

4. The manufacturing method of an aileron adhesive component according to claim 1, characterized in that: The pretreatment in step S3 includes roughening each surface to be bonded evenly with sandpaper at opposite angles, then wiping it clean with a clean cloth moistened with an alcohol reagent and drying it.

5. The manufacturing method of an aileron adhesive bonding component according to claim 1, characterized in that: The pre-foaming process in step S4 includes vacuuming at room temperature, heating, heat preservation, and cooling operations. The heating rate and cooling rate are controlled within a preset range, and the heat preservation temperature and heat preservation time are set according to the characteristics of the film and the foaming adhesive.

6. The manufacturing method of an aileron adhesive component according to claim 1, characterized in that: In step S4, the preformed skeleton is positioned and fixed by the engraving lines, positioning pins and stop strips on the adhesive bonding fixture. After assembly, the gap between the mating surfaces is checked and the gap is filled with metal foil.

7. The manufacturing method of an aileron adhesive bonding component according to claim 1, characterized in that: Step S5, the bonding and curing process, includes room temperature pressurization, heating, heat preservation, and cooling operations. The pressurization rate, heating rate, and cooling rate are all controlled within preset ranges. The pressurization pressure, heat preservation temperature, and heat preservation time are set according to the characteristics of the adhesive film and the bonding requirements.

8. The manufacturing method of an aileron adhesive component according to claim 1, characterized in that: In step S5, the outer edge of the adhesive film extends beyond the preset width of the skin edge. Before sealing the vacuum bag, a non-porous isolation film, an alkali-free glass cloth, a breathable felt, and a vacuum nozzle are laid out in sequence.

9. The manufacturing method of an aileron adhesive component according to claim 1, characterized in that: In step S6, non-destructive testing is performed using a non-metallic material internal defect detection method; edge sealing is performed using an adhesive sealing method.

10. A method for manufacturing an aileron adhesive bonding component according to claim 1, characterized in that: The UAV ailerons include an inner elliptical aileron and an outer elliptical aileron, both of which adopt a single beam multi-rib composite structure. Foam cores are set on the upper side of the beams, and honeycomb cores are set on the lower side of the beams. The joints are machined from aluminum alloy forgings.

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