A composite material protective cover and a method of manufacturing the same

Abstract

The application discloses a composite protective cover and a preparation method thereof, and belongs to the technical field of composite material applications, and comprises the following steps: a) preparing a mold frame, using a mold cleaning agent for mold cleaning treatment before use, and using a demolding agent for demolding treatment; b) laying an outer skin on the lower surface of the frame; c) brushing epoxy glue on the surface of the outer skin, and laying a reinforcing rib and a honeycomb core on the epoxy glue; d) filling foaming glue around the honeycomb core; e) brushing epoxy glue on the surface of an inner skin, and laying the inner skin on the reinforcing rib and the honeycomb core, so that the epoxy glue is bonded with the reinforcing rib and the honeycomb core; f) laying auxiliary materials outside the outer skin and the inner skin; g) performing vacuumizing on the sealed lay-up, and performing warm-pressing and pressure curing to form a solidified product; and h) performing polishing treatment to form a texture after demolding. The application effectively avoids the problems of sagging and deformation in the middle of the protective cover, meanwhile, the light weight characteristic is maintained, the inconvenience in use is significantly reduced, and the operation efficiency and safety are improved.

Description

Technical Field

[0001] This invention relates to the field of composite material application technology, specifically to a composite material protective cover and its preparation method. Background Technology

[0002] The protective covers of marine weapons and equipment are mostly made of metal materials, and most of these metal protective covers are made of steel. Steel is heavy, so the weight of the cover itself is also heavy, which makes it easy for the middle part to sag and deform. For example, a protective cover with a diameter of 2.6m weighs more than 200kg, so special lifting tools are required, making it inconvenient to pick up the cover. Moreover, metal covers are generally made by bending and welding processes, which result in an unsightly appearance and a tendency to deform during welding. Summary of the Invention

[0003] The main objective of this invention is to address the aforementioned technical problems to a certain extent by proposing a composite material protective cover and its preparation method. This protective cover possesses high strength and good mechanical properties, effectively avoiding the problems of sagging and deformation in the middle of the cover, while maintaining its lightweight characteristics. This significantly reduces inconvenience during use and improves operational efficiency and safety.

[0004] On the one hand, a composite material protective cover is proposed, including a frame layer and an outer skin layer and an inner skin layer laid on the upper and lower surfaces of the frame layer. A reinforcing rib layer is laid between the outer skin layer and the inner skin layer in the frame layer. An adhesive layer is provided between the reinforcing rib layer and the outer skin layer and the inner skin layer respectively. A honeycomb core layer is provided between adjacent reinforcing rib layers and in the cavity formed by the reinforcing rib layer and the edge of the frame layer. A foam layer is filled around the honeycomb core layer.

[0005] In some embodiments, the reinforcing rib layup extends from the edge of the frame layer toward the center to form an arc-shaped structure.

[0006] In some embodiments, hollow guide posts are provided along the edge of the frame layer.

[0007] In some embodiments, the frame layer has an upwardly extending flange along its edge.

[0008] On the other hand, a method for preparing a composite material protective cover is proposed, including the following steps: a) Prepare the mold frame, clean the mold with a mold cleaner before use, and release it with a mold release agent; b) Lay the outer skin on the lower surface of the frame; c) Apply epoxy adhesive to the surface of the outer skin, and lay reinforcing ribs and honeycomb core on the epoxy adhesive; d) Fill the perimeter of the honeycomb core with expanding foam; e) Apply epoxy adhesive to the surface of the inner skin and lay the inner skin on the reinforcing ribs and honeycomb core to bond the epoxy adhesive to the reinforcing ribs and honeycomb core. f) Lay non-porous isolation membrane, pressure equalization plate, release cloth and breathable felt on the outer skin and the outer skin of the inner skin, seal the bags with sealing tape and vacuum bag film, and install vacuum extraction valves at the four corners. g) Vacuum the sealed layup and then heat and pressurize it to cure and shape it; h) After demolding, the surface is sanded and polished to create texture.

[0009] In some embodiments, both the outer skin and the inner skin are composed of a carbon fiber veneer layer and a symmetrically laid-up multilayer carbon fiber unidirectional fabric prepreg.

[0010] In some embodiments, the carbon fiber veneer layer uses 200g twill carbon fiber prepreg of T300-3K, and the multilayer carbon fiber unidirectional fabric prepreg uses 150g 1700-12K carbon fiber unidirectional fabric prepreg, and is laid in a symmetrical configuration of 0° / 90° and ±45°.

[0011] In some embodiments, the carbon fiber veneer layer is laid in a 90° / 45° / -45° / 0° / 0° / -45° / 45° / 90° sequence.

[0012] In some embodiments, the epoxy adhesive is a toughened epoxy resin film with a strength of 150 g / m².

[0013] In some embodiments, the foaming adhesive is FM-60 modified epoxy powder foaming adhesive.

[0014] In some embodiments, the reinforcing ribs are made of T700-12K, 150g carbon fiber unidirectional prepreg laid into annular carbon fiber vertical ribs with a wall thickness of 5mm.

[0015] In some embodiments, a thermostatic press is used for curing, wherein the positive pressure inside the thermostatic press is 0.3-0.4 MPa, the curing temperature is 150±5℃, the curing time is 30 minutes, and the product is slowly cooled to room temperature after curing.

[0016] The technical solution provided in this application has the following advantages compared with the prior art: This invention forms a protective cover by laying an outer skin layer and an inner skin layer on the frame layer, and then laying reinforcing ribs and a honeycomb core layer on the outer skin layer and the inner skin layer. This preparation method can produce a lightweight and deformation-resistant protective cover, which can significantly reduce inconvenience during use, improve operational efficiency and safety, and at the same time, the beautiful carbon fiber decorative pattern enhances the appearance value of the product.

[0017] The outer and inner skins of this invention, through specific layup sequences and material selection, ensure that the protective cover has high strength and good mechanical properties, while maintaining lightweight characteristics, further optimizing the performance and service life of the protective cover.

[0018] This invention uses a toughened epoxy resin film to enhance the bonding strength between the outer skin and the aramid honeycomb core, thereby improving the overall structural stability of the protective cover and reducing the risk of structural failure due to environmental changes.

[0019] The invention employs an arc-shaped reinforcing rib design that extends towards the center of the frame layer, effectively preventing deformation and sagging of the cover. In particular, it can maintain the shape and functional integrity of the protective cover when subjected to external impacts and pressure.

[0020] The use of a honeycomb core in this invention provides additional fire safety performance, while the filling of foam enhances the structural strength and durability of the sandwich layer, extending the service life of the protective cover. Attached Figure Description

[0021] 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 some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0022] Figure 1 This is a process flow diagram of the method for preparing the composite material protective cover of the present invention; Figure 2 This is a schematic diagram of the layup of the composite material protective cover of the present invention; Figure 3 This is a structural diagram of the composite material protective cover of the present invention; Figure 4 This is a structural diagram of the composite material protective cover of the present invention.

[0023] Figure label: 1-Outer skin layer; 2-Inner skin layer; 3-Carbon fiber veneer layer; 4-Multi-layer carbon fiber unidirectional prepreg; 5-Flanged edge; 6-Guide post; 7-Reinforcing rib layup; 8-Epoxy adhesive layer; 9-Honeycomb core layer; 10-Foaming layer. Detailed Implementation

[0024] 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 a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0025] It should be noted that if the embodiments of the present invention involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a specific posture. If the specific posture changes, the directional indicators will also change accordingly.

[0026] Furthermore, if the embodiments of this invention involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the use of "and / or" or "and / or" throughout the text includes three parallel solutions. For example, "A and / or B" includes solution A, solution B, or a solution where both A and B are satisfied simultaneously. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0027] like Figure 1-4 As shown, the present invention proposes a composite material protective cover, including a frame layer and an outer skin layer 1 and an inner skin layer 2 laid on the upper and lower surfaces of the frame layer. The outer skin layer 1 and the inner skin layer 2 are both composed of a carbon fiber veneer layer 3 and a multi-layer carbon fiber unidirectional prepreg 4 symmetrically laid together. The frame layer adopts a circular structure with a flange 5 extending upward from its edge, and hollow guide posts 6 are provided on the edge of the frame layer to facilitate subsequent assembly and connection. A reinforcing rib layer 7 is laid between the outer skin layer 1 and the inner skin layer 2. The reinforcing rib layer 7 extends from the edge of the frame layer towards the center to form an arc structure. An epoxy adhesive layer 8 is provided between the reinforcing rib layer 7 and the outer skin layer 1 and the inner skin layer 2 respectively. A honeycomb core layer 9 is provided between adjacent reinforcing rib layers 7 and in the cavity formed by the reinforcing rib layer 7 and the edge of the frame layer. A foam layer 10 is filled around the honeycomb core layer 9.

[0028] like Figure 1 As shown, the method for preparing the composite material protective cover includes the following steps: a) Prepare the mold frame, clean the mold with a mold cleaner before use, and release it with a mold release agent.

[0029] b) Lay the outer skin on the lower surface of the frame.

[0030] In this embodiment, the outer skin is made of a 1.4mm high-strength carbon fiber composite material layer, specifically composed of a carbon fiber facing layer and a multi-layer carbon fiber unidirectional prepreg symmetrically laid up. The carbon fiber facing layer is made of T300-3K 200g twill carbon fiber prepreg, and the multi-layer carbon fiber unidirectional prepreg is made of T700-12K 150g carbon fiber unidirectional prepreg, and is laid up symmetrically at 0° / 90° and ±45°.

[0031] For example, the carbon fiber veneer layer is laid in a 90° / 45° / -45° / 0° / 0° / -45° / 45° / 90° sequence. The outer skin ensures that the protective cover has high strength and good mechanical properties through a specific layup sequence and material selection, while maintaining lightweight characteristics, further optimizing the performance and service life of the protective cover.

[0032] c) Apply epoxy adhesive to the surface of the outer skin. Use a toughened epoxy resin film with a strength of 150g / m². Then, lay reinforcing ribs and honeycomb cores on the epoxy adhesive.

[0033] For example, the reinforcing ribs are made of T700-12K, 150g carbon fiber unidirectional prepreg, laid into 5mm thick annular carbon fiber vertical ribs. The arc-shaped design of the reinforcing ribs, extending towards the center of the frame layer, effectively prevents deformation and sagging of the cover, especially when subjected to external impacts and pressure, maintaining the shape and functional integrity of the protective cover; the honeycomb core uses a density of 32kg / m³. 3 The 3mm thick honeycomb core provides additional fire safety performance, and the use of toughened epoxy resin film enhances the bonding strength between the outer skin and the honeycomb core, improving the overall structural stability of the protective cover and reducing the risk of structural failure due to environmental changes.

[0034] d) Foam is filled around the honeycomb core. The foam is FM-60 modified epoxy powder foam with a foaming ratio ≥2. The filling of foam enhances the structural strength and durability of the sandwich layer and extends the service life of the protective cover.

[0035] e) Apply epoxy adhesive to the surface of the inner skin and lay the inner skin on the reinforcing ribs and honeycomb core to bond the epoxy adhesive to the reinforcing ribs and honeycomb core.

[0036] In this embodiment, the inner skin is made of a 1.4mm high-strength carbon fiber composite material layer, specifically composed of a carbon fiber facing layer and a multi-layer carbon fiber unidirectional prepreg symmetrically laid up. The carbon fiber facing layer is made of T300-3K 200g twill carbon fiber prepreg, and the multi-layer carbon fiber unidirectional prepreg is made of T700-12K 150g carbon fiber unidirectional prepreg, and is laid up symmetrically at 0° / 90° and ±45°.

[0037] For example, the carbon fiber veneer layer is laid in a 90° / 45° / -45° / 0° / 0° / -45° / 45° / 90° sequence. The inner skin ensures that the protective cover has high strength and good mechanical properties through a specific layup sequence and material selection, while maintaining lightweight characteristics, further optimizing the performance and service life of the protective cover.

[0038] f) Lay non-porous isolation membrane, pressure equalization plate, release cloth, and breathable felt on the outer and inner skins, seal them with sealing tape and vacuum bag film, and install vacuum extraction valves at the four corners.

[0039] g) The sealed layup is vacuumed and cured under heat and pressure in an autoclave. The positive pressure inside the autoclave is 0.3-0.4 MPa, the curing temperature is 150±5℃, and the curing time is 30 minutes. After curing, it is slowly cooled to room temperature. The precise control of the autoclave curing conditions ensures uniform curing and optimal performance of the composite material, avoids defects caused by uneven curing, and guarantees the quality and reliability of the protective cover.

[0040] h) After demolding, the parts are polished to form texture. Specifically, after demolding, the surface of the parts is polished with wool wheels and polishing wax. The parts undergo three levels of polishing: coarse polishing, medium polishing, and fine polishing to form carbon fiber texture.

[0041] This embodiment forms a protective cover by laying an outer skin layer and an inner skin layer on the frame layer, and then laying reinforcing rib layers and a honeycomb core layer on the outer and inner skin layers. This manufacturing method can produce a lightweight and deformation-resistant protective cover, which can significantly reduce inconvenience during use, improve operational efficiency and safety. At the same time, the aesthetically pleasing carbon fiber decorative texture enhances the appearance value of the product. Furthermore, the outer and inner skin layers, through a specific layup sequence and material selection, ensure that the protective cover has high strength and good mechanical properties, while maintaining its lightweight characteristics, further optimizing the performance and service life of the protective cover.

[0042] The above are merely preferred embodiments of the present invention and do not limit the scope of the patent. Any equivalent structural transformations made using the contents of the specification and drawings of the present invention under the inventive concept of the present invention, or direct / indirect applications in other related technical fields, are included within the scope of patent protection of the present invention.

Claims

1. A composite material protective cover, characterized in that, The system includes a frame layer and an outer skin layer and an inner skin layer laid on the upper and lower surfaces of the frame layer. A reinforcing rib layer is laid between the outer skin layer and the inner skin layer in the frame layer. An adhesive layer is provided between the reinforcing rib layer and the outer skin layer and the inner skin layer respectively. A honeycomb core layer is provided between adjacent reinforcing rib layers and in the cavity formed by the reinforcing rib layer and the edge of the frame layer. A foam layer is filled around the honeycomb core layer.

2. The composite material protective cover according to claim 1, characterized in that, The reinforcing ribs extend from the edge of the frame layer toward the center to form an arc-shaped structure.

3. The composite material protective cover according to claim 1, characterized in that, The frame layer has hollow guide posts along its edge.

4. A method for preparing a composite material protective cover, characterized in that, Includes the following steps: a) Prepare the mold frame, clean the mold with a mold cleaner before use, and release it with a mold release agent; b) Lay the outer skin on the lower surface of the frame; c) Apply epoxy adhesive to the surface of the outer skin, and lay reinforcing ribs and honeycomb core on the epoxy adhesive; d) Fill the perimeter of the honeycomb core with expanding foam; e) Apply epoxy adhesive to the surface of the inner skin and lay the inner skin on the reinforcing ribs and honeycomb core to bond the epoxy adhesive to the reinforcing ribs and honeycomb core. f) Lay non-porous isolation membrane, pressure equalization plate, release cloth and breathable felt on the outer skin and the outer skin of the inner skin, seal the bags with sealing tape and vacuum bag film, and install vacuum extraction valves at the four corners. g) Vacuum the sealed layup and then heat and pressurize it to cure and shape it; h) After demolding, the surface is sanded and polished to create texture.

5. The method for preparing a composite material protective cover according to claim 4, characterized in that, Both the outer and inner skins are composed of a carbon fiber veneer layer and a symmetrically laid-up multi-layer carbon fiber unidirectional prepreg.

6. The method for preparing a composite material protective cover according to claim 4, characterized in that, The carbon fiber veneer layer uses T300-3K, 200g twill carbon fiber prepreg, and the multilayer carbon fiber unidirectional fabric prepreg uses T700-12K, 150g carbon fiber unidirectional fabric prepreg, and is laid out symmetrically at 0° / 90° and ±45°.

7. The method for preparing a composite material protective cover according to claim 4, characterized in that, The carbon fiber veneer layer is laid in a 90° / 45° / -45° / 0° / 0° / -45° / 45° / 90° sequence.

8. The method for preparing a composite material protective cover according to claim 4, characterized in that, The reinforcing ribs are made of T700-12K, 150g carbon fiber unidirectional prepreg, laid into a ring-shaped carbon fiber vertical rib with a wall thickness of 5mm.

9. The method for preparing a composite material protective cover according to claim 4, characterized in that, The honeycomb core has a density of 32 kg / m³ and a thickness of 3 mm.

10. The method for preparing a composite material protective cover according to claim 4, characterized in that, The autoclave is used for heating and pressurizing curing, with a positive pressure of 0.3-0.4 MPa inside the autoclave, a curing temperature of 150±5℃, and a curing time of 30 minutes. After curing, the autoclave is slowly cooled to room temperature.

Images