Composite material mold

Abstract

The utility model relates to a composite material mold which has the capability of being converted between a liquid phase and a solid phase under a phase change condition. The surface of the composite material mold comprises a strength adjusting structure; the tubular object manufactured by the composite material mold can solve the problem that the structural strength is influenced by wrinkles easily caused in the tube in the traditional bag blowing process, and further solve the technical problems that the time is wasted and the failure is easily caused when a line tube is arranged on a frame in a penetrating manner.

Description

TECHNICAL FIELD

[0001] The utility model relates to a kind of mould, specifically to a kind of composite material mould. BACKGROUND

[0002] The existing carbon fiber product, especially for some composite parts with structural strength requirements, such as pipe or cavity, in order to maintain its strength, a forming cavity is formed inside a mold, and the carbon fiber material is adhered inside the forming cavity, and the mold is blown and cured.

[0003] However, the traditional manufacturing method has the problem that the internal space is not easy to control the local structural strength due to the use of blow bag form, which can cause wrinkles, increase the overall weight and produce initial defects that can be damaged, which is difficult to avoid. INVENTION CONTENTS

[0004] To overcome the problem of wrinkles affecting the structural strength of the traditional blow bag process pipe, and to solve the technical problem of wasting time and easily failing to set up the line pipe on the frame, the utility model provides a composite material mold, which is hollow inside. The mold is made of at least one two-phase material, which changes from a solid phase to a liquid phase under a phase change condition.

[0005] The mold includes a strength adjustment structure, which includes a progressive recess or a progressive protrusion on the outer surface of the mold.

[0006] Further, the composite material mold includes an internal heat source.

[0007] The mold includes two two-phase materials, and the phase change conditions of the two two-phase materials are different.

[0008] Further, the outer surface of the composite material mold is recessed with a wire groove for placing an embedded object.

[0009] Further, the outer surface includes a guide structure for prompting the wrapping direction of a carbon fiber material or the setting position of the internal part of the composite material mold.

[0010] The guide structure forms guide patterns, characters, patterns or concave-convex lines on the outer surface to indicate the type of fiber, the direction of fiber.

[0011] As can be seen from the foregoing description, the composite material mold provided by the utility model has the following advantages:

[0012] 1. The inner mold of the utility model has the advantage of accurate size compared with the traditional carbon fiber blow bag process, which solves the technical problem of wrinkles affecting weight and structural strength in the traditional blow bag process pipe.

[0013] 2. The inner mold surface forming strength adjustment structure of the utility model, the strength adjustment structure can selectively let specific area have relatively thick fiber covering, and then decide the local reinforcement effect of final product; because of pre-setting, the structure strength of reinforcing area will be completely ensured, but the most accurate and least material consumption can be maintained, which is the combination of prior art that is difficult to achieve and unexpected effect.

[0014] 3. The inner buried pipe body or wire frame of the utility model can integrate the wire or retain the wire pipeline in the frame process, which not only solves the technical problem of waste time and easy failure of frame pipe penetration, but also makes the overall weight lighter and the structure stronger.

[0015] 4. The internal heat source can heat the local carbon fiber from inside to outside, cooperate with external heating and high pressure, accelerate the overall manufacturing process and improve the yield, reduce a large amount of energy and reduce a large amount of cost.

[0016] 5. The strength adjustment structure of the mold contour pattern can lay the fiber cloth with correct fiber direction at specific positions according to needs, so that the strength of the area and part to be reinforced can be accurately controlled by local reinforcement. BRIEF DESCRIPTION OF DRAWINGS

[0017] FIG. 1A It is the internal mold appearance local schematic view and sectional view of the utility model embodiment.

[0018] FIG. 1B It is the finished product appearance local schematic view and sectional view of the utility model embodiment.

[0019] FIG. 2A It is the mold part enlarged view of the utility model embodiment.

[0020] FIG. 2B It is the mold plan view of the utility model embodiment.

[0021] FIG. 2C It is the mold sectional view schematic view of the utility model embodiment.

[0022] FIG. 2D It is the mold manufacturing process sectional view schematic view of the utility model embodiment.

[0023] FIG. 3 It is the semi-finished product schematic view of the utility model embodiment.

[0024] FIG. 4 It is the process schematic view of the utility model embodiment.

[0025] FIG. 5 It is the mold blank schematic view of the utility model embodiment.

[0026] FIG. 6 A manufacturing schematic diagram of the mold of the embodiment of the present application.

[0027] FIG. 7 A finished product schematic diagram of the second embodiment of the present application.

[0028] FIG. 8 A manufacturing process schematic diagram of the second embodiment of the present application.

[0029] Symbol explanation:

[0030] 10 inner mold

[0031] 11 outer surface

[0032] 12 inner surface

[0033] 13 strength adjustment structure

[0034] 14 guide structure

[0035] 141 non-coated structure

[0036] 15 embedded object

[0037] 151 wire

[0038] 152 drive terminal

[0039] 16 continuous groove

[0040] 20 carbon fiber material

[0041] 20A first carbon fiber material

[0042] 20B second carbon fiber material

[0043] 30 embryo mold reverse mold

[0044] 31 mold opening

[0045] 50 electric bicycle carbon fiber frame DETAILED DESCRIPTION

[0046] In order to solve the limitations and technical problems of the prior art, the present application provides a manufacturing method of carbon fiber structure, please refer to FIG. 1A and 1B, the steps include the following:

[0047] STEP 1) preparing an inner mold 10, the inner mold 10 is hollow, please refer to FIG. 1 and FIG. 8The inner mold 10 is a two-phase material, which includes at least the ability to transform between two phases, such as a liquid phase and a solid phase, which changes from a solid phase to a liquid phase under a phase transfer condition, so that the inner mold 10 changes from a hollow structure to a liquid state without a fixed shape. The phase transfer condition includes but is not limited to water-soluble, heat-soluble, photodegradation, etc. Water-soluble materials such as polyvinyl alcohol (PVA) or its modified materials, heat-soluble materials can also be composites, such as wax, specific metals, etc.

[0048] Further, the inner mold 10 can include two or more two-phase materials, and the phase transfer conditions of the two or more two-phase materials are different; for example, the inner mold 10 includes two-phase change materials of water-soluble materials and heat-soluble materials, which change their phase states under conditions of contacting water molecules or high temperature or composite high-temperature water molecules, etc.

[0049] As shown in FIGS. 2A-2D , wherein the inner mold 10 includes an outer surface 11, an inner surface 12, and optionally includes a strength adjustment structure 13, a guide structure 14, and an embedded object 15; the outer surface 11 is used to attach a carbon fiber material 20, and the strength adjustment structure 13 is a recessed area or a protruding area on the outer surface 11. Among them, the aforementioned strength adjustment structure 13 can be a gradual recess or a gradual protrusion; the gradual recess or the gradual protrusion respectively represents that the recessed area and the protruding area are gradually recessed or protruded from the outer surface 11, forming the gradual recess or the gradual protrusion; preferably, the gradual recess or the gradual protrusion can be hierarchically progressive, that is, it can be enlarged like contour lines at each level.

[0050] The guide structure 14 is used for guiding the attachment process of the carbon fiber material 20, such as forming guide patterns or characters or patterns or concave-convex lines on the outer surface 11 that can indicate the fiber type and the fiber direction. For example, on each level of the gradual recess of the recessed area, the fiber direction and the layer number used are indicated. To help the carbon fiber material 20 to complete the wrapping layer number or wrapping direction corresponding to the strength adjustment structure 13 or the non-planar area when wrapping.

[0051] STEP 2) wrapping carbon fiber on the inner mold 10: repeatedly wrapping or attaching carbon fiber material 20 such as pre-impregnated carbon fiber fabric, unidirectional pre-impregnated carbon fiber cloth (UD film / fabric), strip-shaped carbon fiber yarn, carbon fiber yarn, etc. on the outer surface 11. The carbon fiber yarn and the strip-shaped carbon fiber yarn can be wrapped on the outer surface 11 of the inner mold 10 in a wrapping manner, as shown in FIG. 3The pre-impregnated carbon fiber fabric or unidirectional pre-impregnated carbon fiber cloth can be applied to the outer surface 11 of the inner mold 10 in a manner of lamination, splicing lamination, or laminar stacking; in particular, it is worth mentioning that carbon fibers with different properties can be used in combination and laminated to the outer surface 11 and the strength adjustment structure 13.

[0052] Please refer to FIG. 3 The inner mold 10 is used to manufacture an electric bicycle carbon fiber frame 50 as an example to illustrate the forming method of the electric bicycle carbon fiber frame 50. The inner mold 10 includes the strength adjustment structure 13 with a hierarchical progressive recess, and the guide structure 14 arranged along the strength adjustment structure 13. The guide structure 14 can also be a non-coated structure 141 provided on the outer surface 11. In this embodiment, the non-coated structure 141 can be, for example, a cylinder provided on the outer surface 11 (such as FIG. 2C and 2D). Further, the non-coated structure 141 is a columnar structure provided in the recessed area of the strength adjustment structure 13. When performing the carbon fiber lamination process, the applicator (such as a production line worker) can coat the inner mold 10 around the non-coated structure 141 and stack multiple layers of fiber cloth or fabric with different strengths in the recessed area. In this way, the applicator (such as a production line worker) can stack the appropriate carbon fiber material 20 on the strength adjustment structure 13 and the outer surface 11 according to the guide structure 14 and the strength adjustment structure 13. After the electric bicycle carbon fiber frame 50 is completed, an opening 51 is formed on the surface corresponding to the non-coated structure 141.

[0053] STEP 3) Apply a forming temperature and a forming pressure to the carbon fiber material 20: Please refer to FIG. 4 The inner mold 10 with the carbon fiber material 20 attached and the carbon fiber material 20 are subjected to the forming pressure and the forming temperature, so that the fiber resin ratio of the carbon fiber material 20 reaches the required ratio, thereby improving the structural strength of the final product. The forming temperature can be provided in various ways, such as placing the inner mold 10 with the carbon fiber material 20 attached in a cavity to provide the required temperature for curing and forming the carbon fiber by radiation or conduction. The forming pressure is applied to the carbon fiber to remove the gaps between the layers and the excess resin during the curing and forming process. The forming pressure can be applied by a vacuum bag combined with atmospheric pressure, or the entire inner mold 10 can be placed in a cavity (such as a pressure cooker) that can apply temperature and pressure, so that the forming pressure can extrude the carbon fiber material 20 radially outward from the inner mold 10, allowing the carbon fiber material 20 to be cured and formed on the surface of the inner mold 10.

[0054] For the person skilled in the art to more easily understand how to manufacture the hollow inner mold 10, please refer to FIG. 5 、 6 The steps of the inner mold forming method include:

[0055] 1) Make a blank mold, which has the same appearance as the inner mold 10, which can be designed and printed with the required appearance by using 3D printing, for example;

[0056] 2) Reverse mold the blank mold reverse mold 30 by using the silicone mold turning method to turn the blank mold into the blank mold reverse mold 30, as shown in FIG. 5 ;

[0057] 3) Pour the two-phase material into the blank mold reverse mold 30, and apply a solidification condition during the multi-axis rotation turning process, so that the two-phase material is solidified on the inner surface of the cavity of the blank mold reverse mold; wherein the solidification condition can be selected according to different two-phase materials, such as lowering the temperature, or removing water molecules; wherein the solidification condition can be determined according to the selection of the two-phase material to determine the solidification time of the two-phase material placed in the blank mold reverse mold 30.

[0058] With the control of the multi-axis rotation technology and the solidification time, the two-phase material will start to solidify from the inner surface of the cavity of the blank mold reverse mold, and after the solidification time ends, the remaining two-phase material that has not been solidified will be poured out through a mold opening 31 of the reverse mold 30, so that the two-phase material can be formed in a hollow shape corresponding to the inner surface of the cavity of the blank mold reverse mold.

[0059] Wherein, the selection of the solidification time can also be used to control the thickness of the inner mold 10 after it is formed.

[0060] 4) If necessary, repeat step 3 above to increase the thickness of the two-phase material solidified in the blank mold reverse mold, forming a hollow inner mold 10 as shown in FIG. 7 . Preferably, the inner mold 10 is closed and hollow.

[0061] Further, in order to shorten the overall solidification forming time, the inner mold 10 of the present application can further be provided with an internal heat source, which is wrapped in the inner mold 10 of the solid phase; the internal heat source heats the inner surface 12 of the inner mold 10, which can greatly shorten the forming and solidification time of the carbon fiber. The internal heat source can heat specific areas in an equal heating manner, such as heating the recessed area; in this way, the introduction of the internal heat source and the hollow inner mold 10 of the present application can not only shorten the solidification forming time of the material with relatively thick thickness, but also achieve many unexpected effects of existing technologies, such as improving the overall solidification forming efficiency, reducing the overall energy consumption, improving the quality, reducing the waiting time, etc.

[0062] STEP 4) Removing the inner mold 10: converting the inner mold 10 from solid phase to liquid phase, separating and taking out the carbon fiber material 20 formed by solidification. Different phase conversion conditions are selected according to the two-phase material type of the inner mold 10 used, such as dissolving the inner mold 10 with water or liquefying the inner mold 10 using a hot melt method.

[0063] The aforementioned inner-embedded object 15 can be divided into removable and non-removable types. The removable type includes, for example, an air bag and a two-phase change material. The non-removable inner-embedded object 15 can be a pipeline or a tube with specific functions, such as a brake line, an electric and electronic lead, and a hydraulic pipeline. In order to integrally form the inner-embedded object 15 in the carbon fiber material 20, please refer to FIG. 7 、 8 The inner mold 10 in the aforementioned manufacturing method of the carbon fiber structure is formed to include a continuous groove 16 continuously extending in all or part of the inner mold 10. Taking the electric bicycle carbon fiber frame 50 as an example, the outer appearance of the inner mold 10 is the electric bicycle carbon fiber frame 50, and the outer surface 11 of the upper tube or the lower tube part of the electric bicycle carbon fiber frame 50 is recessed with a lead groove as the continuous groove 16. The lead groove can match the size of the pipeline such as the brake line, the electric and electronic lead, and the hydraulic pipeline exemplified by the aforementioned inner-embedded object 15. The matching means that the lead groove needs to accommodate the pipeline, and the inner diameter is slightly larger than the pipeline, which is used for pre-laying the carbon fiber material 20.

[0064] Please refer to FIGS. 7-8 The present application provides a method for determining the wrapping method of the carbon fiber material 20 and setting the inner-embedded object 15 by the guiding structure 14, which integrates the inner-embedded object 15 in the manufacturing process steps of the electric bicycle carbon fiber frame 50, including:

[0065] 1) Using the inner mold 10 corresponding to the outer shape of the electric bicycle carbon fiber frame 50, the outer surface 11 includes the strength adjustment structure 13, wherein the recessed part of the strength adjustment structure 13 further includes the continuous recess of the lead groove 16 in the outer surface 11, wherein the outer surface 11 can be provided with the guiding structure 14 (not shown in the figure) to guide the method, position, and sequence of the inner mold 10 wrapping the carbon fiber material 20 and setting the inner-embedded object 15;

[0066] 2) Adhering and wrapping one or more layers of a first carbon fiber material 20A in the strength adjustment structure 13 and the continuous groove 16 of the outer surface 11;

[0067] 3) placing at least one of the inclusions 15 in the continuous groove 16 corresponding to the protrusions and depressions of the continuous groove 16;

[0068] 4) covering the first carbon fiber material 20A, the inclusions 15, and the outer surface 11 with a second carbon fiber material 20B;

[0069] 5) applying an external pressure and a molding temperature to the second carbon fiber material 20B and the first carbon fiber material 20A to solidify and mold the first and second composite fabrics into the electric bicycle carbon fiber frame 50 with integrated functional wires; and

[0070] 6) removing the inner mold 10.

[0071] Thus, the electric bicycle carbon fiber frame 50 formed according to the above manufacturing method can achieve a smooth outer surface, but an inner surface with protrusions inwardly and integrally formed with the inclusions 15, wherein the inclusions 15 are surrounded by the carbon fiber material 20 (the first carbon fiber material 20A and the second carbon fiber material 20B), and the first carbon fiber material 20A and the second carbon fiber material 20B are further integrally solidified after being co-pressed (such as the electric bicycle carbon fiber frame 50 product provided in the embodiment), wherein the inclusions 15 can be removable air bags or two-phase materials; or functional brake lines, wires, oil pressure lines, etc.

[0072] Further, taking the inclusions 15 as the wires 151 as an example, the non-covered structure 141 provided as a column at the continuous groove 16 has been described in the foregoing paragraphs and will not be described again. Thus, after the electric bicycle carbon fiber frame 50 is completed, the opening 51 corresponding to the non-covered structure 141 can be formed on the surface, and the opening 51 can be in communication with the continuous groove 16. Thus, a quick-release terminal 152 connected with the wires 151 can be placed in the opening 51, so that the inclusions 15 can be quickly and releasably connected with the quick-release terminal 152, and functionally connected with a driving device.

[0073] The functional connection can be an electrical connection or an oil line connection.

[0074] Further, the inner-embedded objects 15 can be more than two, and the inner-embedded objects 15 can be mixed with different types of inner-embedded objects 15, for example, removable air bags and water-soluble inner-embedded objects 15 are mixed for use, so that a hollow carbon fiber finished product with complex internal structure and multiple chambers but can be integrally formed. As an example of the previous paragraph, the non-coated structure 141 can be directly replaced by the inner-embedded object 15, so that the wire 151 and the drive terminal 152 can be formed together in the electric bicycle carbon fiber frame 50 when the electric bicycle carbon fiber frame 50 is manufactured.

[0075] As the foregoing description, the technology proposed by the utility model has the following characteristics:

[0076] 1. The inner mold 10 proposed by the utility model has the advantage of accurate size compared with the traditional carbon fiber blowing bag process, which solves the technical problem of wrinkles in the traditional blowing bag process that can affect weight and structural strength.

[0077] 2. The inner mold 10 proposed by the utility model forms a strength adjustment structure 13 on the surface, which can selectively allow specific areas to have relatively thick fiber coverage, thereby determining the local reinforcement effect of the final product. Because of the pre-setting, the reinforcement area structure strength will be completely ensured, but the most accurate and least material usage can be maintained, which is a combination of existing technology that is difficult to achieve and unexpected effect.

[0078] 3. The frame with inner-embedded pipes or wires proposed by the utility model can integrate wires or retain wire pipes during the frame process, not only solving the technical problem of wasted time and easy failure of frame pipe penetration, but also making the overall weight lighter and the structure stronger.

[0079] 4. The internal heat source can heat the local carbon fiber from the inside out, combined with external heating and high pressure, to accelerate the overall manufacturing process and improve production, reduce a large amount of energy, and reduce a large amount of cost.

[0080] 5. The strength adjustment structure 13 of the mold contour pattern can lay the fiber cloth with the correct fiber direction at the specified position according to the needs, so that the area and part that needs to be reinforced can be accurately controlled in strength by local reinforcement.

Claims

1. A composite material mold characterized by, The mold has a hollow interior, and is formed by at least one two-phase material that changes from a solid phase to a liquid phase under a phase change condition.

2. The composite tooling mold of claim 1, wherein, The mold includes a strength adjustment structure that includes a gradual recess or a gradual protrusion on an outer surface of the mold.

3. The composite tooling mold of claim 2, wherein, The composite mold includes an internal heat source.

4. The composite tooling mold of claim 3, wherein, The mold includes two two-phase materials, and the phase change conditions of the two two-phase materials are different.

5. A composite mould according to any one of claims 2 to 4, wherein The outer surface of the composite mold is recessed with a wire groove for placing an embedded object.

6. The composite tooling mold of claim 5, wherein, The outer surface includes a guide structure for indicating a wrapping direction of a carbon fiber material or a placement position of an interior of the composite mold.

7. The composite tooling mold of claim 6, wherein, The guide structure forms a guide pattern, text, or pattern or concave-convex lines on the outer surface to indicate a fiber type or a fiber direction.

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