Rigid-flexible combined mold for molding carbon fiber composite grid rib cabin shell product

Abstract

The application discloses a rigid-flexible combined mold for forming a carbon fiber composite material grid rib cabin shell product, which is composed of a combined male mold and a frame type female mold, the male mold comprises a lining and a male mold shell, the male mold shell is fixed to the outer circumferential side of the lining, the male mold shell comprises a metal shell and a flexible shell, the metal shell is formed by combining a plurality of metal blocks, two metal shells are oppositely arranged in a second direction which is orthogonal to a first direction, and the flexible shell has two flexible shells which are connected between the metal shell and the flexible shell respectively. The principle of the mold is to ensure the shape profile degree of the product and the high continuous ratio of the longitudinal and transverse grid ribs of the internal grid ribs by the expansion of the aluminum alloy and the silicon rubber male mold inner mold and the shape maintaining of the closed steel outer female mold; the carbon fiber composite material mold is formed by utilizing the expansion coefficient difference characteristics of the aluminum alloy and the steel mold under high-temperature curing. The technical problem that the male mold is not easy to demold is solved.

Description

Technical Field

[0001] This application belongs to the field of aerospace composite materials technology, specifically relating to a rigid-flexible combined mold for molding carbon fiber composite mesh rib cabin shell products. Background Technology

[0002] Carbon fiber composites possess advantages such as light weight, high strength, and high stiffness, making them widely used in aerospace and other fields. As a carbon fiber repositioning material product in the aerospace industry, the cabin body is often manufactured using a composite mold method. This involves solidifying and shaping the cabin body through a cavity formed between a male mold and a female mold fitted around the outer periphery of the male mold. However, in practice, the male mold inside the shaped cabin body often faces difficulties in demolding, reducing overall processing efficiency and lowering the overall quality and precision of the cabin body. Utility Model Content

[0003] This application aims to at least partially address one of the technical problems in the related art.

[0004] To address the aforementioned technical issues, this application provides a rigid-flexible combined mold for molding carbon fiber composite mesh rib shell products. The male mold shell of this mold adopts a differential design of metal shell and flexible shell, which facilitates demolding after product molding and improves overall processing efficiency.

[0005] The technical solution adopted to achieve the purpose of this application is as follows:

[0006] The rigid-flexible combined mold for molding carbon fiber composite mesh rib shell products of this application includes a male mold, wherein the male mold includes:

[0007] The liner includes two edges arranged opposite each other in a first direction;

[0008] A male mold housing is fixed to the outer periphery of the inner liner. The male mold housing includes a metal housing and a flexible housing. The metal housing is assembled from multiple metal blocks. There are two metal housings, which are arranged opposite each other in a second direction orthogonal to the first direction. There are two flexible housings, which are respectively connected between the metal housing and the flexible housing, and the two flexible housings are respectively located on the outer side of the two edges.

[0009] In some technical solutions, the outer peripheral wall of the male mold shell is provided with multiple longitudinal rib grooves and multiple circumferential rib grooves;

[0010] The plurality of longitudinal ribs are arranged to extend along a third direction, which is perpendicular to both the first direction and the second direction, and the plurality of longitudinal ribs are arranged at intervals in the circumferential direction of the male mold shell.

[0011] The circumferential grooves extend and close around the circumference of the male mold shell, and multiple circumferential grooves are arranged at intervals along the third direction. Both the longitudinal grooves and the circumferential grooves are used for embedding the mesh ribs of the product.

[0012] In some technical solutions, multiple metal blocks are arranged in a matrix to form multiple block rings and multiple block rows;

[0013] The assembly ring includes a plurality of metal pieces arranged sequentially along the circumference of the male mold housing, and the plurality of assembly rings are arranged sequentially along the third direction. The assembly row includes a plurality of metal pieces arranged sequentially along the third direction, and the plurality of assembly rows are arranged sequentially along the circumference of the male mold housing.

[0014] In some technical solutions, the flexible shell is configured in parts and includes multiple flexible modules, which are arranged sequentially along the third direction.

[0015] In some technical solutions, the metal module is an aluminum alloy module, and the flexible module is a silicone rubber module.

[0016] Some technical solutions also include:

[0017] A first connecting plate is disposed at one end of the inner liner, and one end of the male mold shell is connected to the first connecting plate;

[0018] The second connecting plate is located at the other end of the inner liner, and the other end of the male mold shell is connected to the second connecting plate.

[0019] Some technical solutions also include a female mold, which includes:

[0020] The upper mold and the lower mold are fitted together. The male mold is assembled in the cavity formed by the upper mold and the lower mold, and the annular space between the male mold and the female mold forms a cavity for preparing the product.

[0021] Two baffles are respectively installed on opposite sides of the female mold. One baffle is connected to one end of the male mold, one end of the upper mold, and one end of the lower mold and is used to block one end of the cavity. The other baffle is connected to the other end of the male mold, the other end of the upper mold, and the other end of the lower mold and is used to block the other end of the cavity.

[0022] Furthermore, one of the baffles is sleeved on the outer periphery of a portion of the first connecting plate, and the other baffle is sleeved on the outer periphery of a portion of the second connecting plate.

[0023] In some technical solutions, the upper mold includes two side edges arranged opposite to each other in the first direction, the side edges protruding toward the lower mold, and the two side edges are respectively connected to the two baffles.

[0024] In some technical solutions, the lower mold includes:

[0025] A support frame includes two side plates and multiple middle plates. The two side plates are arranged opposite to each other in a first direction. The top side of each middle plate is provided with a groove. The multiple middle plates are connected between the two side plates and are spaced apart in the opposite direction of the first connecting plate and the second connecting plate.

[0026] A template, the shape of which matches a portion of the outer periphery of the male mold, and the template is fixed within the grooves of the plurality of intermediate plates.

[0027] In some technical solutions, a mold closing assembly is also included. The mold closing assembly includes a guide groove and a guide part. The guide groove is located in the lower mold, and the guide part is located in the male mold. The guide part is used to insert into the guide groove when the mold is closed.

[0028] As can be seen from the above technical solution, the rigid-flexible combination mold for molding carbon fiber composite mesh rib shell products of this application adopts a differential design of metal shell and flexible shell for the male mold shell, which facilitates demolding after product molding and improves the overall processing efficiency. Attached Figure Description

[0029] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0030] Figure 1 This is a schematic diagram of the overall structure of the male mold in the embodiments of this application.

[0031] Figure 2 This is a schematic diagram of the inner lining of the male mold in an embodiment of this application.

[0032] Figure 3 This is an exploded view of the male mold shell of the male mold in the embodiments of this application.

[0033] Figure 4 This is a schematic diagram showing the arrangement of the ribs and blocks of the male mold in the embodiments of this application.

[0034] Figure 5 This is a schematic diagram of the flexible shell in an embodiment of this application.

[0035] Figure 6 This is a schematic diagram of the structure of the female mold in the embodiments of this application.

[0036] Figure 7 This is a schematic diagram of the baffle of the female mold in the embodiments of this application.

[0037] Figure 8 This is an assembly diagram of the male mold and female mold in the embodiments of this application.

[0038] Figure 9 This is a schematic diagram of the lower mold structure of the female mold in the embodiments of this application.

[0039] Figure 10 This is a schematic diagram of the support frame of the lower mold in the embodiments of this application.

[0040] Figure 11 This is a schematic diagram of the mold closing component in an embodiment of this application.

[0041] Explanation of reference numerals in the attached figures:

[0042] 100 - Male mold; 110 - Liner; 1101 - Edge; 120 - Male mold shell; 1201 - Metal shell; 12011 - Metal block; 1202 - Flexible shell; 12021 - Flexible block; 1203 - Longitudinal rib groove; 1204 - Annular rib groove; 1205 - Block ring; 1206 - Block row; 130 - First connecting plate; 140 - Second connecting plate;

[0043] 200-Female mold; 210-Upper mold; 2101-Side edge; 220-Lower mold; 2201-Support frame; 22011-Side plate; 22012-Middle plate; 2202-Shaped plate; 230-Baffle plate;

[0044] 300 - Mold closing assembly; 310 - Guide groove; 320 - Guide section. Detailed Implementation

[0045] To enable those skilled in the art to more clearly understand this application, the technical solutions in the embodiments of this application 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 this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0046] It should be noted that this application is based on the inventor's discovery and understanding of the following facts and problems:

[0047] Due to the special design of the hull and other shell structures, if the positive mold is made entirely of metal materials such as aluminum alloy, the large number of metal blocks in the mold for the two sides of the hull, as well as the complexity of assembly and disassembly, can easily lead to risks such as inability to demold.

[0048] Specifically, if the male mold is made entirely of alloy steel, it suffers from drawbacks such as large weight, high heat resistance leading to excessive heat absorption and slow temperature rise during subsequent curing, resulting in high energy consumption, long cycle time, and difficult assembly. If the male mold's mesh reinforcement and skin are made entirely of silicone rubber, the manufacturing of silicone rubber itself requires molds and vulcanization, resulting in long manufacturing cycles and high costs. Furthermore, due to the inherent hardness and compressive strength of silicone rubber, it is difficult to achieve the design process requirement of a 75%-100% longitudinal and transverse fiber ratio for the mesh reinforcement; only a 50%:50%, 60%:40%, or 70%:30% ratio can be achieved. In this case, the mesh reinforcement part needs to be formed into a cross-shaped mesh reinforcement with a certain radius at the cross intersection using an equal volume calculation method. At the same time, the formation of the end frame requires the addition of steel inserts to avoid the large radius formed by the insufficient hardness and compressive strength of silicone rubber when the fibers are stretched during the curing process of the mesh reinforcement and skin fibers, which does not meet the design and process assembly requirements.

[0049] Based on the above facts and problems, this application provides a rigid-flexible combined mold for molding carbon fiber composite mesh rib shell products.

[0050] The following describes an embodiment of the rigid-flexible combined mold for molding carbon fiber composite mesh ribbed shell products of this application.

[0051] like Figure 1 As shown in the embodiment of this application, the rigid-flexible combined mold for molding carbon fiber composite mesh rib cabin shell products includes a male mold 100, which includes an inner liner 110 and a male mold shell 120.

[0052] The liner 110 includes two edges 1101 arranged opposite each other in a first direction. For example, as Figure 2As shown, the inner liner 110 can be a tubular structure with a triangular cross-section. The inner liner 110 can be arranged to extend along the front-back direction. The first direction can be the left-right direction. The left edge 1101 and the right edge 1101 of the inner liner 110 can be arranged opposite each other in the left-right direction.

[0053] The male mold housing 120 is fixed to the outer periphery of the inner liner 110. The male mold housing 120 includes a metal housing 1201 and a flexible housing 1202. The metal housing 1201 is assembled by multiple metal blocks 12011. There are two metal housings 1201, which are arranged opposite each other in a second direction orthogonal to the first direction. There are two flexible housings 1202, which are respectively connected between the metal housing 1201 and the flexible housing 1202, and the two flexible housings 1202 are respectively located on the outside of the two edges 1101.

[0054] For example, the male mold housing 120 can also be a tubular structure. The overall radial dimension of the male mold housing 120 is larger than the radial dimension of the inner liner 110. The male mold housing 120 can be fitted and fixed to the outer periphery of the inner liner 110. Depending on the material, the male mold housing 120 can include a metal housing 1201 and a flexible housing 1202. The metal housing 1201 can be made of metals such as aluminum alloy, while the flexible housing 1202 can be made of materials with a certain degree of flexibility, such as silicone rubber.

[0055] like Figure 3 As shown, two metal shells 1201 and two flexible shells 1202 can be provided. One metal shell 1201 can have a V-shaped cross-section, and the other metal shell 1201 can be flat. The second direction can be vertical, and the two metal shells 1201 can be arranged opposite each other in the vertical direction. Both flexible shells 1202 can be elongated and can extend along a third direction, which can be front-back. One flexible shell 1202 can be connected between the left edges 2101 of the two metal shells 1201, and the other flexible shell 1202 can be connected between the right edges 2101 of the two metal shells 1201.

[0056] When the metal housing 1201 is installed on the outer periphery of the inner liner 110, the flexible housing 1202 on the left side can be arranged opposite to the left edge 1101 of the inner liner 110 in the inward and outward directions, and the flexible housing 1202 on the right side can be arranged opposite to the right edge 1101 of the inner liner 110 in the inward and outward directions.

[0057] like Figure 4As shown, the metal shell 1201 can be composed of multiple metal blocks 12011. The metal blocks 12011 can be roughly rectangular, and the multiple metal blocks 12011 can be arranged in a matrix, which facilitates the forming of the metal shell 1201.

[0058] In use, carbon fiber products such as cabin bodies can be formed on the outer periphery of the male mold 100. After the product has been cured and formed, a part of the metal shell 1201 can be removed, and then the flexible shell 1202 can be taken out from the corner of the product. Since the flexible shell 1202 has a certain flexible deformation capability, it is convenient for the male mold 100 to be demolded at the corner of the product.

[0059] In some embodiments, the outer peripheral wall of the male mold housing 120 is provided with a plurality of longitudinal rib grooves 1203 and a plurality of circumferential rib grooves. The plurality of longitudinal rib grooves 1203 are all arranged to extend along a third direction, which is perpendicular to both the first and second directions. The plurality of longitudinal rib grooves 1203 are arranged at intervals in the circumferential direction of the male mold housing 120. The circumferential rib grooves extend along the circumferential direction of the male mold housing 120 to form a circle. The plurality of circumferential rib grooves are arranged at intervals in the third direction. Both the longitudinal rib grooves 1203 and the circumferential rib grooves are used for embedding the mesh ribs of the product.

[0060] like Figure 4 As shown, both the longitudinal rib groove 1203 and the circumferential rib groove can be rectangular grooves with a rectangular cross-section. The first direction can be left-right, the second direction can be up-down, and the third direction can be front-back. Each longitudinal rib groove 1203 can extend along the front-back direction, and multiple longitudinal rib grooves 1203 can be arranged at intervals along the circumference of the male mold shell 120. Each annular rib groove 1204 can extend and close around the circumference of the male mold shell 120 to form a circle, and multiple annular rib grooves 1204 can be arranged at intervals along the front-back direction.

[0061] Before processing the product, the mesh reinforcement of the product can be placed in the above-mentioned longitudinal rib grooves 1203 and multiple circumferential rib grooves. Then, the skin can be wrapped around the outer periphery of the male mold shell 120. After the skin is wrapped to a certain thickness, it can be installed on the outer periphery to the rear female mold 200. Then, the skin and mesh reinforcement can be cured in the furnace to obtain products such as cabins.

[0062] In some embodiments, such as Figure 5As shown, multiple metal blocks 12011 are arranged in a matrix to form multiple block rings 1205 and multiple block rows 1206. The block rings 1205 include multiple metal blocks 12011 arranged sequentially along the circumference of the male mold shell 120. The multiple block rings 1205 are arranged sequentially along a third direction, which can be the front-back direction. The block rows 1206 include multiple metal blocks 12011 arranged sequentially along a third direction. The multiple block rows 1206 are arranged sequentially along the circumference of the male mold shell 120.

[0063] It should be noted that the aforementioned longitudinal rib groove 1203 can be formed between two block rows 1206, and the aforementioned circumferential rib groove can be formed between two block rings 1205, thereby facilitating the forming and arrangement of the rib grooves.

[0064] In some embodiments, the flexible housing 1202 is separately configured and includes a plurality of flexible modules 12021, which are arranged sequentially along a third direction. For example, as Figure 5 As shown, the flexible module 12021 can be a V-shaped structure, and multiple flexible modules 12021 can be stacked and assembled in the front-to-back direction to form a flexible shell 1202. This improves the ease of arrangement of the flexible shell 1202.

[0065] In some embodiments, the male mold 100 further includes a first connecting plate 130 and a second connecting plate 140. The first connecting plate 130 is disposed at one end of the inner liner 110, one end of the male mold housing 120 is connected to the first connecting plate 130, the second connecting plate 140 is disposed at the other end of the inner liner 110, and the other end of the male mold housing 120 is connected to the second connecting plate 140.

[0066] For example, such as Figure 2 As shown, both the first connecting plate 130 and the second connecting plate 140 can be generally triangular. The radial dimensions of the two ends of the male mold 100 can be different. For example, the radial dimension of one end of the male mold 100 can be larger and the radial dimension of the other end can be smaller. The radial dimensions of the first connecting plate 130 and the second connecting plate 140 can be matched with the dimensions of the two ends of the male mold 100 respectively. For example, the first connecting plate 130 can be a small-end connecting plate with a smaller radial dimension, and the second connecting plate 140 can be a large-end connecting plate with a larger radial dimension.

[0067] During assembly, such as Figure 2 As shown, the inner liner 110 can be connected between the first connecting plate 130 and the second connecting plate 140 by fasteners such as bolts, and the male mold housing 120 can also be fixed between the first connecting plate 130 and the second connecting plate 140 by fasteners.

[0068] In some embodiments, such as Figure 6As shown, the rigid-flexible combination mold for molding carbon fiber composite mesh rib cabin shell products also includes a female mold 200, which includes an upper mold 210, a lower mold 220 and two baffles 230.

[0069] The upper mold 210 is fastened to the lower mold 220, and the male mold 100 is assembled in the cavity enclosed by the upper mold 210 and the lower mold 220. The annular space between the male mold 100 and the female mold 200 forms a cavity for preparing the product.

[0070] For example, the upper mold 210 can be flat, and the lower mold 220 can be rectangular. The upper part of the lower mold 220 can have a groove structure. During assembly, the upper mold 210 can be placed directly on top of the lower mold 220, forming an inner cavity between them. In use, the male mold 100 can be assembled into the inner cavity of the female mold 200. At this time, an annular space is restricted between the male mold 100 and the female mold 200, which serves as the cavity for processing and preparing products such as cabins.

[0071] Two baffles 230 are respectively installed on opposite sides of the female mold 200. One baffle 230 is connected to one end of the male mold 100, one end of the upper mold 210, and one end of the lower mold 220 and is used to block one end of the cavity. The other baffle 230 is connected to the other end of the male mold 100, the other end of the upper mold 210, and the other end of the lower mold 220 and is used to block the other end of the cavity.

[0072] For example, such as Figure 7 As shown, both baffles 230 can be triangular and can be arranged opposite each other in the front-to-back direction. The front ends of the male mold 100, the upper mold 210, and the lower mold 220 can be connected and fixed to the front baffles 230 by bolts or other fasteners. The rear ends of the male mold 100, the upper mold 210, and the lower mold 220 can be connected and fixed to the rear baffles 230 by bolts or other fasteners. The two baffles 230 can seal the front and rear ends of the cavity, allowing the product to be processed and formed within the cavity.

[0073] One baffle 230 is fitted onto the outer periphery of a portion of the first connecting plate 130, and another baffle 230 is fitted onto the outer periphery of a portion of the second connecting plate 140. For example, as... Figure 8 As shown, a portion of the first connecting plate 130 can be embedded in the inner hole of the corresponding side baffle 230, and a portion of the second connecting plate 140 can be embedded in the inner hole of the corresponding side baffle 230. This improves the sealing performance of the assembly and enhances the overall limiting and restraining effect.

[0074] In some embodiments, the upper mold 210 includes two side edges 2101 arranged opposite to each other in a first direction. The side edges 2101 protrude to the side of the lower mold 220, and the two side edges 2101 are respectively connected to two baffles 230.

[0075] For example, such as Figure 6 As shown, the two side edges 2101 can be evenly located on the lower side of the upper mold 210. The two side edges 2101 can be arranged opposite each other in the left-right direction, and both side edges 2101 can extend along the front-back direction. The side edges 2101 can be a split structure. For example, the side edges 2101 can be formed by assembling multiple block structures in the front-back direction. The arrangement of the side edges 2101 facilitates the docking of the upper mold 210 and the lower mold 220.

[0076] In some embodiments, such as Figure 9 As shown, the lower mold 220 includes a support frame 2201 and a template 2202.

[0077] The support frame 2201 includes two side plates 22011 and a plurality of intermediate plates 22012. The two side plates 22011 are arranged opposite to each other in a first direction. The top side of the intermediate plate 22012 is provided with a groove. The plurality of intermediate plates 22012 are all connected between the two side plates 22011, and the plurality of intermediate plates 22012 are arranged at intervals in the opposite direction of the first connecting plate 130 and the second connecting plate 140.

[0078] For example, such as Figure 10 As shown, the support frame 2201 can be assembled and welded from multiple thin steel plates. Two thin steel plates can form side plates 22011, which can be arranged opposite each other in the left-right direction. Four middle plates 22012 can be provided, and each of the four middle plates 22012 can be connected between the two side plates 22011. The four middle plates 22012 can be arranged at intervals in the front-back direction.

[0079] The support frame 2201 also includes a base plate and two longitudinal plates parallel to the side plates 22011. The bottom sides of the side plates 22011, the middle plates 22012, and the longitudinal plates can all be connected to the base plate. The longitudinal plates can extend along the front-back direction and can connect and fix multiple middle plates 22012. This ensures the overall structural strength and stability of the support frame 2201.

[0080] The shape of the template 2202 matches a portion of the outer periphery of the male mold 100, and the template 2202 is fixed within the grooves of a plurality of intermediate plates 22012. For example, as Figure 9As shown, the template 2202 can be formed by stamping. Each intermediate plate 22012 can have a V-shaped groove on its top side. The template 2202 can be welded and fixed in the groove of each intermediate plate 22012.

[0081] In some embodiments, the rigid-flexible combination mold for molding carbon fiber composite mesh rib shell products further includes a mold closing assembly 300, which includes a guide groove 310 and a guide portion 320. The guide groove 310 is disposed in the lower mold 220, and the guide portion 320 is disposed in the male mold 100. The guide portion 320 is used to insert into the guide groove 310 when the mold is closed.

[0082] For example, such as Figure 11 As shown, two mold clamping assemblies 300 can be provided, and the two mold clamping assemblies 300 can be respectively provided on the front side and the rear side of the mold. Each mold clamping assembly 300 can include a guide groove 310 and a guide part 320, wherein the guide part 320 can be fixed to the end side of the male mold 100, and the guide groove 310 can be fixed to the end side of the female mold 200. During assembly, the guide part 320 can be inserted into the guide groove 310 from above, thereby achieving the guiding and positioning effect through the cooperation of the guide part 320 and the guide groove 310.

[0083] In some embodiments, the female mold adopts a frame-type assembled and welded structure, and the female mold surface is prepared from 20-25mm steel plate using a dot-matrix forming method. Specifically, it employs... Figure 9 The middle section is divided into two halves and formed by dot matrix stamping and stretching. That is, it is symmetrically divided into two pieces along the middle, formed by dot matrix stamping and stretching, and then welded to the frame base. Then, it is subjected to CNC precision milling and polishing.

[0084] In some embodiments, such as Figure 8 As shown, sealing rings are provided on the front and rear end faces and the top, bottom, left and right sides of the mold. An airtightness test is required, with a test pressure of 0.6-0.8 MPa. The test requires that the pressure be maintained for 24 hours without leakage.

[0085] In some embodiments, such as Figure 3 As shown, the three empty spaces in the middle of the male mold are the installation positions for the three reinforcing frames. The reinforcing frames need to be prepared separately in advance using another mold and semi-cured before being embedded into the male mold of the main body. Subsequently, the mesh ribs and skin are laid on the basis and co-cured. The reinforcing frame is both part of the product and part of the main mold.

[0086] The following describes a specific example of a rigid-flexible combination mold for molding carbon fiber composite mesh ribbed shell products of this application.

[0087] The rigid-flexible combination mold for molding carbon fiber composite mesh rib shell products according to the embodiments of this application may include a male mold and a female mold. In some other embodiments, the mold may also include a laying frame and auxiliary tooling.

[0088] The male mold assembly mainly consists of a male mold shell, large and small end connecting plates, a cover plate assembly (inner liner), and a V-shaped frame. The male mold shell is made of 6061 stainless steel and is divided into 16 pieces around the circumference. Each piece is connected by a connecting plate and the large and small end connecting plates are combined to form a complete ring.

[0089] The outer mold assembly consists of an upper mold, a lower mold, and a baffle. The upper mold is mainly made of Q235, with a surface tolerance of ±0.1mm and a roughness of Ra1.6. It is formed by engraving part lines and is machined from a single piece of material. To ensure structural strength, reinforcing ribs are set on the back to ensure processing and its own resistance to deformation. The sides facilitate mold closing and layering, and side edges are set, which are arranged in blocks.

[0090] The lower mold structure is a female mold frame structure. The forming area is a profile machined from a thick steel plate using CNC forming. The back is welded to the support frame to form a single, integrated lower mold. The support frame is made of 15mm thick thin steel plate, formed through flame blanking, welding, annealing, and CNC milling processes. Its main function is to ensure the structural strength and support of the lower mold. Figure 8 As shown; the main material is Q235, the surface accuracy is ±0.1mm, the roughness is Ra1.6, and the part lines are engraved.

[0091] The main function of the baffle plate is to fix and connect the male mold housing components together, serving as a common installation reference. It is made of Q235 steel, machined from thick steel plates.

[0092] The mold closing assembly serves as a guide and positioner when the lower mold and the male mold are joined together. The main material is Q235.

[0093] When using the rigid-flexible combination mold for molding carbon fiber composite mesh rib cabin products, the male mold and female mold can be assembled first. After the male mold is assembled, it can be placed on the laying frame. Then, the mesh ribs of the product can be laid into the rib grooves on the laying frame. Then, the skin can be laid on the outer periphery of the male mold. After the skin is laid, the female mold can be installed on the outside of the male mold assembly. Then, it is placed in the corresponding furnace for curing and molding. After curing and molding, the female mold and the male mold can be removed to obtain the cabin and other products.

[0094] The specific processing steps may also include:

[0095] Vacuum pre-compression optimization: Vacuum pre-compression is performed every 4 layers (or less) and is carried out in an oven. The ambient temperature of the pre-compression oven is controlled at 50-60℃ and the time is 20-30 minutes.

[0096] Autoclave pre-pressurization optimization: Pre-pressurize once every 10 layers before entering the autoclave. During pre-pressurization, thermocouples are placed on the mold. When the mold temperature reaches 70℃, pressurize to 0.6MPa, hold pressure for 10 minutes, and then depressurize to atmospheric pressure. Then the product is removed from the autoclave and cooled to below 60℃ to continue layering.

[0097] In addition, the pre-compression time is shortened, and the heating rate and ambient temperature during pre-compression are controlled as follows: the heating rate is controlled at 1-1.5℃ / min, the autoclave temperature is set at 100℃, and when the mold temperature reaches 70℃, the pressure is increased to 0.6MPa. Meanwhile, to improve the accuracy of thermocouple temperature measurement, the thermocouples are placed on the product surface, such as by laying a layer of metal gasket on the product surface and then placing the thermocouples on the metal gasket, followed by normal vacuum encapsulation.

[0098] Optimization for controlling resin loss: a) After pre-pressing, lay a non-porous separator film on the skin (100mm) and end frame; b) Adhere the edge of the non-porous separator film at the root of the end frame by bonding pressure-sensitive adhesive tape; c) Add a 1mm silicone rubber sheet to the surface of the product end frame (outside the non-porous separator film); d) Fill the inner 2mm circle of the end frame with silicone rubber sheet, and the rubber sheet is outside the non-porous separator film.

[0099] Temperature and pressure control during curing: a) Referring to the warhead curing temperature profile, pressurization should be initiated when the mold temperature reaches 80°C. The time required for the mold temperature to reach 80°C should be controlled within 4 hours. This can be achieved by increasing the autoclave heating rate and holding time, such as an initial heating rate of 1–1.5°C / min and a holding time of 120–140°C (this temperature needs verification). b) When the mold temperature reaches 80°C, the external pressure should be increased to 0.6 MPa. c) After the external pressure reaches 0.6 MPa, the temperature regime should follow the original warhead curing regime, such as a heating rate of 0.5°C / min and holding stages of 180°C, 200°C, and 240°C. d) The maximum temperature inside the autoclave should be controlled at 240°C for at least 7 hours. e) Vacuum leakage is permitted when the autoclave temperature exceeds 200°C or the mold temperature reaches 150°C for 1 hour.

[0100] In unidirectional fiber layup structures, a certain proportion of orthogonal carbon fiber or 90° oriented fibers needs to be added to improve the overall stiffness of the unidirectional fiber structure, such as mesh reinforcement or reinforcing rings. The specific proportion should be determined based on simulation analysis.

[0101] If the design allows, orthogonal carbon cloth should be added to the surface of the structural compartment formed by unidirectional fiber layup. This can effectively improve the processing quality of the shell surface, increase the aesthetics of the shell, and reduce defects such as fiber pulling, fuzzing, and tearing during processing.

[0102] When mesh-reinforced structures, such as circumferential and longitudinal reinforcements, are formed using continuous fiber layup, fiber accumulation occurs at the intersections. When this structure is forcibly compressed and flattened, fiber bending occurs in the internal circumferential and longitudinal fibers, significantly impacting fiber efficiency. Performance can typically decrease by up to 50%, a figure requiring further verification. Therefore, for mesh-reinforced structures, a specific continuous / discontinuous ratio can be used to control the layup of circumferential and longitudinal reinforcements. Furthermore, to improve efficiency, multi-layer fiber layup can be employed.

[0103] The weakest point in the connection between the high-strength mesh reinforcement and the skin is usually at the root region of the connection. The failure mode is mostly interlayer delamination. Therefore, carbon fiber covering can be used to improve this connection. This increases the connection area between the reinforcement and the skin, and adds fiber-direction connections between them, rather than just interlayer fiber connections, thus improving the reliability of the connection between the reinforcement and the skin to a certain extent.

[0104] End frame structures typically employ a uniform ply design, which can improve overall stiffness.

[0105] In a typical autoclave process, rubber and fiber cloth can be used as the outer covering skin, which can prevent the loss of adhesive and improve pressure transmission, thus facilitating internal quality control.

[0106] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0107] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", and "counterclockwise" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0108] It should be noted that all directional indications in the embodiments of this application are only used to explain the relative positional relationship and movement of each component in a specific posture. If the specific posture changes, the directional indications will also change accordingly.

[0109] In this application, unless otherwise expressly specified and limited, the terms "connection," "fixed," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0110] Furthermore, the use of terms such as "first" and "second" in this application is 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. Therefore, features defined with "first" or "second" may explicitly or implicitly include one or more features. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0111] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. In addition, those skilled in the art can combine and integrate the different embodiments or examples described in this specification.

[0112] Furthermore, the technical solutions of the various embodiments can be combined with each other, but only if they are based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection claimed in this application.

[0113] Although embodiments of this application have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of this application, the scope of which is defined by the claims and their equivalents.

Claims

1. A rigid-flexible combined mold for molding carbon fiber composite mesh rib cabin shell products, characterized in that, Includes a male mold, the male mold comprising: The liner includes two edges arranged opposite each other in a first direction; A male mold housing is fixed to the outer periphery of the inner liner. The male mold housing includes a metal housing and a flexible housing. The metal housing is assembled from multiple metal blocks. There are two metal housings, which are arranged opposite each other in a second direction orthogonal to the first direction. There are two flexible housings, which are respectively connected between the metal housing and the flexible housing, and the two flexible housings are respectively located on the outer side of the two edges.

2. The rigid-flexible combined mold for molding carbon fiber composite mesh rib cabin shell products according to claim 1, characterized in that, The outer peripheral wall of the male mold shell is provided with multiple longitudinal rib grooves and multiple circumferential rib grooves; The plurality of longitudinal ribs are arranged to extend along a third direction, which is perpendicular to both the first direction and the second direction, and the plurality of longitudinal ribs are arranged at intervals in the circumferential direction of the male mold shell. The circumferential grooves extend and close around the circumference of the male mold shell, and multiple circumferential grooves are arranged at intervals along the third direction. Both the longitudinal grooves and the circumferential grooves are used for embedding the mesh ribs of the product.

3. The rigid-flexible combined mold for molding carbon fiber composite mesh rib cabin shell products according to claim 2, characterized in that, Multiple metal blocks are arranged in a matrix to form multiple block rings and multiple block rows; The assembly ring includes a plurality of metal pieces arranged sequentially along the circumference of the male mold housing, and the plurality of assembly rings are arranged sequentially along the third direction. The assembly row includes a plurality of metal pieces arranged sequentially along the third direction, and the plurality of assembly rows are arranged sequentially along the circumference of the male mold housing.

4. The rigid-flexible combined mold for molding carbon fiber composite mesh rib cabin shell products according to claim 2, characterized in that, The flexible shell is divided into multiple flexible modules, which are arranged sequentially along the third direction.

5. The rigid-flexible combined mold for molding carbon fiber composite mesh rib cabin shell products according to claim 4, characterized in that, The metal panels are aluminum alloy panels, and the flexible panels are silicone rubber panels.

6. The rigid-flexible combined mold for molding carbon fiber composite mesh rib cabin shell products according to any one of claims 1-5, characterized in that, Also includes: A first connecting plate is disposed at one end of the inner liner, and one end of the male mold shell is connected to the first connecting plate; The second connecting plate is located at the other end of the inner liner, and the other end of the male mold shell is connected to the second connecting plate.

7. The rigid-flexible combined mold for molding carbon fiber composite mesh rib cabin shell products according to claim 6, characterized in that, It also includes a female mold, the female mold comprising: The upper mold and the lower mold are fitted together. The male mold is assembled in the cavity formed by the upper mold and the lower mold, and the annular space between the male mold and the female mold forms a cavity for preparing the product. Two baffles are respectively installed on opposite sides of the female mold. One baffle is connected to one end of the male mold, one end of the upper mold, and one end of the lower mold and is used to block one end of the cavity. The other baffle is connected to the other end of the male mold, the other end of the upper mold, and the other end of the lower mold and is used to block the other end of the cavity. Furthermore, one of the baffles is sleeved on the outer periphery of a portion of the first connecting plate, and the other baffle is sleeved on the outer periphery of a portion of the second connecting plate.

8. The rigid-flexible combined mold for molding carbon fiber composite mesh rib cabin shell products according to claim 7, characterized in that, The upper mold includes two side edges arranged opposite each other in the first direction, the side edges protruding toward the lower mold, and the two side edges are respectively connected to the two baffles.

9. The rigid-flexible combined mold for molding carbon fiber composite mesh rib cabin shell products according to claim 7, characterized in that, The lower mold includes: A support frame includes two side plates and multiple middle plates. The two side plates are arranged opposite to each other in a first direction. The top side of each middle plate is provided with a groove. The multiple middle plates are connected between the two side plates and are spaced apart in the opposite direction of the first connecting plate and the second connecting plate. A template, the shape of which matches a portion of the outer periphery of the male mold, and the template is fixed within the grooves of the plurality of intermediate plates.

10. The rigid-flexible combined mold for molding carbon fiber composite mesh rib cabin shell products according to claim 7, characterized in that, It also includes a mold closing assembly, which includes a guide groove and a guide portion. The guide groove is located in the lower mold, and the guide portion is located in the male mold. The guide portion is used to insert into the guide groove when the mold is closed.

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