Foam sandwich composite main spar

Abstract

The utility model relates to large -scale unmanned plane manufacturing technical field discloses a kind of foam sandwich composite material main wing beam, comprising: inner skin, end inner ring, two reinforcing bars, end side patch, foam layer, outer skin and end outer ring;End inner ring, inner skin, reinforcing bar, end side patch, outer skin, end outer ring are formed by prepreg curing, foam layer is fixed in installation cavity by adhesive. Based on the structure, its manufacturing process only needs to use core mold as mold, without using other tooling mold, simplify mold, reduce manufacturing difficulty, with good application prospect and extensive application range.

Description

Technical Field

[0001] This utility model relates to the field of large-scale unmanned aerial vehicle (UAV) manufacturing technology, and in particular to a foam-core composite material main wing spar. Background Technology

[0002] Currently, large unmanned aerial vehicles (UAVs) utilize foam-core composite material main wing spars with higher load-bearing capacity. Compared to conventional non-foam-core composite material main wing spars, foam-core composite material main wing spars incorporate foam cores and reinforcing ribs, rendering traditional UAV main wing spar manufacturing methods obsolete. Multiple specialized tooling molds are typically required, significantly increasing manufacturing complexity.

[0003] In view of this, how to provide a foam sandwich composite material main wing beam that can reduce manufacturing difficulty and simplify manufacturing molds and methods is a problem that urgently needs to be solved by those skilled in the art. Utility Model Content

[0004] The purpose of this invention is to provide a foam-core composite material main wing beam to solve the problems existing in the prior art.

[0005] To achieve the above objectives, this utility model provides a foam-core composite material main wing beam, comprising:

[0006] The inner skin is a cylindrical structure with openings at both ends;

[0007] Two end inner rings are disposed on the inner surface of the inner skin and close to both ends of the inner skin;

[0008] Two reinforcing ribs are symmetrically arranged on the upper and lower sides of the inner skin along the length of the inner skin;

[0009] An end-side patch is disposed on the inner skin between two reinforcing ribs and close to both ends of the reinforcing ribs; the end-side patch is connected to the reinforcing ribs.

[0010] The foam layer, the end-side patch, the reinforcing rib and the inner skin form an installation cavity with the inner skin as the bottom surface. The foam layer is adapted to the shape of the installation cavity and is disposed in the installation cavity. The outer surfaces of the reinforcing rib, the end-side patch and the foam layer are flush.

[0011] The outer skin covers the outer surface of the reinforcing ribs, end-side reinforcements, and foam layer;

[0012] The end outer ring is disposed on the outer surface of the outer skin and close to both ends of the outer skin;

[0013] The inner end ring, inner skin, reinforcing rib, end side patch, outer skin, and outer end ring are all formed by curing prepreg, and the foam layer is fixed in the installation cavity by adhesive.

[0014] Furthermore, the outer diameter of the inner ring at the end gradually decreases along the length of the inner skin, and the outer diameter is larger at the end closer to the end of the inner skin.

[0015] Furthermore, the reinforcing rib has a first connecting slope on both the left and right sides, and the end-side patch has a second connecting slope on the side near the mounting chamber. The bottom of the foam layer is glued to the inner skin through the inner foam film, and the outer edge of the foam layer is glued to the first connecting slope and the second connecting slope respectively.

[0016] Furthermore, the foam layer is made of polymethacrylamide foam.

[0017] Furthermore, the foam layer is formed by adhesively bonding together multiple foam blocks.

[0018] This utility model also provides a method for manufacturing a foam sandwich composite main wing beam, comprising the following steps:

[0019] S1: Prepare a cylindrical core mold, which includes a laying section and reserved sections on both sides of the laying section. Lay the inner ring prepreg at both ends of the laying section.

[0020] S2: Lay the inner skin prepreg on the outer surface of the laying section and the inner ring prepreg at the end;

[0021] S3: Spread two portions of reinforcing rib prepreg symmetrically on the upper and lower sides of the inner skin prepreg along the length of the inner skin prepreg.

[0022] S4: Lay the end-side patch prepreg on the inner skin prepreg between the two reinforcing rib prepregs and close to both ends of the reinforcing rib prepreg, so that the end-side patch prepreg is connected to the reinforcing rib prepreg.

[0023] S5: Lay the inner foam film on the inner skin prepreg and connect it to the end side patch prepreg and the reinforcing rib prepreg respectively; lay multiple foam blocks on the inner foam film, and glue the multiple foam blocks to form a foam layer. The left and right sides of the reinforcing rib prepreg have a first connecting slope, and the side of the end side patch prepreg near the installation chamber has a second connecting slope. The bottom of the foam layer is glued to the inner skin prepreg through the inner foam film, and the outer edge of the foam layer is glued to the first connecting slope and the second connecting slope respectively.

[0024] S6: The end inner ring prepreg, inner skin prepreg, reinforcing rib prepreg, end side patch prepreg, foam inner layer film, and foam layer are cured to form a one-time cured main wing beam blank consisting of a core mold, end inner ring, inner skin, reinforcing rib, end side patch, and foam layer.

[0025] S7: Roughen the outer surface of the main wing beam blank (excluding the foam layer) after one-time curing to form a roughening zone;

[0026] S8: Lay the outer foam film on the sanding area and the foam layer, and lay the outer skin prepreg on the outer foam film;

[0027] S9: Lay the outer ring prepreg at the end onto the outer skin prepreg and close to both ends of the outer skin prepreg;

[0028] S10: Curing the outer foam film, outer skin prepreg, and end ring prepreg; removing the core mold after curing to obtain the main wing beam of the foam sandwich composite material.

[0029] Furthermore, the curing method for step S6 is as follows:

[0030] Wrap BOPP tape around the outer surfaces of the foam layer, the reinforcing rib prepreg, and the end-side patch prepreg.

[0031] The BOPP tape is wrapped with a breathable felt, and the end inner ring prepreg, inner skin prepreg, reinforcing rib prepreg, end side patch prepreg, inner foam film and foam layer are vacuum sealed with vacuum bags and sealing tape.

[0032] The prepreg of the inner ring at the end, the prepreg of the inner skin, the prepreg of the reinforcing rib, the prepreg of the prepreg of the side patch at the end, the inner foam film, and the foam layer are cured by the curing equipment. After curing, the vacuum bag, breathable felt, sealing tape and BOPP tape are removed to obtain the main wing beam blank that has been cured once.

[0033] Furthermore, the curing method for step S10 is as follows:

[0034] Wrap BOPP tape around the outer surface of the end ring prepreg and the outer skin prepreg;

[0035] A breathable felt is wrapped around the outside of the BOPP tape, and vacuum bags and sealing tape are used to vacuum seal the one-time cured main wing blank, the outer foam film, the outer skin prepreg and the end outer ring prepreg.

[0036] The outer foam film, outer skin prepreg, and end ring prepreg are cured using a curing device and integrally formed with the main wing beam blank that has been cured once. After curing, the vacuum bag, breathable felt, sealing tape, and BOPP tape are removed to obtain the foam sandwich composite material main wing beam.

[0037] The present invention discloses the following technical effects:

[0038] This invention proposes a foam-core composite material main wing beam, wherein the inner end ring, inner skin, reinforcing ribs, end side patch, outer skin, and outer end ring are all formed by curing prepreg, and the foam layer is fixed in the mounting cavity by adhesive. Based on this structure, its manufacturing process only requires a core mold as a mold, eliminating the need for other tooling molds, simplifying the mold, reducing manufacturing difficulty, and showing good application prospects and a wide range of applications. Attached Figure Description

[0039] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0040] Figure 1 Schematic diagram of prepreg laying for the inner ring at the end;

[0041] Figure 2 Schematic diagram of the laying of inner skin prepreg and reinforcing rib prepreg;

[0042] Figure 3 Schematic diagram of prepreg application for end-side reinforcement;

[0043] Figure 4 This is a schematic diagram of the foam layer;

[0044] Figure 5 Schematic diagram of the laying of prepreg for outer skin;

[0045] Figure 6 Schematic diagram of prepreg laying on the outer ring of the end;

[0046] Among them, 1. core mold; 2. inner ring of end; 3. inner skin; 4. reinforcing rib; 401. first connecting ramp; 5. side patch of end; 501. second connecting ramp; 6. foam layer; 7. outer skin; 8. outer ring of end. Detailed Implementation

[0047] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0048] To make the above-mentioned objectives, features and advantages of this utility model more apparent and understandable, the utility model will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0049] like Figures 1 to 6 As shown, this utility model embodiment provides a foam-core composite material main wing beam, comprising:

[0050] The inner skin 3 is a cylindrical structure with openings at both ends;

[0051] Two end inner rings 2 are set on the inner surface of the inner skin 3 and close to the two ends of the inner skin 3;

[0052] Two reinforcing ribs 4 are symmetrically arranged on the upper and lower sides of the inner skin 3 along the length of the inner skin 3;

[0053] The end-side patch 5 is set on the inner skin 3 between the two reinforcing ribs 4 and close to both ends of the reinforcing ribs 4. The end-side patch 5 is connected to the reinforcing ribs 4.

[0054] The foam layer 6, the end side patch 5, the reinforcing rib 4 and the inner skin 3 form an installation cavity with the inner skin 3 as the bottom surface. The foam layer 6 is adapted to the shape of the installation cavity and is set in the installation cavity. The outer surfaces of the reinforcing rib 4, the end side patch 5 and the foam layer 6 are flush.

[0055] The outer skin 7 covers the outer surfaces of the reinforcing rib 4, the end side patch 5, and the foam layer 6;

[0056] The outer end ring 8 is disposed on the outer surface of the outer skin 7 and close to both ends of the outer skin 7;

[0057] The inner ring 2, inner skin 3, reinforcing rib 4, end side patch 5, outer skin 7, and outer ring 8 are all formed by curing prepreg, and the foam layer 6 is fixed in the installation cavity by adhesive.

[0058] In this embodiment, the outer diameter of the inner ring 2 at the end gradually decreases along the length of the inner skin 3, and the outer diameter at the end closer to the end of the inner skin 3 is larger.

[0059] In this embodiment, the reinforcing rib 4 has a first connecting slope 401 on both the left and right sides, and the end side supplement 5 has a second connecting slope 501 on the side near the installation chamber. The bottom of the foam layer 6 is glued to the inner skin 3 through the inner foam film, and the outer edge of the foam layer 6 is glued to the first connecting slope 401 and the second connecting slope 501 respectively.

[0060] In this embodiment, foam layer 6 is made of polymethacrylamide foam.

[0061] In this embodiment, the foam layer 6 is formed by gluing together multiple foam blocks, which can prevent the foam layer 6 from becoming too large and breaking.

[0062] This utility model also provides a method for manufacturing a foam sandwich composite main wing beam, comprising the following steps:

[0063] S1: Prepare a cylindrical core mold 1. The core mold 1 includes a laying section and reserved sections on both sides of the laying section. Lay the end inner ring prepreg onto both ends of the laying section. The laying shape corresponds to the end inner ring 2 (all the prepregs below are laid into the corresponding structural shapes, which will not be described in detail).

[0064] S2: Lay the inner skin prepreg on the outer surface of the laying section and the inner ring prepreg at the end;

[0065] S3: Spread two portions of reinforcing rib prepreg symmetrically on the upper and lower sides of the inner skin prepreg along the length of the inner skin prepreg.

[0066] S4: Lay the end-side patch prepreg on the inner skin prepreg between the two reinforcing rib prepregs and close to both ends of the reinforcing rib prepreg, so that the end-side patch prepreg is connected to the reinforcing rib prepreg.

[0067] S5: The inner foam film is laid on the inner skin prepreg and connected to the end side patch prepreg and the reinforcing rib prepreg respectively; multiple foam blocks are laid on the inner foam film, and the multiple foam blocks are glued to form a foam layer 6. The left and right sides of the reinforcing rib prepreg have a first connecting slope 401, and the side of the end side patch prepreg near the installation chamber has a second connecting slope 501. The bottom of the foam layer 6 is glued to the inner skin prepreg through the inner foam film, and the outer edge of the foam layer 6 is glued to the first connecting slope 401 and the second connecting slope 501 respectively.

[0068] S6: The end inner ring prepreg, inner skin prepreg, reinforcing rib prepreg, end side patch prepreg, foam inner layer film, and foam layer 6 are cured to form a one-time cured main wing beam blank consisting of core mold 1, end inner ring 2, inner skin 3, reinforcing rib 4, end side patch 5, and foam layer 6.

[0069] S7: Roughen the outer surface of the main wing beam blank, excluding foam layer 6, to form a roughening zone;

[0070] S8: Lay the outer foam film on the sanding area and foam layer 6, and lay the outer skin prepreg on the outer foam film.

[0071] S9: Lay the outer ring prepreg at the end onto the outer skin prepreg and close to both ends of the outer skin prepreg;

[0072] S10: Cure the outer foam film, outer skin prepreg and end ring prepreg. After curing, remove the core mold 1 to obtain the main wing beam of the foam sandwich composite material.

[0073] In this embodiment, the curing method for step S6 is as follows:

[0074] Wrap BOPP tape around the outer surfaces of foam layer 6, reinforcing rib prepreg and end side patch prepreg;

[0075] The BOPP tape is wrapped with a breathable felt, and the end inner ring prepreg, inner skin prepreg, reinforcing rib prepreg, end side patch prepreg, inner foam film and foam layer 6 are vacuum sealed with vacuum bags and sealing tape.

[0076] The prepreg of the inner ring at the end, the prepreg of the inner skin, the prepreg of the reinforcing rib, the prepreg of the prepreg of the side patch at the end, the inner foam film, and the foam layer 6 are cured by the curing equipment. After curing, the vacuum bag, breathable felt, sealing tape and BOPP tape are removed to obtain the main wing beam blank that has been cured once.

[0077] In this embodiment, the curing method of step S10 is as follows:

[0078] Wrap BOPP tape around the outer surface of the end ring prepreg and the outer skin prepreg;

[0079] A breathable felt is wrapped around the outside of the BOPP tape, and vacuum bags and sealing tape are used to vacuum seal the one-time cured main wing blank, the outer foam film, the outer skin prepreg and the end outer ring prepreg.

[0080] The outer foam film, outer skin prepreg, and end ring prepreg are cured using a curing device and integrally formed with the main wing beam blank that has been cured once. After curing, the vacuum bag, breathable felt, sealing tape, and BOPP tape are removed to obtain the foam sandwich composite material main wing beam.

[0081] Testing revealed that, compared to existing foam sandwich composite material main wing spars, the foam sandwich composite material main wing spar prepared using this embodiment has a smooth and aesthetically pleasing surface, a weight reduction of approximately 20%, and a strength increase of approximately 30%. All other indicators meet the requirements for use by large unmanned aerial vehicles.

[0082] In the description of this utility model, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model 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 utility model.

[0083] The embodiments described above are merely preferred embodiments of the present utility model and are not intended to limit the scope of the present utility model. Various modifications and improvements made to the technical solutions of the present utility model by those skilled in the art without departing from the spirit of the present utility model should fall within the protection scope defined by the claims of the present utility model.

Claims

1. A foam-core composite material main wing beam, characterized in that, include: The inner skin (3) is a cylindrical structure with openings at both ends; Two end inner rings (2) are disposed on the inner surface of the inner skin (3) and close to the two ends of the inner skin (3); Two reinforcing ribs (4) are symmetrically arranged on the upper and lower sides of the inner skin (3) along the length direction of the inner skin (3); End-side reinforcement (5) is disposed on the inner skin (3) between two reinforcing ribs (4) and close to both ends of the reinforcing ribs (4). The end-side reinforcement (5) is connected to the reinforcing ribs (4). The foam layer (6), the end side patch (5), the reinforcing rib (4) and the inner skin (3) form an installation cavity with the inner skin (3) as the bottom surface. The foam layer (6) is adapted to the shape of the installation cavity and is set in the installation cavity. The outer surfaces of the reinforcing rib (4), the end side patch (5) and the foam layer (6) are flush. The outer skin (7) covers the outer surface of the reinforcing rib (4), the end side patch (5) and the foam layer (6); An outer ring (8) is provided on the outer surface of the outer skin (7) and close to both ends of the outer skin (7); The inner end ring (2), inner skin (3), reinforcing rib (4), end side patch (5), outer skin (7), and outer end ring (8) are all formed by curing prepreg, and the foam layer (6) is fixed in the installation cavity by adhesive.

2. The foam-core composite material main wing beam according to claim 1, characterized in that, The outer diameter of the inner ring (2) at the end gradually decreases along the length of the inner skin (3), and the outer diameter at the end closer to the end of the inner skin (3) is larger.

3. The foam-core composite material main wing beam according to claim 1, characterized in that, The reinforcing rib (4) has a first connecting ramp (401) on both sides, and the end side patch (5) has a second connecting ramp (501) on the side near the installation chamber. The bottom of the foam layer (6) is glued to the inner skin (3) through the inner foam film. The outer edge of the foam layer (6) is glued to the first connecting ramp (401) and the second connecting ramp (501) respectively.

4. The foam-core composite material main wing beam according to claim 1, characterized in that, The foam layer (6) is made of polymethacrylamide foam.

5. The foam-core composite material main wing beam according to claim 4, characterized in that, The foam layer (6) is formed by bonding together multiple foam blocks.

Images