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KR-102961350-B1 - Composite mass production system including composite material mass production mold and composite material mass production method using the same

KR102961350B1KR 102961350 B1KR102961350 B1KR 102961350B1KR-102961350-B1

Abstract

The present invention relates to a composite mass production system and method capable of mass-producing composites, and more specifically, to a composite mass production system with increased mass production efficiency and a composite mass production method using the same. The present invention produces a composite through a C-RTM (Compression Resin Transfer Molding) process that combines a heating press process and an RTM molding process, and by integrating the processes of material lamination, curing agent injection, pressurization, heating, and mold separation into a single transport container, it has the effect of producing high-quality composites while simultaneously reducing production costs and making mass production suitable.

Inventors

  • 이해동

Assignees

  • 한국항공우주산업 주식회사

Dates

Publication Date
20260508
Application Date
20220106

Claims (18)

  1. A composite material mass production mold comprising a lower mold having a concave shape formed on one side of the outer surface of the product and an upper mold having a concave shape formed on one side of the outer surface of the product; A moving part for transferring the composite mass production mold from one side to the other, wherein the composite mass production mold is located on one side; An outer skin lamination part that laminates an outer skin layer on one surface of the upper mold and the lower mold on the moving part; A core lamination part located on the other side of the outer skin lamination part, wherein a core layer is laminated having both sides formed convexly on the upper surface of at least one of the outer skin layer laminated in the upper mold or the outer skin layer laminated in the lower mold; A curing agent injection part located on the other side of the core lamination part above, for injecting a curing agent between the core layer and the outer layer; A pressurizing part located on the other side of the curing agent injection part, which pressurizes the composite mass production mold to impregnate the curing agent into the outer layer; A curing unit located on the other side of the above-mentioned pressurizing unit, which heats the above-mentioned composite mass production mold to cure the above-mentioned curing agent; and It includes a demolding unit located on the other side of the curing unit and separating the product from the composite mass production mold; and The above outer layer is a dry fiber material, and The above core layer is a high-density expanded foam core material, and The above outer shell laminate is, It includes a laminating machine that laminates one or more sheets of dry fiber, and The above laminating machine compresses and laminates a plurality of the above dry fiber layers, and The above composite mass production mold is, It further includes a hardener injection hole formed through the upper mold, and The space between the upper mold and the lower mold is connected to the outside only through the hardener injection hole, The above curing agent is injected in a certain direction through the curing agent injection hole while the upper mold is covered over the upper part of the lower mold, and then overfilled between the upper mold and the lower mold and on the outer side of the outer skin layer. The above moving part is, A composite mass production system characterized by moving the composite mass production mold so that the composite mass production mold passes sequentially through the outer shell lamination section, the core lamination section, the curing agent injection section, the pressurizing section, the curing section, and the demolding section.
  2. In Article 1, The above composite mass production mold is, A lower mold having a concave shape formed on one side of the outer surface of the product; An upper mold having a concave shape formed on one side of the outer surface of the product on the other side; A connecting part that is connected to one corner of each of the upper mold and the lower mold, and connects the upper mold and the lower mold so that the angle formed by one surface of the upper mold and one surface of the lower mold can be changed; A composite material mass production system characterized by the fact that when one surface of the upper mold and one surface of the lower mold face each other and the angle formed is 0 degrees, one surface of the upper mold and one surface of the lower mold are spaced apart from each other by a predetermined distance.
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  4. In Article 1, Located on one side of the above outer shell laminate, A release treatment unit that performs release treatment on one surface of the upper mold and one surface of the lower mold; and A composite material mass production system characterized by further including a plasma device located on one side of the above-mentioned molding unit.
  5. In Paragraph 4, The above-mentioned shape processing unit is, A composite material mass production system characterized by including a spray nozzle for applying a release agent to one surface of the upper mold and one surface of the lower mold.
  6. In Article 1, A composite material mass production system further comprising: a sealing part that covers the upper mold over the upper part of the lower mold and fixes its position so that one side of the upper mold and one side of the lower mold face each other.
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  8. In Article 1, The above outer shell laminate is, A skin layer production unit comprising at least one of a cutter that cuts the laminated dry fibers to produce the skin layer, and Characterized by including a skin layer moving device that stacks the cut skin layer on one side of the upper mold and one side of the lower mold, respectively. A composite mass production system characterized by the following.
  9. In Paragraph 8, The above outer layer production unit is, A composite mass production system characterized by further including a hot forming machine that applies heat or pressure to the outer layer to form the surface to have a curvature greater than a predetermined amount.
  10. In Article 1, The above-mentioned core stacking part is, A housing having a foamed material contained therein and a discharge port formed at one end for discharging the foamed material, A screw embedded inside the above housing that reciprocates in the extension direction to discharge the foam material through the above discharge port, A foam material injection hole for injecting a foam material into the interior of the above housing and A core layer production unit including a mold connected to the above-mentioned discharge port for fixing the shape of the foam material, and A composite material mass production system characterized by including a core layer moving device that laminates the produced core layer onto the upper surface of the outer layer.
  11. In Article 1, The above-mentioned hardening part is, A composite material mass production system characterized by having one or more heaters embedded in one surface of the moving part or disposed on at least one of the top and bottom of the moving part.
  12. In Article 1, A composite material mass production system characterized in that the moving part is a circular conveyor belt with one side and the other side in contact with each other.
  13. In Article 1, A composite material mass production system characterized in that the moving part is a straight conveyor belt extending in a straight line from one side to the other.
  14. In a method for mass-producing composite materials using a composite material mass production system, (a) A step in which the outer skin layer is laminated onto the upper mold and the lower mold; (b) a step of laminating a core layer having both sides formed convexly in at least one of the upper mold and the lower mold; (c) A step in which the sealing part covers the upper mold with the upper part of the lower mold, fixes the position, and seals it; (d) a curing agent injection step in which the curing agent injection unit injects the curing agent between the upper mold and the lower mold; (e) a step in which a pressurizing part pressurizes a composite mass production mold to impregnate the curing agent into the outer layer; (f) a step of curing the curing agent by heating the composite mass production mold, which is composed of the upper mold and the lower mold; (g) A demolding step in which the demolding unit separates the product from the composite mass production mold; and The above step (a) is, (a1) The laminating machine includes the step of laminating dry fibers, The above outer layer is a dry fiber material, and The above core layer is a high-density expanded foam core material, and The above laminating machine compresses and laminates a plurality of the above dry fiber layers, and The above composite mass production mold is, It further includes a hardener injection hole formed through the upper mold, and The space between the upper mold and the lower mold is connected to the outside only through the hardener injection hole, In step (d) above, After the above curing agent is injected in a certain direction through the curing agent injection hole, it is overfilled between the upper mold and the lower mold and on the outer side of the outer skin layer, and A method for mass production of composite materials characterized by the above steps (a), (b), (c), (d), (e), (f), and (g) being performed sequentially.
  15. In Paragraph 14, The above step (a) is, (a2) A step in which a cutter cuts the dry fibers stacked in step (a1) above and (a3) A method for mass-producing a composite material characterized by including the step of moving the outer layer after molding is completed and stacking it on the composite material mass-production mold.
  16. In Paragraph 15, (a4) A method for mass-producing composite materials characterized by further including a step in which a hot forming machine applies heat or pressure to the outer layer to form the surface so that it has a curvature greater than a predetermined amount.
  17. In Paragraph 14, The above-mentioned core stacking part is, A housing in which a foamed material is contained internally and an outlet is formed at one end for discharging the foamed material, A screw embedded inside the above housing and reciprocating in the extension direction to discharge the foamed material to the discharge port, A foam material injection hole for injecting the foam material into the interior of the above housing, and A core layer production unit including a mold connected to the above-mentioned discharge port for fixing the shape of the above-mentioned foam material, and It includes a core layer moving device that stacks the produced core layer on the upper surface of the outer shell layer, The above step (b) is, (b1) A step in which the discharge port of the above housing is connected to a mold, (b2) A step in which the screw reciprocates to inject the foam material inside the housing into the mold, (b3) A step of waiting for a predetermined time so that the foamed material is fixed inside the mold, (b4) A step of separating the above mold and the above core layer and (b5) A method for mass-producing a composite material characterized by including the step of moving the core layer after molding is completed and stacking it in the composite material mass-production mold.
  18. In Paragraph 14, Prior to the above step (a), (h) A method for mass production of composite materials characterized by further including a step of a release treatment unit releasing one side of the upper mold and one side of the lower mold.

Description

Composite mass production system including composite material mass production mold and composite material mass production method using the same The present invention relates to a composite material mass production system and method capable of mass-producing composite materials, and more specifically, to a composite material mass production system with increased mass production efficiency and a composite material mass production method using the same. Conventional propeller blades or propellers used in distributed propulsion aircraft or future mobility (PAV, UAM) have utilized a high-density expanded foam core material for weight reduction and coated the core surface with fiber materials, such as carbon fiber or aramid fiber, to provide anti-icing and de-icing capabilities in high-latitude environments. Conventional technologies for manufacturing these components included the hand layup method, the heating press method, and the Resin Transfer Molding (RTM) method. In the case of the conventional hand layup method, the operator directly layers the raw material and cures it in an oven or autoclave; however, this method suffered from very low productivity and quality varying depending on the operator's skill level. In the case of conventional heat press molding, while the layering of resin-prepared fibers provided the advantage of high adhesion to the core and ease of operation, it was inefficient in terms of cost due to the high price of prepreg fibers. Finally, the RTM molding method utilized general fibers (dry fibers) that were not impregnated with resin; although the raw material cost was lower compared to the aforementioned heat press molding method, it was difficult to guarantee high-quality parts because the molding was performed under low pressure. In addition, since high-density expanded foam core material is used as the main material for the core layer to reduce the overall weight of the propeller, the foam core material, which is generally supplied in the form of a flat plate, is used after undergoing post-processing such as milling. However, during this process, there is significant material waste, and the foam core material often breaks in parts that need to be machined into sharp points, such as the blades of the propeller. FIG. 1 is a schematic diagram illustrating a mass production system for composite materials according to the present invention. FIG. 2 is a plan view illustrating a mass production mold for composite materials according to the present invention. FIG. 3 is a cross-sectional view illustrating the curing agent injection hole of the present invention. FIG. 4 is a schematic diagram illustrating the mold processing unit of the present invention. FIG. 5 is a schematic diagram illustrating the function of the outer shell laminate of the present invention. FIG. 6 is a schematic diagram illustrating a first embodiment of the fiber lamination method of the present invention. FIG. 7 is a schematic diagram illustrating a second embodiment of the fiber lamination method of the present invention. FIG. 8 is a schematic diagram illustrating the function of the core stacking part of the present invention. FIG. 9 is a cross-sectional view illustrating the core layer production section of the present invention. FIG. 10 is a schematic diagram illustrating the function of the core layer production unit of the present invention. FIG. 11 is a schematic diagram illustrating the function of the sealing part of the present invention. FIG. 12 is a schematic diagram illustrating the function of the curing agent injection part of the present invention. FIG. 13 is a schematic diagram illustrating the function of the pressurizing part of the present invention. FIG. 14 is a schematic diagram illustrating the function of the curing part of the present invention. FIG. 15 is a flowchart illustrating the method for mass production of composite materials according to the present invention. FIG. 16 is a flowchart illustrating the detailed steps of the cover lamination step of the present invention. FIG. 17 is a flowchart illustrating the detailed steps of the core stacking step of the present invention. FIG. 18 is a flowchart illustrating one embodiment of the method for mass production of composite materials according to the present invention. Hereinafter, the technical concept of the present invention will be explained in more detail using the attached drawings. Prior to this, terms and words used in this specification and claims should not be interpreted as being limited to their ordinary or dictionary meanings, and should be interpreted in a meaning and concept consistent with the technical concept of the present invention, based on the principle that the inventor can appropriately define the concept of the terms to best describe his invention. Hereinafter, the basic configuration of the composite mass production system (1000) of the present invention will be described with reference to FIG. 1. The composite ma