CN100538088C - 将热塑性插件单元安排在热塑性夹芯产品中的方法 - Google Patents

将热塑性插件单元安排在热塑性夹芯产品中的方法 Download PDF

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CN100538088C
CN100538088C CNB2004800317088A CN200480031708A CN100538088C CN 100538088 C CN100538088 C CN 100538088C CN B2004800317088 A CNB2004800317088 A CN B2004800317088A CN 200480031708 A CN200480031708 A CN 200480031708A CN 100538088 C CN100538088 C CN 100538088C
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马丁·西奥多·德格鲁特
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Abstract

一种用于通过施加超声能(6，8)将热塑性插件单元(2)安排在热塑性夹芯产品(1)中的方法，所述热塑性夹芯产品(1)具有至少一个平面或实际上是平面的部分。热塑性夹芯产品(1)包括至少一个纤维增强的热塑性覆盖层(7)和一个不完全是固体的热塑性塑料芯(8)。热塑性夹芯产品的例子包括：平板，稍微弯曲的产品，折叠的产品，等等。凹槽在热塑性夹芯产品的表面中产生，同时把塑料插件单元焊接在凹槽中。

Description

将热塑性插件单元安排在热塑性夹芯产品中的方法
本发明涉及一种方法，所述方法用于将热塑性插件单元安排在热塑性夹芯产品中，上述热塑性插件单元包括一个主体，而上述热塑性夹芯产品具有至少一个平面或实际上是平面的部分，上述夹芯产品包括一层不完全是实心的热塑性芯材料和至少一个由纤维增强的热塑性塑料形成的覆盖层。
用于在热塑性夹芯板中安排局部增强部分的方法在专业领域中，例如从欧洲专利申请EP 0 383 409中已知。在上述申请中已知的方法包括通过将热塑性塑料注塑到夹芯板中而在热塑性夹芯板中安排局部增强部分。为了在局部增强部分中安排固定点，可以将金属插件安排在仍是液态的注塑塑料中，如在EP 0 671 992中更详细说明的。
在专业领域中，例如从美国专利5437750中，已知另外的用于将塑料插件单元安排在夹芯板中的方法，所述夹芯板具有至少一个热塑性纤维增强的覆盖层。在那个文献中所公开的方法包括将一塑料插件放入并粘合在夹芯板中，上述夹芯板包括两个纤维增强的热塑性塑料覆盖层，所述两个覆盖层用粘合剂粘合到一个芯层上，芯层包括多个芳酰胺纸条或其它薄而重量轻的材料，它们以这种方式用粘合剂粘合并变形，以便形成一种蜂窝状泡孔的阵列。这种方法包括钻孔穿过夹层板，将热塑性插件单元放入孔中，然后通过施加超声能将塑料插件单元顶部上的薄的两侧熔合到纤维增强的热塑性材料覆盖层上。
在美国专利5536344提供了另一种方法，所述方法说明把热塑性插件单元焊接到一夹芯板中，上述夹芯板包括用粘合剂粘合到蜂窝状结构上的纤维增强热塑性覆盖层。这种方法说明了通过旋转焊接安排塑料插件单元。
本发明的目的是提供一种用于将热塑性插件单元安排在热塑性夹芯产品中的方法，和进一步优化和简化热塑性插件单元在热塑性夹层制品中的安排，同时能节约成本和重量。
为此，按照本发明，在前言中所介绍的这种类型的方法，即用于安排热塑性插件单元的方法，上述热塑性插件单元包括在热塑性夹芯产品中的主体和凸缘，所述热塑性夹芯产品具有至少一个大体上是平面的部分，上述热塑性夹芯产品包括一层热塑性泡沫芯材料和至少一个覆盖层，上述覆盖层由纤维增强热塑性塑料形成，方法包括以下步骤：
从纤维增强热塑性塑料的覆盖层中形成进入热塑性夹芯产品的热塑性泡沫芯材料的孔，以除去一部分所述热塑性泡沫芯材料；
将所述热塑性插件单元放入所述孔中；
将所述热塑性插件单元定位在超声设备的焊头和砧座之间；
施加超声能和压力，以便在所述热塑性插件单元和所述热塑性夹芯产品的纤维增强热塑性塑料覆盖层之间产生热量；
在供给足够的热量让所述热塑性插件单元和所述热塑性夹芯产品的纤维增强热塑性塑料覆盖层之间熔化之后，通过冷却将所述热塑性插件单元固定；
按照本发明所述用于将热塑性单元安排在热塑性夹芯产品中的方法，一般包括将钻孔到热塑性夹芯产品的覆盖层中，这个孔的大小通常与塑料插件单元主体横截面的至少最大尺寸相对应。然后，将热塑性插件单元放在热塑性夹芯产品内的孔中，此后通过施加超声能和压力在热塑性插件单元和一个或多个纤维增强热塑性覆盖层之间的接触面上产生热量，并加足够的热量让上述接触面熔合在一起。冷却之后，优选的是在压力下，将热塑性插件单元固定在热塑性夹芯产品中。
如在本说明中所用的术语“夹芯产品”包括具有至少一个平面或实际上是平面部分，换句话说，基本上是平面部分的热塑性夹芯产品。一些例子包括：平板；稍微弯曲的制品，折叠的产品，稍微弯曲的三维形状产品，等等。
夹芯产品有利的是包括一个顶部覆盖层，一个芯层，和一个底部覆盖层，上述顶部覆盖层用纤维增强的热塑性塑料形成，上述芯层用热塑性塑料，尤其是泡沫塑料层形成，而上述底部覆盖层用纤维增强的热塑性塑料形成。在下面说明中，插件单元安排于其中的覆盖层总是指的是顶部覆盖层，不过除非另有说明，基本上不需要也有底部覆盖层。
用热塑性塑料制成的插件单元优选地包括主体和凸缘。插件单元可以包括有内螺纹的镗孔。
如上所述，在一优选实施例中，孔的尺寸基本上等于插件单元主体横截面的尺寸。然而，孔的尺寸也可以较大或较小，如下面更详细说明的。借助于如上所述按照本发明的方法，一方面热塑性插件单元凸缘的下侧可以固定到热塑性夹芯产品顶部覆盖层的顶侧上，而另一方面，若规定了热塑性插件单元的合适尺寸，则能同时实施热塑性热插件单元的下侧与热塑性夹芯产品底部覆盖层顶侧之间的粘合。在插件单元没有凸缘的情况下，插件单元的下侧可以固定到热塑性夹芯产品底部覆盖层的顶侧上。
塑料插件单元具有一圆形凸缘，所述圆形凸缘具有一直径比塑料插件单元主体的直径大，所述主体有利的是也是圆形。插件单元的热塑性材料优选的是与一个或多个纤维增强的覆盖层热塑性塑料和芯中的热塑性塑料相同或者至少兼容。
在按照本发明所述方法的优选实施例中，将插件单元待安排在该处的顶部覆盖层以塑料插件单元主体最大直径的形状除去。此后，优选的是不除去热塑性芯材料或只除去一部分热塑性芯材料，以便一方面增加插件单元的尺寸公差，另一方面减小(减少)插件单元与底部覆盖层之间粘合印记的可视性。
按照本发明所述方法另一个优选实施例是，由于在夹芯产品的芯层中使用泡沫塑料的结果，当把插入单元焊接到夹芯板上时，产生通称的缓冲效应。缓冲效应包括通过超声能和压力，将泡沫塑料加热到芯层热塑性塑料的熔点周围和附近，其结果是超声能不能通过刚性连接从插件单元主体传送到底部覆盖层。这是由于这种传送使能量并因此使热量集中到插件单元凸缘的顶侧上和/或在插件单元主体下侧位置处的底部覆盖层上，上述情况尤其是在使用不是金属的插件单元时如插件单元通过本身己知的复合物流态压塑法制成时，应该避免，因为如果存在，则这会导致损坏凸缘的顶侧和塑料的螺纹。
按照本发明所述方法还有另一个优选实施例，是基于下述令人惊奇的发现，插件单元在夹芯产品中的结构整体性通过下述方法增加：一方面通过在热塑性夹芯产品顶部覆盖层中形成孔比热塑性插件单元主体的最大横截面小，和/或另一方面，通过在顶部覆盖层中，把至多在穿过插件主体的最大横截面尺寸处的横截面分成至少两个或多个部分，或者上述两种措施的组合，和然后利用本发明的方法。假定上述缓冲效应一方面是由于热塑性插件单元与热塑性夹芯产品之间粘合的表面积大小增加引起，和另一方面例如通过折叠顶部覆盖层在抗热塑性插件单元被拉出热塑性夹芯产品方面，提高了孔的稳定性引起。这提供进一步减小插件单元的尺寸，并因此减轻了插件单元重量的可能性，当所得到的产品在运输领域，尤其是在航天航空工业中应用时，减小尺寸和减轻重量很重要。
在某些上述实施例中，首先可能希望借助于压力和速度，把热塑性插件单元放入热塑性夹芯产品中，然后通过施加超声能和压力，将插件单元固定在夹芯产品中。
在本发明的另一个优选实施例中，首先在热塑性夹芯产品的表面中形成一个凹槽，此后利用上述方法步骤，如钻孔到凹槽中并把插件单元放在孔中，通过施加超声能和压力，把热塑性插件单元焊接到热塑性夹芯产品内的凹槽中。
利用上述凹槽提供将塑料插件单元的顶部表面至少与热塑性夹芯产品顶部覆盖层齐平焊接的方案。而且，热塑性插件单元的长度可以通过利用热塑性夹芯产品中的凹槽并把塑料插件单元超声焊接在凹槽中来减少，其结果是塑料插件单元的重量减轻，这在运输工业，尤其是航空航天工业中特别重要。
热塑性夹芯产品表面中的上述凹槽有利的是通过使用通称为热/温加热法形成，其中将经过加热的热金属变形压模放在热塑性产品的表面上，此后由于压力，温度和时间结合的结果，通过顶部覆盖层和芯中热塑性塑料的塑料变形和熔化，金属压模沉入热塑性夹芯产品中。一旦达到所希望的热塑性夹芯产品顶部覆盖层的变形，就除去变形压模，并在数秒种内将凹槽最终形状的热固结印模在压力下放入已经成形的凹槽中。然后凹槽优选的是在压力下冷却，并且一旦凹槽中顶部覆盖层热塑性塑料的温度降到低于热塑性塑料的玻璃转变温度，就可以取出固结压模。取出变形压模和固结压模放在热塑性夹芯产品中已成形的凹槽中之间的时间必须十分短，以使顶部覆盖层必须不冷却到低于熔点-10％，以便产生最终希望的凹槽，并且这个时间一般至多10秒钟。产生的凹槽取固结压模的形状。
变形压模的温度是在顶部覆盖层中热塑性塑料的熔点±10％附近。固结压模的温度是等于热塑性夹芯产品顶部覆盖层热塑性塑料玻璃转变温度或低于所述转变温度的10-30％，以便防止温度骤变。用来加热热塑性夹芯产品顶部覆盖层表面的变形压模形状不一定必须与固结压模的形状相同。对变形压模的形状没有提出限制。合适形状的例子包括：平面，稍微凸起的形状，等等。对固结压模的形状没有限制，但这种形状一般与插件单元凸缘的下侧形状匹配。当然，上述凹槽也可以通过热/温变形法用装配在变形压模中的冷却零部件成形，上述冷却零部件也用作固结压模。
本发明的另一个实施例包括在凹槽中安排一增强层。为此，将一块聚酯胶片或层压制品(固结的聚酯胶片)放到覆盖层表面上形成凹槽的位置处。如果合适的话，聚酯胶片或层压制品可以用超声焊接法固定。然后，用热/温变形法形成凹槽，如上所述。然而，为了将聚酯胶片成层压制品成功的固结在凹槽中，变形温度选定是在顶部覆盖层中热塑性塑料熔点的-5％-+10％范围内，同时加热时间更短和提升变形压模与施加固结压模之间的时间保持最少，以便防止热塑性芯材料的熔垂。然后可以将塑料插件单元焊接到已成形的增强凹槽中。
上述热/温变形法还可以用来在热塑性夹层产品中用凹槽加上例如航线的字母或名称，如KLM。
在用于借助热固性树脂将插件固定在热塑性夹芯产品中的可供选择的方法中，首先是在热塑性夹芯产品中穿过一个或两个覆盖层钻或铣削一个孔，所述孔至多是插件主体横截面的大小。然后借助于加热，例如经过加热的热的(温度T大于芯中热塑性塑料的玻璃转变温度)金属丝，如果合适的话，装备一小块扁金属，一般是在整个表面和孔周围的高度上，将热塑性芯材料除去或者熔化到覆盖层之间连续致密的材料上。芯材料从中除去的孔周围的距离与夹芯产品的使用和厚度有关，但一般是孔横截面的约2-3倍。
上述方法具有优点是，覆盖层不必除去，如在Nomex的蜂窝状夹芯的情况那样，其结果是保持更好的力传送，并因此可以减少热固性树脂的量。
热塑性夹芯产品包括至少一个纤维增强的热塑性覆盖层，所述纤维增强的热塑性覆盖层接合到一个由不完全是实心的热塑性塑料组成的芯上，在覆盖层和芯之间可能的接合层由热塑性塑料组成。
对一个或多个覆盖层来说，优选的是，中间层或增强层与芯的热塑性塑料相同或至少兼容。一个或多个覆盖层，中间层和增强层及芯的热塑性塑料都不受任何特殊限制。一些例子包括PEI聚醚酰亚胺(通用电气公司生产的Ultem)；PES聚醚砜；PC聚碳酸酯，PP聚丙烯或共聚物的混合物等。热塑性夹芯产品不完全是实心的热塑性芯材料可以任选地用纤维或用纳米粒子增强。芯形式的例子包括：各向同性泡沫塑料；各向异性泡沫塑料；热塑性蜂窝体；共挤塑物；包括热塑性塑料的短切纤维(Azdel)等。
热塑性夹芯产品可以包括一个或多个中间层。为了成本和重量的目的，上述一个或多个中间层将只在夹芯产品中使用，所述夹芯产品不用胶粘剂膜，例如用于用通称为现场发泡法生产的夹芯产品，如在以本申请人名下的EP 0636 463中所述。
芯材料，一个或多个覆盖层，一个或多个中间层，增强层中及塑料插件单元中纤维的选择不受任何限制。无机纤维如玻璃纤维、金属纤维、碳纤维、及有机纤维如芳酰胺纤维，都可以如所希望的使用，象天然纤维一样，只要它们能承受方法实施时所遇到的状态。
一个或多个覆盖层，一个或多个中间层及增强层中的纤维可以任选地定向，并且无论对长度和方向都没有限制。编织纤维、纺织纤维、纤维垫、棉布及单向纤维代表纤维的各种表现形式。塑料插件中的纤维可以有或没有方向。纤维的长度和方向不受任何限制；短纤维，长纤维和单向纤维代表纤维的各种实施例。
热塑性夹芯产品的优选实施例包括两个由纤维增强聚醚酰胺形成的覆盖层和一个聚醚酰亚胺泡沫塑料芯，芯用通称的现场发泡法生产，如本申请人名下的EP 0636 463中所述。结果是一种各向异性泡沫塑料芯层，所述芯层其特征在于，在垂直于覆盖层的方向上有高压缩强度。这样得到的热塑性夹芯产品其特征在于，较高的挠曲强度，重量轻和很好的防火性能。泡沫塑料在表面上的高压缩强度和均匀分布对通过超声能和压力加入热塑性插件单元具有有益的效果。
对上述借助按照本发明所述方法得到的产品的适用范围包括用于飞机、火车、船等的内部产品。用于芯的热塑性材料也可以与纤维增强覆盖层的热塑性塑料，例如带PC纤维增强覆盖层的PEI现场发泡的泡沫塑料有很大不同，参见本申请人名下的NL1020640。在这种情况下，一般需要钻孔和除去全部或几乎全部芯材料。
下面根据附图说明本发明，其中：
图1示出通过将塑料插件单元超声焊接到热塑性夹芯产品中的一般剖视图；
图2示出穿过塑料插件单元一个实施例的剖视图；
图3示出在热塑性夹芯产品中钻孔；
图4示出将一塑料插件单元安排在孔中，所述孔具有一直径为小于插件单元主体的最大直径，同时孔中的所有芯材料都没有除去；
图5示出焊接到图4中热塑性夹芯产品上的塑料插件单元；
图6示出在热塑性夹芯产品的顶部覆盖层中缺口的一个实施例；
图7示出放到热塑性夹芯产品上的热变形压模实施例；
图8示出由于变形压模已下降到热塑性夹芯产品中所希望位置的结果在热塑性夹芯产品中所形成的初步凹槽实施例；
图9示出通过把固结压模放在已成形的凹槽中，在热塑性夹芯产品中固结所希望的凹槽；
图10示出穿过热塑性夹芯产品中凹槽的横截面实施例；
图11示出用于将热固性树脂安排在热塑性夹芯产品中的孔实施例。
参见图1-11，作为本发明的结果，热塑性插件单元2固定在热塑性夹芯产品1中。按照优选实施例制造的热塑性夹芯产品1包括一个PEI(聚醚酰亚胺)纤维增强的顶部覆盖层7，一个现场发泡的PEI热塑性塑料芯8和一个底部PEI纤维增强的覆盖层9。
热塑性插件单元2由一种优选的是纤维增强的热塑性塑料如聚醚酰亚胺制成，并可以包括钢插件5或孔，螺纹安排在上述孔中，以便插件单元2可以起夹芯产品1中固定点的作用。塑料插件单元一般具有一带圆形凸缘4的圆筒体3。圆筒体3在凸缘4和插件单元端部12之间具有一较小的直径6，如图2所示。上述插件单元2可以例如用注塑法由一种短纤维增强的热塑性塑料生产，或者例如用连续纤维增强的热塑性塑料通过复合物流态压塑法生产。
现在参见图3，在热塑性夹芯产品所希望的位置处，例如用低速钻头形成具有预定直径的孔11。用来产生孔的切削工具也可以是手动或自动操作的铣床。然后，将热塑性插件单元2放入孔11中。插件单元的圆筒形部分3长度尺寸准确地与夹芯产品1的厚度匹配，以便熔融可以在凸缘4的下侧与顶部覆盖层7之间和插件单元2下侧12与下底部覆盖层9的顶侧之间进行。钻头13的直径一般等于或稍大于插件单元2圆筒形部分3的直径。
如果钻头13的直径比插件单元2圆筒形部分3的直径小例如2-4mm，则插件单元2可以首先在压力和/或速度下放入夹心产品1中，参见图4。圆形凸缘4具有一直径为大于钻头13的直径或大于插件2圆筒形部分3的最大直径，并且与插件单元2的圆筒形部分3相比是较薄。图3和图1示出插件单元2通过钻孔或焊接安装。然后将热塑性夹芯产品的平面或实际上是平面的部分放到工作台14上，并以这种方式定位，以便插件单元2位于超声波设备的焊头6和砧座10之间。插件单元也可以放在孔上。然后把超声波设备，例如BransonUltrasonic Corporation生产的900系列的焊头6刚好放在插件单元2的上方。施加超声能和压力在热塑性插件单元2的接触面之间产生热量，亦即在凸缘4的下侧与顶部覆盖层7的顶侧之间和同时在插件单元2的下侧与底部覆盖层9的顶侧之间产生热量。如果产生了足够的热量用于使插件单元2和覆盖层7，9的接触面塑化并熔化在一起，则停止施加超声波能。在冷却之后，优选的是在压力下，将插件单元2固定(焊接)在热塑性夹芯产品1中。
如果使用一个孔17，所述孔17具有直径为小于插件主体的最大直径，参见图4，则产生一更大的焊接面13，参见图5。
图5还用标号16表示，芯材料是通过施加超声能和压力进行压缩和熔化。优选的是除去少于90％的芯材料，以便由此增加插件单元在凸缘下侧与插件单元主体下侧之间的距离方面和热塑性夹芯产品厚度之间的尺寸公差。
上述方案优选的是用来超声焊接整个塑料插件单元，如通过上述流压压塑法所生产的那些，以便防止损坏插件单元中的孔，所述孔常常是带螺纹的。
如果孔是切开的缺口18而不是钻孔，则也可能用于顶部覆盖层来增强孔，参见图6。
当把插件单元安排在热塑性夹芯产品中时，上述用于在插件单元主体最大直径处使用夹芯材料(芯和顶部覆盖层)的方案当然可以以任何方式结合。
为了节约重量和/或免除待把插件单元的顶侧设置成与热塑性夹芯产品1顶部覆盖层7的表面齐平或者在上述表面下方的需要，可在热塑性插件单元2焊接在热塑性夹芯产品1内的凹槽22中之前，在热塑性夹芯产品1中形成凹槽22(图10)。热塑性夹芯产品1中的凹槽22可以用通称的热/温变形法生产。
热/温变形法包括把加热的热金属压模19放到热塑性夹芯产品1的顶部覆盖层7上，然后金属压模19缓慢地沉入热塑性夹芯产品1中，同时由于压力、温度和时间相结合的结果，使顶部覆盖层7和泡沫塑料8软化和/或熔化。当在热塑性夹芯产品1中形成所要求的凹槽22初步形状21时，在几秒钟之内把具有最终形状的固结压模20放到初步形状21中，结果初步形状21固化，以便形成凹槽22的最终形状。热变形压模19一般是在等于热塑性夹芯产品1顶部覆盖层7热塑性塑料的熔点±10％的温度下。固结压模20一般是金属，一般是在低于顶部覆盖层7中热塑性塑料玻璃转变温度的温度下。作为例子，如在本发明已说明的那样，在热塑性夹芯产品1内的凹槽22中钻孔，此后借助于压力和超声能将塑料插件单元2焊接到凹槽22内的孔中。很显然，插件单元2、主体3和凸缘4的大小与所用的热塑性夹芯产品1，具体的应用，所应用的凹槽及插件单元2用的材料选择有关。
通过本发明，能在不到10秒时间里将热塑性插件单元2固定在热塑性夹芯产品1中。现已发现，尤其是当使用复合物流压塑法生产的插件单元时，用本发明大大减少了工作时间，费用和重量。
借助加热，除去孔周围的泡沫塑料在热塑性夹芯产品1中产生空腔23，参见图11。这个空腔可以充装热塑性树脂，以便对固定点起额外增强作用。

Claims (8)

1.用于安排热塑性插件单元的方法，上述热塑性插件单元包括在热塑性夹芯产品中的主体和凸缘，所述热塑性夹芯产品具有至少一个大体上是平面的部分，上述热塑性夹芯产品包括一层热塑性泡沫芯材料和至少一个覆盖层，上述覆盖层由纤维增强热塑性塑料形成，方法包括以下步骤：
从纤维增强热塑性塑料覆盖层中形成进入热塑性夹芯产品的热塑性泡沫芯材料的孔，并除去一部分所述热塑性泡沫芯材料；
将所述热塑性插件单元放入所述孔中；
将所述热塑性插件单元定位在超声设备的焊头和砧座之间；
施加超声能和压力，以便在所述热塑性插件单元与所述热塑性夹芯产品的纤维增强热塑性塑料覆盖层之间产生热量；
在供应足够热量以使所述热塑性插件单元和所述热塑性夹芯产品的纤维增强热塑性塑料覆盖层之间熔化之后，通过冷却将所述热塑性插件单元固定。
2.按照权利要求1所述的方法，其中所述热塑性夹芯产品包括一个由纤维增强热塑性塑料形成的顶部覆盖层，一个由热塑性泡沫芯材料形成的芯层和一个由纤维增强热塑性塑料形成的底部覆盖层。
3.按照权利要求1-2中之一所述的方法，其中所述孔的尺寸等于所述热塑性插件单元的主体尺寸。
4.按照权利要求2所述的方法，其中所述热塑性插件单元主体与所述热塑性夹芯产品的厚度匹配，以便施加超声能和压力同时实施将所述热塑性插件单元的下侧熔化到底部覆盖层的顶侧上，及把所述热塑性插件单元凸缘的下侧熔化到所述热塑性夹芯产品的顶部覆盖层的顶侧上。
5.按照权利要求2所述的方法，还包括在形成所述孔之前，在热塑性夹芯产品的表面中形成凹槽的步骤，所述孔设置在所述凹槽内。
6.按照权利要求5所述的方法，其中利用热/温变形法施加所述凹槽。
7.按照权利要求5所述的方法，其中热塑性夹芯产品的顶部覆盖层的所述凹槽用纤维增强的热塑性塑料层增强。
8.按照权利要求1-2中之一所述的方法，其中施加热量以在所述热塑性夹芯产品中的所述孔周围产生一个在热塑性泡沫芯材料中的空腔，在此之后将空腔装满热固性树脂。
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