CN101043954B - 纤维增强复合材料的高强度连接系统 - Google Patents

纤维增强复合材料的高强度连接系统 Download PDF

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CN101043954B
CN101043954B CN2005800359780A CN200580035978A CN101043954B CN 101043954 B CN101043954 B CN 101043954B CN 2005800359780 A CN2005800359780 A CN 2005800359780A CN 200580035978 A CN200580035978 A CN 200580035978A CN 101043954 B CN101043954 B CN 101043954B
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resin
fiber
sulfuration
reinforced composites
fibre
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CN101043954A (zh
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亨利K·奥柏梅尔
埃里克N·吉尔伯特
奎因·格兰特·贝克
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/32—Processes for applying liquids or other fluent materials using means for protecting parts of a surface not to be coated, e.g. using stencils, resists
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Abstract

本发明涉及利用在粘结基片交界面上交叉分布的增强纤维的连续性连接纤维增强复合结构，在随后被粘结的构件制作过程中，树脂或者树脂阻拦物质的浸渍程度的温度梯度控制，提供了部分暴露的增强纤维，该增强纤维用来增强随后形成的接头或边界。

Description

纤维增强复合材料的高强度连接系统
这个申请要求得到2004年8月31日提出的美国临时申请No.60/606231的优先权，因此，该美国临时申请被作为参考采用。 
发明背景 
技术领域
本发明涉及纤维增强结构的连接，尤其涉及在纤维增强构件的边缘或表面暴露的非树脂浸渍处理纤维的构造，这种纤维的使用有利于加固这些纤维增强构件之间随后形成的结合面。 
相关技术的说明 
在纤维增强复合材料中，多数胶着粘接的结合面根本没有任何增强连续性，只有Benson等的美国专利6,821,368B2中公开的Z-pin技术是个明显的例外。结合面之间的纤维增强材料的连续性是合乎需要的，因为该纤维增强材料不但远比聚合体基质坚固，而且与聚合体基质内部的胶着粘接结合面相比也更坚固。可以料到缺乏纤维增强材料的聚合体结合面缺少纤维增强结构的内在抗疲劳性。另外，聚合体结构之间的胶着粘接结合面容易受到环境影响而降解。之后当该物品在次级粘结步骤被粘合时，复合材料构件中硫化树脂方法的使用留下相对少的晶格点用于化学粘结。纤维增强复合材料中传统胶着粘接结合面的局限性已经很好的由如下文件得到证明： 
J.M.Koyler，等的国际SAMPE科技大会辑，45，365(2000)(J.M.Koyler，et al，Intl.SAMPE Tech.Conf.Series，45，365(2000))； 
D.M.Gleich，等的国际SAMPE科技大会辑，45，818(2000)(D.M.Gleich，et al，Intl.SAMPE Tech.Conf.Series，45，818(2000))； 
R.H.Bossi及R.L.Nereberg的国际SAMPE科技大会辑，45，1787(2000)(R.H.Bossi，R.L.Nereberg，Intl.SAMPE Tech.Conf.Series，45，1787(2000)；HeselhurstR.B.，连接复合结构，教学笔记SAMPE2001(Heselhurst R.B.，Joining Composite Structures，Tutorial notes SAMPE2001)。 
上述的参考文献被作为参考采用。Jacaruso等的美国专利5464059公开了增强纤维在用于随后的热固性复合结构连接的热塑性材料中的部分实施，但是在其中并没有揭示通过已完成的热固性/热塑性/热固性结合面的纤维的持续性。以增加表面能和潜在胶结晶格点为目的的各种工艺不仅劳动力密集、价格昂贵、可靠性不确定，而且容易因为短暂地暴露于环境中而 恶化。 
单个复合材料物品内部Z轴纤维的好处是已知。例如：为了增加层理间的强度，预浸处理材料的每一层已经用束状纤维处理过了。成形之前的三维编织也已被采用。施密特等人的美国专利6,712,099B2公开了一个此类成形之前三维编织的例子。虽然这样的结构可以使整体硫化构件内部具有优良的Z轴抗脱层性能，但是这样的结构本身并不能确保粘合结合面的强度得到增加。过去已经提出了使结合面加固的一些方法。这包括公开了剥离层片的使用的Reis和Wong的美国专利5,879,492和6,645,610B1，剥离层片被从硫化构件上剥离下来是为了将其嵌入该复合结构中，也就是嵌入用来加强随后的粘合接头的纤维中。相互编织和束状纤维的使用也已公开。这种方法导致了下述两个需求之间的矛盾，即对留在硫化树脂中的纤维的良好湿润性的需求以及对被剥离去掉的纤维的良好分离性的需求。明显地，采用单一类型表面处理的单一类型的纤维效果不好。此外，隔离剂可能被应用于被剥离的纤维，这种隔离剂在被硫化到要嵌入的纤维上的过程中可能会流动，这会削弱嵌入纤维所要加固的粘合接头的强度和可靠性。 
静电束状碳纤维也已用于提高电器部件的热传递和在斯特林发动机中的热传递。 
发明概述 
本发明的目的之一是提供各种纤维增强构件之间的高强度连接。例如，一架飞机机身结构的内部可能装备有由暴露纤维组成的通常为环形的区域，以便使其被黏附地粘结到一个压力隔框上。该区域具有与机身相配合的周长，其特点类似于暴露纤维。粘结时，从该机身结构内部延伸出的纤维与从该压力隔框结构内部延伸出的纤维相混合并共同埋入硫化粘接剂中。该结合结构的牢固性因为与硫化树脂粘结的交界面上交叉分布的纤维具有连续性而得到提高，因此不必依赖粘结到硫化树脂上的接头的力量，也不必依赖非增强粘接剂的力量。负荷可以可靠地完成从纤维到树脂再到纤维的传递而不需要穿过粘合接头线路的拉伸载荷的传递。粘接剂本身内部应力的减少与粘接剂内部的纤维重叠程度相一致。纤维重叠可以适应负荷需求。例如，为使接头内部Z轴纤维排列的比例最大化，可以采用抗静电束状连接条。编织加强织物的局部暴露可以提供与占多数的剪切载荷的充分连接。针织物将有望提供介于由毛束状连接条和方形编织织物所提供的连接特性之间的连接特性。 
本发明的进一步实施例的一个方面在提供一种下层结构和涂层系统之间的高强度连接。例如，一种复合宇宙飞船结构可能包括露出纤维的表面区域，该表面区域对应于最大再进入 热化区域。室温硫化硅橡胶(RTV)等粘接剂可以使诸如二氧化硅泡沫陶瓷或氧化铝纤维等隔热耐火材料易于附着于这种表面。通过这种方式，粘接剂可以被可靠地附着于该下层复合结构，而不必依赖于硫化树脂表面的化学键。硫化树脂表面的化学键的化学性质相对不活泼。本发明适用的其它涂层系统包括环氧树脂涂料、弹胶涂层、热塑涂层、热固性涂层比如酚醛树脂涂层、雷达吸收涂层、电精密涂层、抗化学涂层、耐火涂层、用于电磁干扰(EMI)保护或雷击保护的电传导涂层、烧蚀层，等等。可以埋入本发明所公开的纤维的任何材料都可以被可靠地粘附到所述下层结构上，在该下层结构中上述纤维是连续的。 
本发明的进一步方面的目的是提供一种可用于几个构件之间的具有挠性的高强度连接。例如，为了将连接载荷降到安全极限以内，两个可以相对彼此移动的相对刚性结构的接头可能需要挠性连接。附着到机身的起落架或引擎属于此类。根据本发明，暴露纤维在要连接部分的表面的应用，容许在相对刚性结构之间形成弹性联接。各结构的暴露纤维结合成这样一个弹性联接，不仅提供了连接附着的可靠性，而且提供了通过这种联接传送相当大的张力载荷的可能性。在现有技术中，弹性体的连接主要依靠受压弹性元件。在载荷反向的情况下，需要多余的弹性元件，在任一特定时刻只有一个弹性元件传送载荷。 
本发明的进一步的目的是，在具有预期挠性的区域内提供一个柔性基质。该柔性基质位于在两个或更多相对铰接的构造单元之间大致呈连续状态分布的纤维周围。例如，一些结构纤维构成加强翼。在加强翼中它们被埋入刚性聚合物基质中，在那里它们可以以暴露的状态延伸，穿过具有预期挠性的区域，进入一个副翼。在副翼中它们再次被埋入刚性聚合物基质中。露出纤维的区域因而充当铰接手段，该区域无论随后是否埋入挠性基质(比如弹性体环氧树脂)都可使用。 
根据本发明上述实施例的进一步方面，一个或多个加强织物板料可以有选择地浸渍树脂和树脂阻拦物质。这种方式使在那里制成的硫化构件具有预期的性能。例如，这种有选择性的浸渍可由丝网印刷或喷墨式印刷完成。接着，这种板料可以被组装和硫化，然后，含有树脂阻拦物质的区域中的这种物质会被完全清洗掉，之后该区域将被并用来形成铰接，加入或不加入浸渍弹性体和接头都可以。 
本发明进一步的目的是提供改进的分离紧固件。这种分离紧固件与钉子、钩环或铆钉相等同，特别有利于纤维增强结构的连接。例如，5厘米长的碳纤维丝在各端用刚性(非增塑性)PVA浸渍1厘米，PVA进一步形成尖端。这个丝线则能形成具有2厘米长腿的普通纸订书钉 的形状。所有非PVA浸渍的丝线接着用树脂浸渍并硫化成刚性形式。这种订书钉能从预浸处理层压制品的最厚处插入，尖锐的PVA浸渍端伸入可穿透弹性体衬垫，此可穿透弹性体衬垫类似于在有Z-pins插脚的结构被硫化时用到的那个可穿透弹性体衬垫。在层压制品硫化以后，PVA溶解，该″订书钉″端部的纤维散开并粘合到该层压制品的表面。 
根据本发明实施例的一个方面，可建立一个垂直于树脂浸渍纤维和非树脂浸渍纤维之间的期望边界的温度梯度区域。溶解树脂阻挡物质，比如石蜡，可用于靠近该温度梯度区域的高温端的增强纤维。树脂阻挡物质，比如石蜡，浸润热纤维并借助于毛细作用沿着该纤维到达边界，在该边界该纤维的温度致使石蜡凝固和毛细管运输停止。没有浸渍石蜡的纤维部分随后用树脂浸渍，在该纤维基质内部产生一清楚的树脂边界。在该树脂阻拦物质比如石蜡的熔点温度以下，树脂可被硫化。在树脂被硫化之后，该石蜡借助于例如真空升华以及随后在柠檬酸溶液中的溶解而移除。这个程序留下易于并入一个二级接头的暴露非树脂浸渍纤维。例如，两个邻接部分的边缘通过重叠或联锁各部分的暴露纤维相连接，随后用树脂浸渍处理该联锁纤维区域。由此产生的结构因接头具有增强连续性而获益。 
根据本发明另一个实施例的一个方面，增塑聚乙烯醇(PVA)溶液可用来浸渍纤维区域并产生一供控制随后的树脂浸渍使用的隔层。在凝固以后，该增塑PVA形成一柔性和耐热的隔层，该隔层在热硫化周期内有选择地阻挡树脂浸渍，这可能会用到放热性硫化树脂处理方法。在树脂系统硫化时，PVA溶解于温水中，留下对随后接头的形成很有用的暴露纤维。 
根据本发明的一个实施例的一个更进一步的方面，金属或金属合金可以在温度梯度控制下浸渍到纤维基质中。该纤维基质剩余的非金属浸渍部分可用树脂浸渍，该树脂也被硫化。如果愿意，可通过熔融、化学腐蚀或电化学去除方法将该金属除去。为了某些用途，例如为增强电特性，金属可以留下来。 
根据本发明的更进一步的方面，一可溶弹性膜片可以将与该弹性膜片平面基本垂直的短纤维固定。这种膜片可以贴于未硫化的复合结构的表面，并在硫化期间留在原地。在硫化之后，该弹性膜片可能溶解，留下暴露纤维从该硫化复合结构的表面向外伸出。 
根据本发明进一步实施例的一个方面，可溶纤维织物比如PVA可以以与地毯或绒面革的载体或基底织物相类似的方式使用。例如碳纤维的增强丝，随后可以按照传统的地毯制作工艺插入和附着，或作为丝绒革的毛圈织物成分插入。该载体或基底织物表面用柔性可溶填料比如PVA密封。这种织物可用于未硫化复合结构的表面，暴露加强纤维朝向下层结构。根据例 如真空辅助树脂传递模塑法，要硫化的树脂可预先渗透进这种织物或可浸入作为一个整体的该织物和该复合结构中。该复合材料制品硫化之后，可溶织物和可溶填料将会溶解，留下暴露加强纤维以备后用。 
另外，根据本发明一实施例的更进一步的方面，一可溶性聚合物薄膜，比如处于软化和粘附状态的PVA混合物，可以利用静电植绒方法使连接加强纤维直立插入其中。静电植绒已经用来在每平方英寸上插入超过150,000根的纤维。当该聚合物薄膜硬化时，由此产生的承载薄片的挠性纤维可被应用于一未硫化的复合材料制品的表面。该未硫化的复合材料制品的表面将用于随后的粘结。在这种结构中，该柔性聚合物薄膜的非纤维承载面保持暴露，而从那里伸出的纤维将被压入该复合材料制品的下层纤维中并与之混合。上述步骤可以发生在导入树脂之前或之后。该制品最终使用树脂浸渍。当该树脂浸渍制品硫化时，可溶性聚合物薄膜会溶解并被清洗掉，留下非常适合随后的粘接或加敷层的有绒毛的表面。 
根据本发明上述实施例的进一步的方面，连接加强纤维可以以特定不均匀取向的方式使用，比如通过气动力学聚集。 
根据上述实施例的进一步的方面，使用可溶解的粘接剂可使毛束状连接加强纤维固定到一个诸如用PVA纤维编织成的织物等的薄片上。 
比如，根据上述实施例的进一步方面，使用可溶解的粘接剂，可以将毛束状连接加强纤维固定到一个不可溶解的薄片上，该薄片在随后的制造阶段通过剥离等机械手段去除。 
根据本发明的进一步方面，在所述制品树脂浸渍之后和硫化之前，毛束，无论是否带有静电组分，都可用来将连接加强纤维直接地附加到复合材料制品的表面。这种方法省去了清洗步骤，适宜于通过湿敷层法织造的制品的连接。在这种情况下，要带有暴露连接加强纤维的表面不是像通常那样由真空包围，而是处于足以平衡表面张力和树脂流体静压的综合效应的气体压力下。在这种情况下，气体压力可以是大气压力。控制是借助于树脂流体静压和该连接加强纤维的润湿特性的设计控制来完成的。基于表面能、纤维直径和纤维间距等因素，该连接加强织物的润湿特性将被优先选择，以便完全地浸润该下层结构纤维而只部分地浸润该连接加强纤维。 
根据本发明的进一步的方面，一连接加强织物可应用于随后连接的一复合材料制品的外表面。上述的连接加强织物具有受控的润湿特性，因此，下层结构的加强纤维在预设的树脂流体静压下会完全润湿，而该连接加强织物仅会部分润湿。在该复合材料制品的硫化初期，该用 于随后连接的外表面将部分埋入连接加强纤维。 
根据本发明进一步的实施例的一个方面，可提供一个连接，在此连接中，一个或多个部件彼此相配模压。例如，可以构造一个包含一个或多个表面区域的层状或夹层结构，其中，外部纤维受到树脂阻挡物质的保护。在这种结构硫化前或硫化后，它的上面可设置附加的结构，该附加结构把背对背结构中的树脂阻挡纤维的对应区域与第一个结构的树脂阻挡纤维成分合并在一起。当这种组装结构在它们各自的组装位置硫化时，该结构可彼此分散并且它们各自的粘合区的树脂阻挡物质也被清除掉。对于芯模的去除或其它部件的插入，这种分散可能是有用的或必要的。在除去树脂阻挡物质以后，该结构可以随后重新组合并且用一可靠接头彼此黏附地胶结。 
根据本发明的一个实施例的进一步方面，钝的楔形物可能被彼此相对地用于更合适的位置，即复数个增强层的边缘。这种增强层最好在它们与该楔形物接触的长度范围内阻拦树脂的渗透，只有最接近该楔形物窄端的区域除外。通过这样的方式，该纤维呈扇形展开进入一个燕尾槽内，在该燕尾槽中，它们可以通过一个二级树脂浸渍工艺得到固定。 
根据本发明的进一步方面，为了形成一个期望的树脂浸渍结构或区域，温度梯度可能用来直接地控制树脂浸渍。为了在不打乱树脂结构的情况下硫化该树脂，可以使用一放射源来把该树脂固定在适当的位置，同时保持足够低的温度以防止树脂移动。电子束硫化因其可控性和透入性被优先选择。紫外线硫化、X射线硫化以及γ射线硫化也是适合的。就用紫外线硫化而言，可配置玻璃纤维来控制光的方向和保证结构的增强。 
根据本发明进一步实施例的一个方面，加强织物组合的浸渍可与硫化放射物在预期的浸渍不充分的地方的出现同步。这样的方式可能会引起接近该放射源的树脂的硫化，形成一阻止树脂进一步浸入的坝。例如，一紫外线光源可能用来形成一树脂隔层，该树脂隔层恰好处于正在被浸渍的制品的一个被选表面的最上面纤维的下面。这样形成的树脂坝提供未经浸渍的纤维。这些纤维的使用对粘结其他部件或专门的覆盖层非常有利。靠近表面树脂的放射硫化，可马上继之以剩余树脂的热硫化。如果使用先有技术，粘滞性会随热硫化的开始而下降，这使得树脂浸渍的受控限制不太可能。 
根据本发明一个方面的进一步实施例，温度梯度可以用来控制热熔塑胶浸入纤维基质内的程度。随后热固性树脂浸入到剩下的纤维基质中，用于产生一个部件，该部件可通过穿过树脂交界面的纤维增强材料的连续性被热粘结到另一个同样的部件上。本方法把高玻璃态转化 温度以及热固性树脂的良好结构性能与热熔塑胶部分的可焊性结合起来。 
就本发明而言，″连接加强纤维″包括具有将涂层系统粘结到物品上的功能的纤维。″树脂″包括任何可聚合或可横向连接的化合物。该化合物在硫化时提供一种有用的从内部连接该纤维基质的基质。例子包括环氧树脂、聚酯树脂、丙烯酸树脂、酚醛树脂、乙烯树脂、聚酰胺、硅树脂，以及双顺丁烯二酰亚胺。 
附图说明
图1、图2是玻璃纤维绳编织的照片，描绘了一个在受控温度梯度下利用石蜡浸渍的树脂阻挡区域，接着，通过真空升华以及随后的溶解过程，石蜡被从该区域去除掉。 
图3是一碳织物照片，从左至右，未浸渍过的，PVA浸渍表面，以及与该PVA浸渍表面相对的表面。 
图4是一碳织物照片，从左至右，未浸渍过的，PVA浸渍表面，以及与该PVA浸渍表面相对的表面。 
图5是根据本发明一个方面的一个步骤绘制的时间-温度图表的例子。 
图6a和图6b是暴露在根据本发明一个方面做出的一硫化复合结构表面上的碳纤维的电子扫描显微照片。 
图7是根据本发明一个的方面用树脂阻挡物质浸渍加强织物的说明示意图。 
图8是根据本发明的一个方面进行树脂阻挡物质的末端向上的浸渍控制的说明示意图。 
图9是根据本发明一个方面制作的单向加强带例图。 
图10根据本发明的一个方面对连接先前硫化的层压橡胶的接头进行说明。 
图11a到图11e是根据本发明在一支柱和一蜂窝夹层结构之间建立接头的工序说明。 
图12a和图12b根据本发明的一个方面对阶梯接缝的制备进行说明。 
图13a到图13d是根据本发明制造燕尾接头的步骤说明。 
优选实施方式的详细说明 
如图1和图2所示，初始温度为20摄氏度的编织玻璃纤维绳被短暂地浸入到熔化的石蜡中，以便使该石蜡的浸渍(油绳)达到一预定的预期树脂边界。浸渍一直延伸到边界2，在边界2，已熔化的石蜡的温度下降到足以使它开始凝固并停止浸入的程度。瞬时温度变化梯度以此来控制石蜡浸渍的延伸程度。在这种情况下，石蜡被用作树脂阻拦物质。接下来，为了使石蜡凝固，图1和图2所示的样品被冷化并被浸渍于环氧树脂中，该环氧树脂随后被允 许硫化，然后该样品中的石蜡通过升华和溶解被清除掉。环氧树脂的浸渍(在有效的等温情况下)受到边界2的精确控制，该边界2位于随后被硫化的环氧树脂3浸渍的玻璃纤维和未经浸渍的玻璃纤维1之间。这样的结构可用于多种纤维增强复合材料制品，这些纤维增强复合材料制品随后将被粘结；或者用于挠性非浸渍纤维，这些挠性非浸渍纤维可以用于其他目的，如揉曲、传热，或粘结特殊用途的涂层。 
参考图3，照片的左边是一方形碳纤维编织物。照片的中间部分是在穿过厚度温度梯度的情况下，浸有增塑聚乙烯醇(PVA)的碳纤维编织物的一个表面。图3中照片的左侧部分是浸有增塑聚乙烯醇(PVA)的碳纤维编织物表面的背面。这是冷表面。穿过厚度的温度梯度致使PVA凝胶并在材料内的预定边界处停止浸渍。这样就产生了一个样品，该样品产生于纤维增强构件的表面上随后被粘结的一部分，可作为增强结构的最外层使用。在最后被组装并粘结之前的任何时间，用热水将PVA移除之后，暴露的纤维将直接编入构件中，而PVA浸渍纤维将被保护，或者避免被树脂浸渍，直到树脂被硫化并停止移动。应该注意的是，图3所示的PVA经处理过的这种纤维也可使用树脂浸渍，然后被部分地硫化或胶化，以提供一个适用于将要被粘结或涂覆的表面的预浸处理材料，该表面也是由预浸材料构造组成。 
图4显示了一玻璃纤维编织物。照片的左侧部分是未经处理的纤维，照片的中间部分是经PVA处理的表面，右边的部分是经PVA处理的表面的背面。所有适用于图3的说明同样适用于图4，只是织物材料不同。例如，图3中的织物材料是碳，而图4中的是玻璃。 
图5显示了本发明的一方面的过程序列的主要阶段。这些主要阶段依次是：(1)准备一熔点降低的树脂阻拦物质。冷的转筒或者其它适合传热的表面的温度，被控制在低于熔点降低的树脂阻拦物质的凝胶点的温度范围内。注意，上述步骤是为后面的步骤做准备，接下来的纤维处理步骤通常适合于连续的程序流程。(2)纤维与冷的转筒紧密接触，而熔点降低的树脂阻拦物质通过浸泡等方式与纤维紧密接触。熔点降低的树脂阻拦物质可能会是溶于水的PVA。如果使用PVA，为了给浸渍纤维提供可挠曲性，最好用1—3％的甘油或乙二醇对它进行增塑处理。在渗入纤维的时候，树脂阻拦物质冷却并最终凝胶，此时它停止渗入，并从相反的方向为以后的树脂浸渍界定出一个边界。应该注意的是，为了浸渍并停止树脂阻拦物质所需的温度梯度可以是不稳定的，也可以是稳定的，还可以是二者的结合。总之，本过程的显著特点在于某种类型的温度梯度的使用。(3)附加的冷却凝胶剂可暂时地固定织物内的树脂阻拦物质。(4)在处理过的织物的一边，脱水处理提供了一个坚固的涂层，使织物在传送、 保存和处理时不受损害。注意，接下来的步骤不再直接与之前连续的过程匹配步骤相关联。(5)为了在树脂浸渍纤维增强构件的表面提供暴露的纤维，织物像原来设想的那样使用。这种纤维增强构件的硫化，可能需要升高的硫化温度，此温度可能会引起原始熔点降低的树脂阻拦物质的熔化。相反地，树脂阻拦物质的干燥形态与所述的升温硫化周期并不矛盾。(6)从纤维增强构件硫化之后，直到该构件的表面被粘结，在此期间的任一时刻树脂阻拦物质均可被溶解，或者从材料的表面移除，以便提供易于形成可靠连接的暴露的纤维。应该注意的是，为了防止将要被粘结的纤维损坏或者污染，最好使树脂阻拦物质在这些构件被传输或储存时留在原地，保持静止。 
图6a和图6b是方形碳纤维编织物表面的暴露碳纤维的扫描电子显微照片。该样品是在热梯度的控制下，将图示织物的表面浸入到熔点降低的增塑聚乙烯醇中制作出的。作为多层层压材料的最外层，根据本发明制作的样品与朝向表面的树脂阻拦纤维混合在一起。这样，图6a和图6b中所示的电子显微照片中的纤维可以避免被环氧树脂浸渍。在环氧树脂硫化以后，将使用热水将树脂阻拦PVA构件移除。这个样品的表面提供了从样品内部到随后使用的胶合剂或涂层的增强连续性。 
图7显示了图5的浸泡步骤。织物4通过张力的作用与冷的转筒面接触。涂胶辊6将树脂阻拦物质，如熔点降低的增塑PVA涂于织物表面。转筒面附近的露点温度应被控制在低于转筒面温度的范围内。转筒面上的冷凝水可以进入织物里面，与树脂阻拦物质接触，并进一步降低它的熔点，从而使树脂阻拦物质不受控制地浸入到织物里。为了使树脂阻拦物质最大程度地渗入，转筒面的速度和温度可能会受到控制。对于许多应用来说，渗透到最厚部分的大约50％处是理想的。干燥剂7使得有涂层的织物不粘结并且适于处理、储存，或者接下来的树脂浸渍或贴敷。需要注意的是，在融入到最后的物品之前，挠性涂层可以于织物的非树脂阻拦表面。在这种情况下，树脂阻拦物质将在组合前被溶解。 
图8显示了建立温度梯度的过程，建立温度梯度目的是为了控制树脂阻拦物质沿着边缘浸入到板料织品的边缘或末端。散热器8在织物4内部产生了一个寒带，以限制树脂阻拦物质9的浸渍。 
如图9所示，织物4的末端被树脂阻拦物质9浸渍，形成一个树脂阻拦浸渍区域11。 
如图10所示，为了在边缘13上形成一个层压材料12以适合高强度交织连接14的建立，织物可能被集中，用树脂浸渍并硫化。所述的层压材料12硫化后，阻拦物质从织物的边缘移 除，以便使纤维层可以分解和粘结。 
图11a，11b，11c，11d，和11e，显示了把加强部(rib)粘结到蜂窝板上的基本步骤。图11a显示了预先做好的织物条20的使用。该织物条的一个表面20a可阻拦树脂的浸入，而另一表面20b已被预浸处理的树脂浸渍过。经预浸处理的表面20b被用于未经硫化的蜂窝结构21，整个蜂窝结构21也是一个经过预浸处理的结构。图11b显示与预先做好的织物条20有关的剥落层17、通气孔18和真空袋19的结构。图11c显示了硫化后树脂阻拦物质的移除。图11d显示了小条粘合剂(第二阶段)15在上述预先做好的表面以及加强部16的表面之间的应用。加强部16的表面的做法与上述表面的做法相同。图11e显示了与已有接口相关的剥落层、通气孔以及真空袋的结构。该接口为连接用的粘合剂的硫化做准备。 
如图12a和图12b所示，对根据本发明一方面所做的阶梯接缝进行说明。层压材料22a与预先做好的粘结带20a一起被硫化。层压材料22b以同样的方式与粘结带20b一起被硫化。该接口是通过从粘结带20a和20b移除树脂阻拦物质和硫化粘结剂来完成的。只要适合需要，粘结剂可以是各种类型的，如液体胶，凝胶，胶水，或B阶(B-stage)片状粘结剂。在使用片状粘结剂的情况下，可以使用图11e所示的真空袋硫化。 
图13a，13b，13c，13d显示了燕尾接头(dovetail joint)的结构，其中，纤维从硫化构件23内部延伸到结构33内部的燕尾接头容器24中。在硫化构件23之前，用来形成楔形榫头31a，31b，31c，31d和31e的纤维增强部分被树脂阻拦物质浸渍。空间28a，28b，28c，28d和28e，可能会被合成橡胶楔形体阻塞。在构件23硫化后，树脂阻拦物质被移除，留下织物部分31a，31b，31c，31d和31e，这些部分是可挠曲的，并可利用引导33a和33b将其插入到燕尾接头容器24中。图13c显示了硫化结构的例子，该结构可为燕尾接头容器24的排空和随后的树脂浸渍做准备。真空/树脂注入管线30连接到腔体24上，腔体24由树脂粘条32密封。 
在此专利申请案中提到的任何专利、出版物或其它参考文件在此均列为参考。此外，关于每个词的使用须了解，除非在本申请案中的使用与其解释不符，传统字典与普通字典中的定义应被视为包含每个词、定义、替代名词和同义词，正如此处列为参考的包含在RandomHouse Webster’s Unabridged Dictionary第二版中的词、定义、替代名词和同义词那样。最后，所有列入本专利申请案中作为参考的文件一览表中的参考文件或随此申请案提出其它信息陈述均被列入本案或随附于本案作为参考。但是，至于上述的每一项，若列为参考的信 息或陈述被认为与这个发明或这些发明不符，此陈述即被认为非申请人所提出的陈述。 
因此须了解，申请人在此提出的权利要求至少包括：i)在此公开及叙述的每一种连接方法；ii)在此公开及叙述的相关方法，iii)每个装置和方法的类似、均等、甚至隐含的变体，iv)在此公开及叙述的用来完成每个展示的功能的替代设计，v)完成每个展示的功能的替代设计及方法，这些替代设计及方法对完成所公开及叙述者是隐含的，vi)每个显示的特征、组件及步骤均被作为分开且独立的发明展示，vii)由公开的各种系统或组件所优化的应用，viii)由此系统或组件所生产的最终产品，ix)上文所叙述且参考任一附属例子的方法及装置，x)任一公开的组件的各种结合及置换，xi)依附于提出的每个独立权利要求或概念的每一个可能的依附权利要求或概念。xii)在此方面须了解，由于实际原因以及为了避免增加可能的数百项权利要求，本申请人最后仅对最初的依附项提出要求。须了解，在新的民事法下存在必要的支持，允许在一个非独立权利要求或概念下提出的各种依附项或其它组件中的任何一个作为任何其它独立权利要求或概念下的依附项或组件被添加。所述新的民事法包括但是不限于欧洲专利会议条款123(2)及美国专利法35USC132或其它相关法律。又，当使用时，依照权利要求的传统解释，过渡短语“comprise”在现在和将来都会被用来保留“敞口”的(即无限制的)权利要求。因此，除非本文需要，否则须了解，“comprise”一词或其变体，比如“comprises”或“comprising”意指包括所述的一个组件或步骤或者组件或步骤的群组，而非排除任何其它组件或步骤或者组件或步骤的群组。此类词必须以最宽泛的方式解释，以使申请人享有法律上许可的最宽权利范围。

Claims (2)

1.一种用于制作纤维增强复合材料的方法，所述纤维增强复合材料的第一选择部分部分地浸入有可移除的树脂阻拦物质，所述树脂阻拦物质的浸入程度是通过热梯度控制的；所述纤维增强复合材料的第二选择部分随后浸入有树脂，所述树脂随后被硫化以在纤维之间形成结构基质；所述方法包括：
在热梯度控制下，利用可移除的树脂阻拦物质浸渍所述纤维增强复合材料的第一选择部分；
利用可硫化的树脂浸渍所述纤维增强复合材料的第二选择部分；
硫化所述可硫化的树脂。
2.根据权利要求1所述的方法，其中，在硫化所述纤维增强复合材料的第二选择部分的树脂基质后，所述树脂阻拦物质从所述纤维增强复合材料的第一选择部分移除。
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US20140138026A1 (en) 2014-05-22
AU2005279775A1 (en) 2006-03-09
EA010821B1 (ru) 2008-12-30
US8470404B2 (en) 2013-06-25
DK1791997T3 (da) 2012-08-13
US20090068365A1 (en) 2009-03-12
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KR20120088843A (ko) 2012-08-08
EP1791997A2 (en) 2007-06-06
CA2620563C (en) 2013-05-28
ATE556166T1 (de) 2012-05-15
CN101043954A (zh) 2007-09-26
KR20070056103A (ko) 2007-05-31
CA2620563A1 (en) 2006-03-09
WO2006026734A2 (en) 2006-03-09
EA200700520A1 (ru) 2007-12-28
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