CN101155682B - 带有埋置的导电层的组合式航空飞行器部件 - Google Patents

带有埋置的导电层的组合式航空飞行器部件 Download PDF

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CN101155682B
CN101155682B CN2005800293995A CN200580029399A CN101155682B CN 101155682 B CN101155682 B CN 101155682B CN 2005800293995 A CN2005800293995 A CN 2005800293995A CN 200580029399 A CN200580029399 A CN 200580029399A CN 101155682 B CN101155682 B CN 101155682B
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conductive layer
panel
aviation aircraft
chopped fibers
surface panel
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CN101155682A (zh
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安东尼·P·伯格森
贾森·L·霍伊尔
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Bell Helicopter Textron Inc
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Abstract

模压部件具有在部件模制期间埋置到该部件内的导电层。导电层通常与部件的外表面相邻并优选由网、箔、拉制的筛网、或多层导电元件形成。部件优选最佳用于航空飞行器的外部以用作雷击或EMI保护或用作天线。用于形成本发明的面板的方法包括将导电层放置在紧贴压模的型面之处，然后形成带有埋置在部件内的导电层的模压部件。

Description

带有埋置的导电层的组合式航空飞行器部件
技术领域
一般而言，本发明涉及模制部件领域，尤其涉及一种带有埋置的导电层的模压部件。 
背景技术
模压部件通过使用由阳模和阴模组成的合模组构成。将可以是粉末、颗粒、薄片、类似油灰般的块、液体之类的模制材料在部分硬化(cured)的条件下导入阴模内并且可在放置到模具内之前对其进行预热。然后用阳模件使模具闭合，对模具施压以迫使材料与模具的全部区域接触，保持加热和压力直到模制材料硬化为止。所述过程采用热固性树脂，也可将高性能的复合热塑性塑料和单向带、织物纤维、无规则取向的纤维垫、或碎断的线绳一起模压。模压的优点是可在非常低的劳动成本下模制成大型的、相当复杂的部件。 
在航空飞行器上的某些模压的外部整流罩和面板要求雷击保护。为模压部件提供雷击保护的现有方法包括：(1)使铜网经过结构胶粘层二次接合到部件上；以及(2)用加铜涂料(copper-filled paint)涂敷在模压部件上。二次接合过程的主要缺点是增加粘合剂的重量。另外，由于固有的后模制处理使每单元的成本增加，还需要附加的工艺装置和任何所需要的返工或表面缺陷的修复。铜涂覆方法以重量重为代价，而且由于在应用中厚度的变化而具有不一致的保护性能。另外，在例行的维护中铜涂料很容易受损而且在修复或重新涂敷时由于不注意铜涂料可能剥离。 
发明内容
因此，需要带有埋置的导电层的模压部件。此外，需要制造带有埋置的导电层的模压部件的方法。 
于是，本发明的一个目的是提供带有埋置的导电层的模压部件。 
本发明的另一目的是提供制造带有埋置的导电层的模压部件的方法。 
模压部件具有在部件的模制过程中埋置于部件中的导电层。通常使导电层与部件的外表面相邻，且优选导电层由网、箔、拉制的筛网、或多层导电元件形成。优选所述部件最适合的用在航空飞行器的外部以提供雷击保护或EMI保护或作为天线使用。 
用于形成本发明中的面板的方法包括紧贴压模的型面放置导电层，然后与埋置在部件内的导电层一起形成模压部件。 
本发明具有的一些优点包括：(1)提供带有埋置的导电层的重量轻的部件，导电层提供了雷击或EMI保护或可用作天线；(2)提供形成本发明的部件的方法；以及(3)在形成本发明的部件期间提供了抑制导电层移动的方法。 
附图说明
下面结合附图对本发明进行详细描述以便更全面地理解本发明的特征和优点，附图中相似的部件用相同的附图标记表示。附图中： 
图1为本发明的模压的航空飞行器部件的透视图； 
图2为图1所示的模制的航空飞行器部件沿线II-II剖切的部分横截面图； 
图3为具有本发明的模制部件的航空飞行器的侧视图； 
图4为形成本发明的模制部件的用于本发明的方法中的组件的分解侧视图； 
图5为组装图4所示的组件的横截面图； 
图6为形成本发明的模制部件的用于本发明的可供选择的方法中的组件的分解侧视图； 
图7为形成本发明的模制部件的用于本发明中的第二种可供选择的方法中的阴模的横截面图。 
具体实施方式
本发明披露了能通过带有埋置的导电层的模压部件形成雷击保护的模制部件。本发明也可用于提供静电放电应用、用于天线、或用于EMI(电磁干扰，也称为RFI，或射频干扰)保护的所需的导电表面。 
图1示出了可形成航空飞行器的外壳的一部分的面板11，其带有埋置 在构件15的外部分内的导电网13。构件15可由如热固性塑料之类的可硬化的模制材料模压而成，以便优选形成刚性材料片。构件15可以由复合材料模压而成，所述复合材料含有如包括单向带、织物纤维、不规则取向纤维垫、或碎断的线绳之类的玻璃或碳纤维。优选的实施方式是由碎断纤维的薄片或由可用树脂覆盖的碎断纤维的粒状材料形成。虽然可供选择的是可将构件15形成为平面或杯形部件，但所示出的构件15为弯曲部件。 
网13包括多个导电元件17，这些导电元件可由任何具有足够的导电性的材料形成，以用作天线或引导由雷击引起的电流。尽管在某些应用中由铝或其他金属形成的导电元件17在机械、热、或电磁性能方面具有优势，由铜形成的导电元件17尤其适合用于网13中。可将元件17形成为织物网、箔、或拉制的筛网，或者也可使用一或多层独立的导电元件17。虽然可使网13位于只要通过表面19保持网13可见的情况下距离表面19一小段距离之处，通常将网13埋置在构件15内与外表面19相邻之处。虽然若用模制材料的纤维覆盖网13可降低雷击效果，例如，理想的是，用树脂覆盖网13来防止其受损或被腐蚀。理想的位置是，通常可将另外的网13埋置在构件15内与内表面21相邻之处。导电元件17的末端22优选延伸到构件15的边缘，或可从构件15的边缘突出，使网13可导电地与另外的面板11的网13连接，或与用于耗散网13内的电能的金属结构连接。可供选择的是，网13可通过金属固定件或延伸穿过面板11且与网13导电接触的插入件与另外的面板11的其他构件导电性连接。 
图2为图1中的面板11沿线II-II剖切的横截面图。构件15具有为具体应用而选择的横截面厚度，由于网13的位置处于或靠近表面19，此厚度不决定网13的有效性。如上所述，虽然元件17可位于距离外表面19一小段距离之处，所示出的导电元件17与外表面19相邻或正切。 
图3示出了在常规的可以使用如面板11那样形成的部件的位置设置的本发明的外部面板的航空飞行器、直升机23。例如，本发明的带有埋置的导电层的模压部件可形成为门24、25，也可形成为观察板27和尾部整流罩29。虽然未示出，其他应用还包括在军用航空飞行器的武器支架上的前和后整流罩。本发明的成型部件可用于任何适当的外表面，只要其机械(例如，空气动力学的，结构的)负载和热条件不妨碍其使用即可。 
如果面板11被雷电或其他放电击穿，通过导电元件17从击穿部位导 出电荷，该导电元件的末端22(图1)优选在面板11的外边缘处可导电地与相邻面板11连接或与航空飞行器的金属结构连接。如图2所示，导电元件17具有横截面厚度，此厚度可根据形成元件17所选择的材料以及根据埋置到面板11中的元件17的数量来选择，以确保能充分导出雷击中产生的大电流。同样的考虑也常常用来选择用作天线的适当的网13。 
本发明还提供一种用于形成带有埋置的导电层的模压部件的方法。图4示出了包括阳模31以及与之配合的阴模33的模具。阳模31具有外型面34。阴模33具有成形为可接收阳模31的铸型腔35，腔35具有内型面37。虽然图中示出的是球形，铸型腔35可形成为具有成品部件所需的任何适当的形状。如所示出的那样，图1中所示的被设置成如网13那样的导电网39可作为带有铸型腔35的通用形状的预型件。或者，网39可以为任何适当的形状，例如如下面将描述的多片状。虽然也可选择使用颗粒材料，在该图中，可选地使用部分被硬化、覆盖了树脂的纤维薄片41。 
为了形成所述部件，将网39插入到铸型腔35内并将其压靠着内表面37，使网39符合内表面37的形状和轮廓。然后将模制材料薄片41放入铸型腔35内并与网39相邻，将阳模31插入到阴模33内。阳模31的插入挤压薄片41使之贴靠网39并使薄片41与外表面34和内表面37一致。图5中示出了这种配置，所示出阳模31被完全压入阴模33中，并将薄片41和网39挤压在外表面34和内表面37之间的空隙中。薄片41中的树脂围绕网39的导电元件流动。保持使模31、33在一起的压力，并对模具加热以使薄片41中的树脂固化。固化后，从铸型腔35取出阳模31，然后从腔35中取出成品部件。 
图6示出了本发明的形成本发明的模压部件的一种可选的方法。模具包括阴模43和与之配合的阳模(未示出)。阴模43包括具有形状为用于接收阳模的内表面47的铸型腔54。在所示出的方法中，示出的导电网49由多片形成，而不是作为预型件，将该导电网插入铸型腔45内并对其施压使其紧贴内表面47。网49的所述片的边缘重叠，以确保在网49的所述片之间存在导电路径。 
另外，图6示出了在模制材料硬化之前防止或限制网49在铸型腔45内移动的方法。为了有利于防止在阳模被压入阴模43时网49从内表面47的理想位置上移开，将如玻璃纤维垫51之类的非导电层放置在靠着网49 的内侧。如图所示，可将玻璃纤维垫51形成为预型件，或可作为多片插入。然后用阳模将模制材料挤压于铸型腔45内，且使模制材料内的树脂流入玻璃纤维垫51和网49内。再可对模具进行加热而使树脂固化，固化后将成品部件从铸型腔45中取出。 
图7示出了防止导电网在模内移动的另一种方法。图中示出了阴模53，阴模53具有铸型腔55。铸型腔55的内表面57带有点刻部分59，或相似的凸起的表面修琢(surface finish)，以防止或限制在将阳模插入时导电网沿内表面57滑动。点刻部分59也可以与或不与图6中所示的并在上面所描述的玻璃纤维垫一起使用。如果要求成品部件的外表面光滑，例如对空气动力表面的要求那样，可以不使用在模具内点刻或其他不光滑表面修琢。 
虽然本发明的方法示出的是导电层位于与阴模的型面相邻之处，也可选择使导电层位于与阳模的型面相邻之处。例如，可将该方法用于形成航空飞行器的外部的弯曲或凹形面板。 
本发明具有一些优点，其包括：(1)可提供带有埋置的导电层的重量轻的部件，导电层具有雷击或EMI保护能力或用作天线；(2)提供了用于形成本发明的部件的方法；以及(3)提供了在形成本发明的部件的过程中抑制导电层移动的方法。 
尽管已参考图示的实施方式对本发明进行了描述，但不应对这些描述作限制性解释。对于本领域技术人员来说，在参考这些描述的情况下可以对本发明的图示实施方式作出多种改型和组合，也可以提供其他实施方式。 

Claims (28)

1.一种用于结构的表面面板，该面板包括：
模压构件，包括碎断纤维；及
在模制所述构件期间埋置到所述构件内的导电层；
其中，所述导电层保持暴露至所述构件的外表面的边缘并从该边缘突出，以允许导电层导电连接到另外的面板的导电层或连接到导电层内的金属结构。
2.如权利要求1所述的表面面板，其中，所述模压构件至少部分地由热固性塑料形成。
3.如权利要求1所述的表面面板，其中，所述导电层由金属材料形成。
4.如权利要求1所述的表面面板，其中，所述导电层至少部分地由铜形成。
5.如权利要求1所述的表面面板，其中，所述导电层至少部分地由铝形成。
6.如权利要求1所述的表面面板，其中，所述导电层由网形成。
7.如权利要求1所述的表面面板，其中，所述导电层由箔形成。
8.如权利要求1所述的表面面板，其中，所述导电层由拉制的筛网形成。
9.如权利要求1所述的表面面板，其中，所述导电层由多层的导电元件形成。
10.如权利要求1所述的表面面板，其中，所述模压构件至少部分地由纤维加强塑料形成。
11.如权利要求1所述的表面面板，其中，所述导电层最适合用于雷击保护。
12.如权利要求1所述的表面面板，其中，所述导电层最适合用作天线。
13.如权利要求1所述的表面面板，其中，所述导电层被配置成导电地与导电结构连接。
14.一种航空飞行器，包括：
覆盖该航空飞行器外部的至少一部分的模压面板；及
在模制面板期间埋置到所述面板内的导电层；
其中，所述导电层保持暴露至所述构件的外表面的边缘并从该边缘突出，以允许导电层导电连接到另外的面板的导电层或连接到导电层内的金属结构；和
其中，模压构件包括碎断纤维。
15.如权利要求14所述的航空飞行器，其中，所述模压构件至少部分地由热固性塑料形成。
16.如权利要求14所述的航空飞行器，其中，所述导电层由金属材料形成。
17.如权利要求14所述的航空飞行器，其中，所述导电层由网形成。
18.如权利要求14所述的航空飞行器，其中，所述导电层由多层的导电元件形成。
19.如权利要求14所述的航空飞行器，其中，所述模压构件至少部分地由纤维加强塑料形成。
20.如权利要求14所述的航空飞行器，其中，所述导电层最适合用于雷击保护。
21.如权利要求14所述的航空飞行器，其中，所述导电层最适合用作天线。
22.如权利要求14所述的航空飞行器，其中，还包括：
覆盖所述航空飞行器的外部的至少一部分的第二模压面板，该第二面板具有在模制该第二面板期间埋置到该第二面板内的导电层；
其中，所述面板的导电层被导电地连接，以使电能在所述面板的导电层之间流动。
23.如权利要求14所述的航空飞行器，其中，所述面板的导电层与所述航空飞行器的金属结构导电地连接，以使电能从所述面板的导电层流进所述金属结构。
24.用于形成带有埋置的导电层的模压面板的方法，该方法包括：
a)将导电层放置在与压模的一部分的型面相邻的位置；
b)将未固化的碎断纤维放置在与所述导电层相邻的位置并使所述模具闭合；
c)对所述模具的所述部分一起施压以使碎断纤维在铸型腔内流动，至少使碎断纤维的一部分流入所述导电层内；及
d)使模具内的碎断纤维硬化，以形成面板，被埋置到所述面板内的所述导电层从所述面板的外表面突出。
25.如权利要求24所述的方法，其中，还包括：
在步骤(a)之前，将所述导电层形成为形状一般与所述型面的形状近似的预型件。
26.如权利要求24所述的方法，其中，所述导电层由多个重叠部分形成。
27.如权利要求24所述的方法，其中，还包括：
在步骤(a)之后以及在步骤(b)之前，将非导电层放置在与所述导电层相邻之处，使所述非导电层被置于所述碎断纤维和所述导电层之间；以及
其中步骤(c)还包括使所述碎断纤维的至少一部分流入所述非导电层内。
28.如权利要求24所述的方法，其中，还包括：
在步骤(a)之前，在所述型面上进行表面处理以便在执行步骤(b)到步骤(d)期间抑制所述导电层相对于所述型面移动。
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CN101155682A (zh) 2008-04-02
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CA2577029C (en) 2010-10-26
US20070257152A1 (en) 2007-11-08
US8625250B2 (en) 2014-01-07
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WO2006025890A3 (en) 2007-07-05
EP1827815B1 (en) 2015-12-23
DE05819580T1 (de) 2008-04-24
EP1827815A2 (en) 2007-09-05
US20130328226A1 (en) 2013-12-12
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US9895831B2 (en) 2018-02-20
CA2577029A1 (en) 2006-03-09

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