CN101198459B - 用于加固夹层结构的芯部材料的制造方法 - Google Patents

用于加固夹层结构的芯部材料的制造方法 Download PDF

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CN101198459B
CN101198459B CN2006800185389A CN200680018538A CN101198459B CN 101198459 B CN101198459 B CN 101198459B CN 2006800185389 A CN2006800185389 A CN 2006800185389A CN 200680018538 A CN200680018538 A CN 200680018538A CN 101198459 B CN101198459 B CN 101198459B
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M·A·罗特
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Abstract

本发明涉及借助于加固装置加强夹层结构。夹层结构的覆盖层可以主要由纤维塑料复合材料(FKV)制成，并且芯部材料由聚合物硬泡沫材料制成。加固过程通过一夹纱器实现，其从该结构的一侧刺入夹层结构内或仅仅刺入芯部材料内(见图1；步骤1)。夹纱器在对置侧上夹住一加固结构(例如缝纫线，拉挤的纤维塑料复合材料杆)(见图1；步骤2)并且在一个返回运动期间将所述加固结构引入夹层结构内。由此通过加强结构附加地扩宽了贯通孔，由此可以获得芯部材料的贯通孔中的非常高的纤维体积份量。与传统的缝纫技术相比，芯部材料中贯通孔的直径主要通过加固结构影响。在加固过程之后可以在一个液体-复合材料-模制方法中向夹层结构内注入热固性或热塑性的矩阵材料。由此被注入材料的缝纫线在芯部材料中表现为高刚度和高强度的单向的纤维塑料复合材料元件，其加强芯部材料和整个夹层结构。

Description

用于加固夹层结构的芯部材料的制造方法
技术领域
本发明涉及一种用于加强夹层结构的芯部材料的制造方法以及所述夹层结构。 
本发明适合于加强夹层结构。夹层结构可以优选由纤维塑料复合材料制成，其包括由纺织物半成品构成的覆盖层(图1；3和5，例如织物、布、垫子等)、芯部材料(图1；4和5，例如聚合物泡沫材料)和聚合物的矩阵材料(热塑性或热固性塑料)。夹层结构是分层构成的结构，其由相对薄的上覆盖层(图1；3)和下覆盖层(图1；5)以及较低的堆积密度的相互较厚的芯部层(图1；4)构成。 
借助于本发明，借助于在厚度方向上贯穿的加固结构显著提高芯部材料的横向的(例如在z方向上的抗压强度或抗拉强度和抗压刚度或抗拉刚度；在xz及yz平面内的抗剪刚度及抗剪强度；在覆盖层和芯部之间的抗剥离性能；破损安全特性)和面内的机械特征(例如朝板平面的方向的刚度和强度)。 
背景技术
所以至今已知用于在厚度方向上加固夹层结构的制造方法，例如双骑马订缝纫技术、暗缝缝纫技术或双针缝纫技术以及簇绒法，共同点在于加固元件(例如缝纫线、粗纱)与针共同地引入夹层结构内。在传统的纺织物类型的缝纫件中，包含缝纫线的针的引入和紧接着的拉出缝纫针并且将缝纫线留在缝纫孔内由于纺织物的弹性恢复效果通常不产生问题。然而在具有聚合物硬泡沫材料作为芯部材料的夹层结构中，包含缝纫线的针的引入导致蜂窝形的结构的破坏，并且由于塑性和弹性变形导致聚合物的硬泡沫材料的变形至缝纫针直径的大小。 
在拉出缝纫针和将缝纫线留在缝纫孔内后，由于蜂窝壁的弹性的 变形部分导致贯通孔的直径的减小，由此芯部孔直径再次小于缝纫针直径(见图2)。在芯部中所产生的贯通孔的直径和所使用的缝纫针之间形成一个几乎线性的关系(图2)，即缝纫线直径越大，则在芯部中形成的贯通孔越大。此外，缝纫线用于附加地扩宽芯部孔直径。所述附加的扩宽大致对应于缝纫线(图2)的横截面面积。在此也适用的是，所使用的缝纫线的横截面面积越大，那么附加的扩宽也越大。 
在将液体的矩阵材料(matrix material)注入夹层结构并且紧接着硬化后，可以借助于显微检查确定芯部孔直径以及芯部孔内的缝纫线纤维体积含量(Faservolumengehalt)。对借助于双骑马订(Doppelsteppstich)缝纫技术和利用直径为1.2mm的、具有62g/km线性质量的芳香族聚酰胺线的缝纫针缝合的夹层结构的试验表明，在唯一一次刺入时在芯部材料中所产生的树脂柱的直径(约1.7mm)大于未注入的夹层结构所测定的芯部孔直径(约1.1mm；见图2和图3)。原因在于，通过缝纫针的刺入在缝纫针直径范围相邻的蜂窝壁被损坏。在接下来的渗透过程中可以将树脂渗入这些具有约0.7mm的平均直径的敞开孔内(图4)。 
在应用双骑马订缝纫技术时每次刺入总是在夹层结构的z方向上引入两个缝纫线(见图4和图5)。为了提高贯通孔内的缝纫线体积含量并且因此提高加固作用，可以将业已缝合的位置再次或多次缝合。然而在此业已位于芯部孔内的缝纫线可能由于缝纫针的重新刺入被损坏。借助于显微观察可以确定，缝纫线体积含量不能按照期望地与刺入的数量成比例地上升(图3、4和5)。原因在于，随着刺入和引入的缝纫线的数量的提高，芯部孔的直径不保持恒定，因为芯部孔直径通过附加地引入缝纫线大约加大了纱线横截面面积(图3，虚线)。然而同样仍然确定，在非常高的刺入数量时真实的曲线走向(图3，实线)才遵循这个理论。而在非常小的刺入数量时芯部孔的直径不成比例地强烈上升。原因在缝纫机的定位精确度。如果重新到达需要被缝合的位置时，那么缝纫针不会精确定心地刺入业已存在的孔内，而是在定位精确度的范围内较小地向旁边偏离，由此芯部孔不成比例地 加大。在大致八次刺入相同的芯部孔内后，其业已被如此强烈地加宽，使得缝纫针进入存在的孔内，对蜂窝壁不产生附加的损坏。在进一步刺入时，扩宽仍然仅通过附加引入的缝纫线实现。在图4和5中示出随着缝纫线的数量的增多，芯部孔内缝纫线体积含量的可能的升高。图4中的黑色曲线描述了在芯部孔直径恒定时缝纫线体积含量的成比例的上升；根据上述的精确定位精度的理论和由于引入的缝纫线附加扩宽芯部孔直径，黑色的点化线描述了随着缝纫线或刺入的数量的升高，缝纫线体积含量的真实走向。在唯一的刺入时可以仅仅获得约3.2％的纤维体积含量，其通过直至10倍的刺入仅可以提高至约20％(图4和图5)。而一个单个的缝纫线束的纤维体积含量大约为58％(见图5)。 
借助于这个观察清楚的是，在应用传统的制造方法(例如双骑马订缝纫技术)时在聚合物芯部材料中所产生的直径主要依赖于所使用的缝纫针直径、缝纫针横截面面积以及所应用的聚合物硬泡沫材料的气孔直径。因为在所有至今已知的加固方法中缝纫针和缝纫线同时刺入夹层结构中，所以在此总是导致引入的加固元件的横截面面积与芯部孔直径的大小之间不利的比例。因此芯部孔直径中的高的纤维体积含量，与覆盖层的纤维体积含量(＞50％)差不多大小，利用传统的加固方法是不能实现的。因为然而机械特性主要通过所引入的高刚度的且高强度的加固结构影响，因此目的必须是，追求在芯部孔直径内的尽可能高的加固结构纤维体积含量。此外芯部孔直径中高的树脂含量提高重量，这特别是在航空和宇宙飞行中不能忍受。 
任务
本发明的任务在于，通过在夹层结构的厚度方向(z方向)上引入加固结构来改善夹层结构的机械特性，其中存在这样的可能性，即在芯部孔直径上获得高的加固结构纤维体积含量。此外将加固结构引入夹层结构内应当不是非常不利地影响重量。这种新型的缝纫技术同样可以用于预成型附加的结构元件(例如纵梁、框架等)以及将其固定在夹层结构上。 
方案
上述目的这样实现，即，在芯部材料内引入必要的贯通孔和引入加固结构在彼此不同的时间上实现，由此可以通过所使用的缝纫线的横截面面积调节在芯部孔直径上的加固结构纤维体积含量。图1示出本发明的这样类型的加固的夹层结构的构造。一个夹纱器系统2(Greifersystem)从夹层结构的一侧刺入芯部材料4(步骤1和2)并且选择性地穿过上面的纺织物层3和下面的纺织物层5(步骤2)并且借助于一个夹纱器1在对置侧接受一个加固结构6例如缝纫线、拉挤的纤维塑料加强的杆(步骤2)，其经由一个装置7供给，并且夹纱器系统在返回运动期间将加固结构6送入夹层结构内(步骤3)。在接下来的处理步骤中夹纱器系统2向上移动并且将加固结构拉入芯部或夹层结构内(步骤3)。 
可以使用一种聚合物硬泡沫塑料(例如PMI、PVC、PEI、PU等)作为芯部材料4。芯部材料4可以具有直至150mm的厚度、约1250mm的宽度和2500mm的长度。上面的纺织物的覆盖层3和下面的纺织物的覆盖层5可以相同地或不同地构成，并且由玻璃、碳、芳香族聚酰胺或其它的加强材料制成。各单个的纺织物的覆盖层的厚度可以是相同的或不同的并且在0.1mm至1.0mm之间。可以使用热塑性塑料或热固性塑料作为聚合物矩阵材料。 
加固结构6不仅可以由纺织物的加强结构(缝纫线或粗纱)制成，而且也可以由杆状的元件(例如由单向的纤维塑料复合材料、未加强的塑料或金属等制成的钉)构成。加固结构6的典型直径可以是0.1mm至2.0mm。 
在接下来的处理过程中缝纫件或加固单元被进一步输送至下一个刺入位置并且而后在那儿重复加固过程。附加地所输送的加固结构被定长切断，从而一个刺入与另外一个刺入之间没有联系。定长切断可以通过所以通常的技术手段实现，例如通过机械切割或火焰切割实现。通过拉入加固结构可以附加地扩宽通过夹纱器系统的刺入而产生的芯部孔直径，由此可以实现较高的纤维体积含量。因为加固元件通过拉 动被引入夹层结构内或仅仅引入芯部材料内，所以导致加强结构的非常好的定向并且没有纵向弯曲。借助于这种加固方法所引入的加固元件同样可以具有一个与z轴线不成0°的角度，例如在纯粹的横向力时为+/-45°。 
本发明的在厚度方向上加强的夹层结构可以应用在运输领域，如航空交通、宇宙飞行、汽车及轨道车辆制造以及造船中，以及应用在体育或医疗领域以及建筑业中。 
在加固过程之后可以在一个液体-复合材料-模制方法中向夹层结构内注入热固性或热塑性的矩阵材料。 
附图标记清单 
1  夹纱器 
2  夹纱器系统 
3  上面的纺织物的覆盖层 
4  芯部材料 
5  下面的纺织物的覆盖层 
6  加固材料 
7  用于供给加固结构6的装置 

Claims (5)

1.用于夹层结构的加固方法，其特征在于，一夹纱器系统从该结构的一侧刺入芯部材料(4)内或刺入加设有覆盖层的芯部材料内，在对置侧上央住一加固结构(6)并且通过一个返回运动将所述加固结构引入芯部材料(4)内或引入加设有覆盖层的芯部材料内。
2.如权利要求1所述的用于夹层结构的加固方法，其特征在于，加固结构(6)由纺织物类型的加强结构或杆形的元件构成。
3.如权利要求1所述的用于夹层结构的加固方法，其特征在于，覆盖层(3)由纺织物半成品制成，芯部材料(4)由聚合物的、天然的或结构化的芯部材料制成，并且覆盖层、芯部材料和加固结构嵌入一聚合物的矩阵材料中。
4.如权利要求1至3之一项所述的方法，其特征在于，加固结构(6)在引入芯部材料(4)内或引入加设有覆盖层的芯部材料内后不进行定长切断。
5.如权利要求1至3之一项所述的方法，其特征在于，加固结构(6)在引入芯部材料(4)内或引入加设有覆盖层的芯部材料内后进行定长切断。
CN2006800185389A 2005-07-27 2006-04-05 用于加固夹层结构的芯部材料的制造方法 Expired - Fee Related CN101198459B (zh)

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