CN101351327A - 具有嵌入的预固化模具的复合结构的制造工艺 - Google Patents

具有嵌入的预固化模具的复合结构的制造工艺 Download PDF

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CN101351327A
CN101351327A CNA2005800524608A CN200580052460A CN101351327A CN 101351327 A CN101351327 A CN 101351327A CN A2005800524608 A CNA2005800524608 A CN A2005800524608A CN 200580052460 A CN200580052460 A CN 200580052460A CN 101351327 A CN101351327 A CN 101351327A
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subassembly
subassemblies
instrument
composite construction
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CN101351327B (zh
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昂里克·加拉特菲尔
昂里克·雷东多瓦拉
若泽·桑谢斯戈麦斯
拉斐尔·鲁伊斯伊卡萨尔加多
塞萨尔·塞拉诺威拉斯
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Airbus Operations SL
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Airbus Espana SL
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    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B29C70/342—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using isostatic pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/434—Joining substantially flat articles for forming corner connections, fork connections or cross connections
    • B29C66/4344—Joining substantially flat articles for forming fork connections, e.g. for making Y-shaped pieces
    • B29C66/43441—Joining substantially flat articles for forming fork connections, e.g. for making Y-shaped pieces with two right angles, e.g. for making T-shaped pieces, H-shaped pieces
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8145—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/81455—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps being a fluid inflatable bag or bladder, a diaphragm or a vacuum bag for applying isostatic pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/0003—Producing profiled members, e.g. beams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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Abstract

本发明涉及一种制造由相同材料构成的两个子部件形成的复合结构的工艺，特征在于其包括如下步骤：提供第一子部件(13)，特别是外壳；提供用于制造第二子部件(17)的由复合物制成并预固化的模具(15)，特别是加强肋；将所述模具(15)置于所述第一子部件(13)上；在所述模具(15)上施加预浸渍复合物(21)以形成该第二子部件(17)；在合适的压力和/或温度情况下，通过固化先前步骤中得到的组件的工艺而凝固该复合结构。

Description

具有嵌入的预固化模具的复合结构的制造工艺
技术领域
本发明涉及一种复合结构的制造工艺，且更具体地涉及一种工艺，该工艺用于成型一个其中的子部件的至少一个模具保持嵌入在该结构中。
背景技术
在当今的航空和航天工业中，大量使用基于环氧树脂和碳纤维的主体有机基体和长纤维复合物。
使用这种类型的结构的标准逐渐地提高了，尤其在航空和航天工业中，直到现在，环氧基体和碳纤维复合物被认为是众多构件选择使用最多的。这种情况已经迫使并不断迫使能够以量产方式制造所需质量并且对所制造的部件具有合适的制造成本的部件的制造工艺的发展。在这方面，该模具起到一个基本的作用，所以取消或减少该模具是使得制造工艺花费更少的一个重点。
通常认为，在单一制造周期中部件的大集成度意味非常复杂且因此使用模具系统是昂贵和困难的。另一方面，在最终键合或铆接工艺中将简单部件连接在一起的制造通常意味着更简单的模具和更小的成本以及更可靠的部件制造系统。然而，这种最新的系统具有明显地缺点，一种观点认为复杂的制造系统必须与大量部件一起工作，且一种观点认为该结构自身包含先于键合的复杂的表面预处理系统以及，当然，增加了最终产品的重量。
因此，似乎表明，允许制造具有高结构集成度但又具有减少的或不存在的模具系统的部件的任何制造系统将解决上述缺点，其允许制造更节省成本的结构，同时具有高集成度并因此降低了最终的重量。
公知的使用共凝固、共键合或次级键合系统的有机基体和长纤维复合物结构的制造工艺通常基于烤箱、真空袋和/或高压蒸汽系统和被制造的部件外部的模具，其根据被制造的最终部分的复杂性和可靠性等级而具有不同的复杂性。
本发明涉及一种制造所述结构的更有效率的工艺。
发明内容
本发明提出一种由两个相同材料的子部件形成的复合物结构的制造工艺，包括如下步骤：
提供第一子部件，特别具有平行或弯曲表面。
提供用于制造第二子部件的预固化复合模具，特别是加强肋。
将所述模具置于所述第一子部件上。
在所述模具上施加预浸渍复合物以形成该第二子部件。
在合适的温度和压力情况下，通过固化先前步骤中得到的组件的工艺而凝固该复合结构。
对本发明来说，术语复合物理解为任何有机基体材料(环氧树脂、苯酚、双马来酰亚胺、聚酰亚胺、乙烯基酯，...)和长增强纤维(碳、不同类型陶瓷、玻璃、有机物(聚芳酰胺、聚苯并噁唑(pbo)，...))。对本发明来说，结构的子部件理解为在其制造工艺中，不同时段造型的部分。
根据本发明的工艺的本质特征是使用保持嵌入该结构自身内的模具。这些模具优选与该结构采用相同复合物或与该结构兼容的复合物，且将这些模具在预固化状态下提供给实现本发明的工艺。
根据本发明的制造有机基体复合结构的工艺可以理解为子部件的共凝固或共键合工艺，该工艺避免或限制在真空袋内部和外部使用复杂模具。
通过根据实现本发明的工艺的方式制造的结构是更适合应用到航空和航天工业中的结构，然而制造该结构的工艺还可有益的应用到军事、海洋、汽车制造、发电或建筑工业，或其他任何要求使用良好机械特性材料的工业中。
本发明的工艺的一个优点在于，其开启了具有高集成度，模具嵌入该结构本身以及在外部上具有简单模具的制造结构的可能性，简单模具在某些构造形状中甚至不需要。该嵌入模具可以进一步设计以允许其具有双重功能，该双重功能是作为模具和作为用于所设计的部件的负载的支撑结构。
本发明其他特征和优点将从实现其的阐述性实施例的下述详细描述与其相关的附图中获悉。
附图说明
图1示出用于根据本发明的工艺中的模具的立体图。
图2a和2b分别示出根据实现本发明的工艺制造的结构的安装截面图。
图3示出根据实现本发明的工艺制造的结构的安装立体图。
具体实施方式
根据本发明的制造复合结构的工艺尤其应用于制造具有T-形、Ω-形或H-形加强肋的平面或弯曲结构，且下文描述的是具有T-形纵梁刚化的平面结构的情况。
预固化T-形部件15(参照图1)由厚度超过0.4mm的预浸渍环氧树脂的平面碳纤维结构构成，该预固化T-形部件15用作将保持嵌入在结构中的模具。该模具15可以是连续的或不连续的，取决于制造的最终结构的形状。
该工艺在其上安装了平面结构13、该结构的第一子部件的台面11上实施。
该模具15位于该平面结构13之上，在它们之间能够应用辅助工具19，该辅助工具例如是预浸渍材料的粘合膜或层。如果该模具需要实现耐久功能，该模具15需要在提供所需的校正键合的键合工艺之前处理。
之后，预浸渍材料层21施加到该模具15上，以便构形出T-形纵梁17、该结构的第二子部件。
当纵梁17的构形工艺完成后，制造如本领域公知的其包括几个层33、35、37的真空袋31，该真空袋用于该结构使用公知工艺例如烤箱或高压蒸汽的后续凝固。
在该工艺中利用与所使用的复合物兼容的粘合膜实现将该纵梁17共键合到该模具15。
图2a示出该纵梁17，其中该预固化模具15的网状物沿着该纵梁的网状物延伸，而图2b示出纵梁具有没有延伸该预固化模具15的部分39。在这种情况下，将考虑该部件的结构需要而实施预固化模具的尺寸。
特别地，在具有部分39的纵梁17都是由预浸渍材料制成的情况下，例如图2b中所示，且为了保持该纵梁17的形状，可以使用一个在真空袋31外部的外部模具43，以便保持将要被制造的该结构的最终几何形状(参照图3)。
该内部预固化模具15可以由与制造该结构其它部分的复合物相同或由认为具有兼容性的材料制成。只在其它该结构的共键合工艺时考虑兼容性。这种情况下，将该预固化模具键合到该结构其它部分的工艺可以通过预浸渍材料的树脂或通过使用与预浸渍材料兼容的粘合膜直接完成。
鉴于前述说明，可以理解的是，该预固化模具必须根据要制造的结构而设计，首先要考虑所使用的材料(可兼容或一种与最终固化系统经历退化(degradation))，第二是该部件的结构需求(需要或不需要用于表面处理和粘合膜)，以及第三是第二子部件的尺寸需求，该第二子部件将顺便确定在该第二子部件的外部的简单的外部模具的需要。
本制造工艺提供的减少或甚至取消复杂模具的可能性对降低最终固化工艺的功耗起到重要作用，且其更可防止实施额外的固化周期，进而降低该工艺所需的最终能耗。
包含在由下述权利要求所定义的范围内的任何改变可以引入到上述优选实施例中。

Claims (8)

1.一种制造由相同材料的两个子部件形成的复合结构的工艺，特征在于其包括如下步骤：
a)提供第一子部件(13)；
b)提供由复合材料制成且预固化的工具(15)，该工具(15)用于制造第二子部件(17)；
c)将所述工具(15)置于所述第一子部件(13)上；
d)在所述工具(15)上涂布预浸渍复合材料(21)，以便形成该第二子部件(17)；
e)在合适的压力和/或温度条件下，通过固化先前步骤中得到的组件的工艺而固结该复合结构。
2.根据权利要求1所述的制造具有相同材料的两个子部件的复合结构的工艺，特征在于该工具(15)由与第一和第二子部件(13，17)的材料相同的材料制成。
3.根据权利要求1所述的制造具有相同材料的两个子部件的复合结构的工艺，特征在于该工具(15)由与第一和第二子部件(13，17)的材料不同，但为了其与该第一子部件(13)粘接，而与其兼容的材料制成。
4.根据前述任一项权利要求所述的制造具有相同材料的两个子部件的复合结构的工艺，特征在于该工具(11)被制造以致其在该结构的抵抗功能上合作。
5.根据前述任一项权利要求所述的制造具有相同材料的两个子部件的复合结构的工艺，特征在于该第一子部件(13)是未固化的，且粘合剂或预浸渍体层(19)配置到其与该工具(15)之间。
6.根据前述任一项权利要求所述的制造具有相同材料的两个子部件的复合结构的工艺，特征在于在步骤e)中使用额外的工具(43)，以促进第二子部件(17)的成形。
7.根据前述任一项权利要求所述的制造具有相同材料的两个子部件的复合结构的工艺，特征在于该第一子部件(13)是平面结构且该第二子部件(17)是所述面板的T形、Ω形或H形的加强件。
8.根据前述任一项权利要求所述的制造具有相同材料的两个子部件的复合结构的工艺，特征在于该第一子部件(13)是弯曲结构且该第二子部件(17)是所述面板的T形、Ω形或H形加强件。
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