CN101663155B - 用具有长纤维及热固性基质的复合材料制造复杂工件的方法 - Google Patents

用具有长纤维及热固性基质的复合材料制造复杂工件的方法 Download PDF

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CN101663155B
CN101663155B CN200780049965.8A CN200780049965A CN101663155B CN 101663155 B CN101663155 B CN 101663155B CN 200780049965 A CN200780049965 A CN 200780049965A CN 101663155 B CN101663155 B CN 101663155B
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component
resin
fiber
ribs
flat sheets
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CN101663155A (zh
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帕特里斯·勒费比尔
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Airbus Group SAS
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European Aeronautic Defence and Space Company EADS France
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
    • B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
    • B29B15/10—Coating or impregnating independently of the moulding or shaping step
    • 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
    • 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
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • 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
    • B29C31/00—Handling, e.g. feeding of the material to be shaped, storage of plastics material before moulding; Automation, i.e. automated handling lines in plastics processing plants, e.g. using manipulators or robots
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C31/00—Handling, e.g. feeding of the material to be shaped, storage of plastics material before moulding; Automation, i.e. automated handling lines in plastics processing plants, e.g. using manipulators or robots
    • B29C31/04—Feeding of the material to be moulded, e.g. into a mould cavity
    • B29C31/08—Feeding of the material to be moulded, e.g. into a mould cavity of preforms to be moulded, e.g. tablets, fibre reinforced preforms, extruded ribbons, tubes or profiles; Manipulating means specially adapted for feeding preforms, e.g. supports conveyors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
    • B29C66/40—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
    • B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
    • B29C66/474—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially non-flat
    • 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
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B29C66/543—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles joining more than two hollow-preforms to form said hollow articles
    • 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
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B29C66/545—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles one hollow-preform being placed inside the other
    • 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
    • B29C66/72—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 characterised by the structure of the material of the parts to be joined
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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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    • B29C66/73—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 characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/73—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 characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
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Abstract

为了制造具有热固性基质的复合材料工件(1)，基于预浸渍热固性树脂的纤维带单独地制造工件(1)的至少一个部件(3)，所述部件受到不完全热烘烤(32)，以使所述第一部件的树脂部分聚合，所述不完全热烘烤一方面持续到所述第一部件(3)既获得足以确保其在环境温度下保存的化学稳定性又获得在制造工件(1)的后续操作中足以确保其操纵和保持其完整性的尺寸稳定性的阶段，另一方面不能超越这样的阶段：构成所述第一部件的材料具有热塑性，所述热塑性允许通过第一部件的至少局部升温而使所述第一部件塑性成形(34)。在后面的阶段中，第一部件(3)与未受到任何硬化热烘烤或者受到不完全烘烤(32)的第二部件(2)组合，并且组合的两个部件同时受到热烘烤(50)，所述热烘烤引起两个部件的树脂的确保建立部件之间的分子键的完全且均匀的聚合。

Description

用具有长纤维及热固性基质的复合材料制造复杂工件的方法
本发明属于用在热固性有机基质中包含长纤维的复合材料至少部分地实现的工件的制造领域。本发明涉及特别适合制造或多或少有些复杂的工件的制造工艺，其中可以由在组装后构成所述工件的多个部件来实现所述工件。
如今在许多工业领域中，大量地使用复合材料用于工件的制造，其中包括结构件，即当使用时需承受显著的力的部件。
存在多种复合材料，最普遍的是由包含在由硬有机树脂形成的基质中的长短不一的无机或者有机材料(玻璃、碳、芳纶......)的纤维构成的复合材料。
在所使用的许多复合材料和许多有关的实施工艺中，特别由于适当的成本的原因，最普遍的类型之一与热固性预浸渍材料有关。
在该类复合材料工件中，首先加工在进入工件的制造之前预浸渍树脂的长纤维带，即例如通过使用凹形或者凸形模具进行切割和成形。在相当的期间内浸渍纤维的树脂不聚合并且通常在该期间内所述树脂呈现为糊状。那么预浸渍的长纤维带(例如层状的或者织物形式的)没有任何刚性，这样允许所述长纤维带最近地贴合模具的形状。
当工件的所有部分都以这样的形式布置好时，对该工件进行烘烤操作，即按照适合所用树脂的循环进行热烘烤，以通过聚合不可逆地硬化树脂。通常在所述烘烤的某些阶段在向工件上施加压力的同时执行热烘烤，以便在工件硬化之前通过挤压排出多余的树脂，以在完成的构成工件的材料中获得尽可能高的纤维率，并且还尽可能消除孔隙痕迹。
预浸渍本身是复杂且专业的操作，所使用的材料往往在进行预浸渍后的成形之前送入车间，并且以低温保存以避免在使用之前在环境温度下硬化。
当用复合材料实现复杂工件时，特别当产品的质量和可再现性很重要时，可以精细地实现布置预浸渍纤维的操作。
复杂工件是指包括这样的区域的工件：所述区域的形状导致在相应模具上布置预浸渍长纤维比较困难，甚至不可能实现。例如图1a示出的加强板就可能是这种情况，所述加强板包括恒定或者可变厚度的外壳2以及在所述外壳的一面或者两面上的加强肋部件3。加强肋可以具有不同的形状，例如图1c示出的Ω形、Z形、U形或者L形，这些形状中的某些形状在硬化之后很难从模具中取出，例如具有Z形截面的加强肋，甚至不可能用常规方法从模具中取出，比如图1a或者图1b所示的Ω形加强肋。
在工业上不能一步完成工件时，最普遍的解决方案包括在复杂的工件上确定如图1b所示的不同组件(每个所述组件都是将用复合材料单独实现的部件)，然后通过粘合或者其它的已知的组装方法把已经硬化的不同部件组装起来。
这样，在图1a和图1b的示例中，用在专门模具中硬化的材料实现加强肋3，在另一模具中实现外壳并且随后组装不同的硬化部件。
该方法被大量地使用，但是该方法具有组装工件的缺陷，所述工件应当被实现为具有与最终的工件尽可能接近的紧密的形状和尺度公差，而且该方法意味着部件以后的组装无法获得均一性，而各部件相互接触地在同一聚合热烘烤工艺中硬化时可以获得所述均一性。
在不削弱所实现的工件获得的结构性能的情况下，根据本发明的方法避免了用于实现热固性复合材料工件的已知方法的大多数缺点。
为此，基于用至少一种热固性树脂预浸渍的长纤维带的复合材料工件包括两个或者多个组装的部件，所述热固性树脂在聚合热烘烤过程中不可逆的硬化，在实现所述工件的过程中，所述工件受到已知方式的聚合硬化热烘烤。根据该方法，基于基本平坦的板材，独立于所述工件，实现构成要实现的工件的一部分的至少一个第一部件，所述平坦的板材本身通过预浸渍热固性树脂的纤维带的堆积实现，在所述堆积之后，在本方法的一个步骤中，所述平坦板材受到不完全热烘烤以便不完全地聚合所述平坦板材的树脂。该不完全聚合一方面进行到这样的阶段：第一部件获得足够的尺寸稳定性，在制造工件的后来的操作中允许操纵该工件并保证该工件的完整性，另一方面所述不完全聚合限于这样的阶段：构成所述第一部件的材料具有类似于热塑性复合材料的流变特性，所述流变特性允许所述第一部件通过其至少局部地升温而进行轧板工艺型的塑性成形，以便可以修改所述第一部件的形状。
在本方法的后续步骤中，所述平坦板材经受至少一个塑性成形步骤，以便使第一部件成形获得想要的形状，第一部件成形与构成所述第一部件的材料的至少局部升温相结合。
对单独实现的第一部件给定的几何形状既是稳定的又是可修改的，并且由于聚合没有进行到成熟，所述第一部件的树脂可以建立新的分子键。有利地，这样的部件可以在没有昂贵的制冷设备的环境温度下保存。
当铺放热固性树脂预浸渍的长纤维带时，第一部件成形或者仅不完全成形，并且在受到不完全热烘烤后，经过与构成所述第一部件的材料的至少局部升温相结合的塑性成形步骤。优选地，当第一部件的形状允许时，由已经经过不完全热烘烤的热固性复合材料实现基本平坦的板材，之后利用所述板材获得的热塑性特性对板材进行切割、弯曲或者成形而形成第一部件的形状。
所述的至少一个经受不完全热烘烤的第一部件与至少一个基于热固性树脂预浸渍的长纤维带的第二部件组装，以便在第二部件的树脂完全硬化前形成要实现的工件，并且所述的第一部件和所述的第二部件经受完全聚合所述第一和第二部件的树脂的共同的热烘烤，使得在形成工件的部件界面处形成树脂高分子链的相互扩散，并且在整个工件中获得最终均匀的烘烤程度。
在第一实施模式中，第一部件和第二部件在这样的阶段组装：在该阶段，在第二部件中使用的预浸渍纤维未经受任何硬化热循环，当所述第一部件容易设置在第二部件的纤维上时，这显得很有利。
在第二模式中，优选地在放置第一部件之前应从模具中取出第二部件或者第二部件应成形的情况下，使第一部件和第二部件在下述阶段组装：在该阶段，在第二部件中使用的预浸渍纤维也经过了不完全热烘烤。
为了保证不同部件之间的连接质量，用于浸渍第一部件的纤维的热固性树脂和用于浸渍第二部件的纤维的热固性树脂是化学相容的，以便当共同热烘烤时能够建立分子键。优选地，使用同样的热固性树脂浸渍不同部件的纤维。
根据该方法，受到不完全热烘烤的部件或者板材被存放在环境温度下以便用于以后的组装，以后的组装需要或不需要为了优化部件生产周期而进行的预先热成形。
为获得高机械强度的工件，实施的用于实现平坦板材(用于实现部件2、3)的预浸渍纤维具有在重量上等于或大于65％或者在体积上等于或大于60％的纤维率，即单独的纤维和具有预浸渍树脂的纤维之间的比率。
通过参考示出的附图描述根据本发明的方法：
图1：作为例子示出了代表复合材料复杂工件的加强板，图1a中示出了组装状态，图1b示出分离的各个部件，并且图1c示出加强肋截面的示例；
图2：加强板制造方法的各个步骤。
根据图2示出的本发明的方法，基于由热固性树脂预浸渍的长纤维带实现复合材料的复杂工件。
“带”是指为了便于纤维的堆积，独立于要实现的工件准备的长纤维的任何平坦且单向的布置。
在随后的说明中，将详述用于实现与图1中示出的同类型的加强板1的方法，该示例不是限制性的。
图1a的加强板包括外壳2，所述外壳的厚度可以基本恒定，或者如在寻求尽可能轻的质量的结构中最常见的情况那样，根据施加在所述板上的局部应力而随板的相关位置而变化。加强板1还至少包括加强肋3，例如开口部分与外壳2的表面之一连接的Ω形的加强肋。
在复杂工件的第一步，加强板1分解成如图1b中示出的部件或组件，即一方面是外壳2且另一方面是所述至少一个加强肋3，它们能够分开成形而后组装，以便构成需要的复杂工件。
在第二步30中，用选择的热固性预浸渍材料实现第一部件中的至少一个(例如所述至少一根加强肋3)以便实现工件。
该第二步30包括一些变化的形式，但该步骤以下述事实为特征：所述步骤包括热烘烤工序32，称为不完全热烘烤，其目的在于不完全聚合所述树脂，使得：
-在20摄氏度左右的车间环境温度下，所述步骤给出所实现的部件的适合的刚度，所述刚度允许部件在不经受重大的机械应力时基本保持其形状，并能够长时间储存而树脂不会发生重大的化学变化(在相关工业制造方法的尺度上)；
-后来的暂时温度升高导致构成部件的复合材料刚度降低，使所述复合材料获得类似热塑性复合材料的物理和流变特征。
所述的不完全热烘烤工序例如是一般用于使复合材料聚合及硬化的热固性材料硬化热烘烤，且在树脂完全凝固前中断所述不完全热烘烤工序，树脂的完全凝固即聚合过程中的这样的点：树脂内部的分子链的三维网的密度达到使得所述树脂不再具有足以进行预浸渍纤维传统实施的特性的阶段。希望中断热烘烤的时刻取决于使用的树脂类型。例如经过实验确定在所述树脂的凝固点附近。
因此该方法利用称为热塑性的特性，即在聚合后(在聚合树脂的化学稳定性的限度内)通常对热量不敏感的热固性材料在聚合硬化的正常过程中暂时具有的特性。
就发明人所知，实现已知复合材料的结构件的任何方法都没有利用通过聚合热固性材料的不完全热烘烤获得的热塑性特征。
在实施本方法的第二步30的方法中，把预浸渍材料放置31到凹形或者凸形的模型中以便赋予部件与其在复杂工件中应具有的形状最近似的形状。
例如把预浸渍纤维放置到具有加强肋3的外部轮廓的凹形模型中。例如通过手工铺展或者借助于机器铺展预浸渍纤维层实现该操作。
结合适合材料的压力，部件受到不完全热烘烤32，然后从模具中取出已经成形的部件。注意到在该阶段，在部件恢复到环境温度后，树脂的聚合很缓慢，根据试验，在温度保持在40摄氏度以下、相对湿度小于60％时部件可以在环境条件中保存33至少6个月，其热塑性特性基本不改变。
在必要时，部件脱模之后，利用热塑性特性以便局部修改其形状。例如优选地在直的模具中实现加强肋3，然后该加强肋3经过热塑性成形34，以赋予其适合其在板1上的目标位置的弯曲和/或扭转(螺旋)。这样可以使用同样的模具形成具有基本相同截面但最终形状不同的加强肋。
在本方法第二步30实施的另一种优选方法中，用预浸渍材料实现31基本平坦的板材，然后经受不完全热烘烤32以便获得具有热塑性特性的板。然后切割所实现的具有部件所需厚度(例如加强肋壁板的厚度)的板，然后热成形34，以便实现部件3。
实现平坦板材的优点一方面是实现这种板材比较简单，不需要使用复杂形状的模具也不需要复杂机器(例如用于摆放预浸渍纤维带的具有多轴头的机器)，另一方面是既可通过选择使用的材料又可通过允许使用均匀高压实现板材的方法来获得在重量上等于或大于65％或者在体积上等于或大于60％纤维率，即所获得的材料的纤维的重量或者体积相对于由纤维和预浸渍树脂获得的总重量或者总体积的比率。
优选地，为了实现平坦板材，所使用的预浸渍纤维本身包括在重量上等于或大于65％或者在体积上等于或大于60％的纤维率。
根据常规的方法实现热成形，例如弯曲或者在模型和对模(下模，底模，contre-forme)之间成形。该解决方案的优点是可以容易且低成本地实现平坦板材(它们可以连续生产，并可以在环境温度下没有困难地保存，等待使用)，并且已经知道和掌握了各种热成形技术。
在本方法的第三步20中，按照传统的在模型上或者模具中放置热固性材料预浸渍的纤维(例如铺展纤维层)的方法准备工件的第二部件(例如板1的外壳2)。
注意，本方法的步骤30和20的执行顺序不是强制性的，而是相应于部件2、3的准备顺序的产业选择的结果。特别地，所述的步骤可以在时间上同时或者甚至交错。
在本方法的称为组装的第四步40中，在本方法的第二步中实现的所述至少一个第一部件，例如加强肋3，以及在必要时的其他部件，例如根据本方法第二步30的循环准备的其它加强肋，被根据所述至少一个第一部件即所述加强肋3在要实现的工件即加强板1中应当具有的位置而布置为靠着在所述第三步准备的第二部件(外壳2)的热固性材料。
所述的至少一个第一部件即加强肋3的安放就位显得比已知的方法容易许多。
一方面，在环境温度下所述的部件具有一定的刚性以及稳定性，这允许不使用特别的工具(如在已知方法中所需的未硬化预浸渍纤维的支撑模具或者支撑型芯)就能操控所述部件。
另一方面，所述部件仍有足够的非刚性，以便当其安装就位时容易变形成需要的形状，并且容易保持在想要的靠紧其它部件的位置，这与完全聚合从而过于刚性而不能显著变形的部件的组装方法相反。
在本方法第五步50中，组装的部件受到完全热烘烤，其目的在于引起在本方法的第三步20期间使用的预浸渍纤维树脂(外壳2的材料)的完全聚合，并且结束在第二步30期间使用的受到不完全热烘烤的预浸渍纤维树脂(加强肋3的材料)的聚合。
“完全聚合”是指当认为复合材料获得作为最终结果接受的稳定机械性能时，在常规的方法中所使用的树脂达到的聚合程度。
在步骤50过程中，当使用的树脂化学相容时，经受不完全热烘烤的所述至少一个第一部件(加强肋3)的树脂的分子链仍然能够与不经受该不完全烘烤的第二部件(外壳2)的树脂建立连接键，这允许将工件的部件(外壳2和加强肋3)连接起来，这是由于在两个组装部件的材料中长分子链互相扩散，这与通过同时烘烤没有经受不完全热烘烤的部件的已知方法所获得的性能相同。
用于组成工件的不同部件的预浸渍纤维的热固性树脂优选的是具有良好分子亲和力的树脂。在一种具体实施方式中，不同部件(外壳2和加强肋3)的树脂是一样的。
在通过图2的示意图上的虚线围绕的可选择的步骤表示的本方法的一种变型中，在构成工件之前的不同部件(外壳2和加强肋3)是通过应用本方法的第二步实现的，因此第二部件(外壳2)也要经受不完全热烘烤。在该变型中，前面描述的本方法的第三步20因此由与第二步30同样的步骤替代，以同样的方式包括堆积预浸渍纤维的步骤21、不完全热烘烤的步骤22，在必要时包括储存步骤23，在必要时还包括成形步骤24。
在该情况下，可以改变第五步50的热烘烤，以便考虑到工件的全部部件已经经受不完全热烘烤32、22这一事实。
因此，根据本发明的方法允许在简化构成工件的部件的操控操作以及使用同样简化的设备的情况下，实现基于预浸渍热固性树脂的纤维的复合材料工件。

Claims (8)

1.一种制造结构加强板(1)的方法，所述结构加强板(1)包括至少一个第一部件和第二部件，即外壳(2)和至少一个加强肋(3)，所述结构加强板是复合材料的，所述复合材料基于用至少一种热固性树脂预浸渍的长纤维带，所述树脂适合在热烘烤过程中不可逆地聚合和硬化，在制造所述加强板的过程中，所述树脂经过聚合硬化热烘烤，该方法的特征在于：
通过预浸渍热固性树脂的纤维带的堆积(2l，31)实现基本平坦的平坦板材，在所述堆积之后，在本方法的一个步骤中所述树脂受到不完全热烘烤(22，32)，所述不完全热烘烤不完全地聚合所述第一部件的树脂，该不完全聚合一方面进行到这样的阶段：第一部件(2，3)获得足够的尺寸稳定性，在后来的制造操作中足以确保操纵该第一部件并保证该第一部件的完整性，另一方面所述不完全聚合限于这样的阶段：构成所述平坦板材的材料具有热塑性，允许所述平坦板材通过其至少局部地升温而进行塑性成形；
构成所述加强板的一部分的至少所述第一部件，即所述外壳(2)或者所述至少一个加强肋(3)，是通过对所述平坦板材或者所述平坦板材的局部进行塑性成形(24，34)，基于所述平坦板材或者所述平坦板材的局部单独实现的(20，30)；
所述第一部件和所述第二部件分别经受完全热烘烤(50)步骤，在该步骤中所述第一和第二部件的树脂分子链在所述第一和第二部件之间的界面处相互扩散，所述第一部件是所述外壳(2)而所述第二部件是所述至少一个加强肋(3)，或者所述第一部件是所述至少一个加强肋(3)而所述第二部件是所述外壳(2)。
2.如权利要求1所述的方法，其中，利用预浸渍了热固性树脂的纤维带实现(30，20)至少一个第二部件(3，2)，其中，在所述第二部件(3，2)中使用的预浸渍纤维未经受任何预先硬化烘烤循环的阶段，已经经过了不完全热烘烤的所述第一部件(2，3)与所述第二部件一起放置，并使所述第一部件和所述第二部件经受使所述第一和第二部件的树脂完全聚合的共同完全热烘烤(50)。
3.如权利要求1所述的方法，其中，所述至少一个第二部件(3，2)是通过对平坦板材进行热塑性成形(24，34)实现的(30，20)，所述平坦板材是通过预浸渍热固性树脂的纤维带预先实现的，所述热固性树脂已经经过了不完全热烘烤(32、22)，使得所述树脂不完全聚合到这样的阶段：所述平坦板材获得足够的尺寸稳定性，在制造所述加强板(1)的后来的操作中足以确保操纵该第二部件并保证该第二部件的完整性；所述树脂的不完全聚合限于这样的阶段：构成所述平坦板材的材料具有热塑性，允许所述第二部件通过其至少局部地升温而进行塑性成形(34，24)。
4.如权利要求3所述的方法，其中，所述至少一个加强肋的不完全热烘烤(32)为在如下阶段的中断热烘烤：在环境温度下所述至少一个加强肋具有足够的非刚性，以在完全热烘烤(50)之前，在定位所述至少一个加强肋时，允许所述加强肋符合所述外壳(2)的形状。
5.如权利要求2、3或4所述的方法，其中，用于浸渍第一部件(2，3)的纤维的热固性树脂和用于浸渍第二部件(3，2)的纤维的热固性树脂是化学相容的，以便当共同热烘烤(50)时能够建立分子键。
6.如权利要求5所述的方法，其中，用于浸渍第一部件(2，3)的纤维的热固性树脂与用于浸渍第二部件(3，2)的纤维的热固性树脂相同。
7.如权利要求1-4之一所述的方法，其中，在环境温度下储存(23、33)经过不完全热烘烤(22、32)的一个或者多个部件(2、3)和/或一个或者多个板材，用于以后进行有或者没有预先热成形(24、34)的组装(40)。
8.如权利要求1-4之一所述的方法，其中，用于实现用来制造部件(2、3)的平坦板材的预浸渍纤维具有在重量上等于或大于65％或者在体积上等于或大于60％的纤维率，所述纤维率即单独的纤维和具有预浸渍树脂的纤维之间的重量或者体积比。
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