CN101702890B - 用于在复合部件之间形成连接的方法 - Google Patents

用于在复合部件之间形成连接的方法 Download PDF

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CN101702890B
CN101702890B CN200880018528.4A CN200880018528A CN101702890B CN 101702890 B CN101702890 B CN 101702890B CN 200880018528 A CN200880018528 A CN 200880018528A CN 101702890 B CN101702890 B CN 101702890B
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structure member
thermoplastic
packing elements
leading edge
join domain
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CN101702890A (zh
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J·利斯特
R·克吕托夫
J·M·J·特尼桑
H·范克隆嫩博格
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GKN Fokker Aerospace BV
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    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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    • B29C66/739—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 characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—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 characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本发明涉及一种将结构部件连接在一起的方法，所述结构部件由复合材料制成并相互横向延伸，例如型材的凸缘和腹板，所述方法包括以下步骤：将结构部件彼此相对应地布置在所需位置以形成连接区域，在所述连接区域，其中一个结构部件接靠或邻近另一结构部件，促使热塑性材料流到连接区域中，使结构部件在热和压力的作用下熔合在一起。

Description

用于在复合部件之间形成连接的方法
技术领域
本发明涉及一种将由复合材料制成的部件连接在一起的方法。这种类型的部件包括嵌入在由塑性材料制成的基体中的一层或多层纤维。塑性材料的基体可以是热塑性或热固性的；塑性材料的基体的选择通常由最终产品所需具有的属性来决定。 
背景技术
在将由复合材料制成的两个部件连接在一起的常规方式中，部件相靠着被平放。随后，热塑性基体在热作用下熔化，此后所述部件通过局部熔化在压力下相互紧固。在这样的紧固方式中，通常在一个或两个部件上形成凸缘，随后在该凸缘或多个凸缘的位置上形成连接。实例包括将具有凸缘的腹板连接在两个附属檩条上以形成I形梁。 
以这样的方式在两个复合部件之间形成连接不是没有其缺点的。首先，在复合部件中的一个上存在的被用于形成连接的一个或多个凸缘会产生问题。尽管对于平的复合部件来说这样形成凸缘可能很容易，但对于非平的复合部件，例如用于I形梁的波形腹板来说使凸缘成形却变得很难，因为这样还会使弯折线具有非平形状。然而，通过相对于不直的弯折线进行弯曲来连接凸缘变得困难，因为与其相关的变形在凸缘和腹板的平面上产生高应力。另一缺点在于在最终结构中的凸缘不会一直有助于发挥总体强度和刚度特性。尽管它们确保了在腹板与檩条之间的所需连接，但这一点不会一直对上述特性做出有效贡献。 
在某些情况下，与这种类型的凸缘连接相关的额外重量是一个缺陷。这一点在航空和宇宙飞行应用中尤其相关。通常通过使纤维材料层连续延伸到凸缘或多个凸缘内来形成凸缘。如果存在特别规定的最小厚度的凸缘，则相应复合部件的其余部分必须也具有特定层厚度，出于刚度和强度的原因这一点不总是必须的。 
发明内容
因此，本发明的目的是提供一种不具有这些缺点的用于将复合部件连接在一起的方法。这一目的通过以下技术方案实现，即一种将结构部件连接在一起的方法，所述结构部件由复合材料制成并相互横向延伸，例如型材的凸缘和腹板，所述方法包括以下步骤： 
-将结构部件彼此相对应地布置在所需位置以形成连接区域，在所述连接区域内其中一个结构部件接靠或邻近另一结构部件， 
-促使热塑性材料流到连接区域， 
-使结构部件在热和压力的作用下熔合在一起。 
根据本发明，当在两个复合部件之间形成连接时省去了采用连接凸缘。相反，使在热和压力作用下熔化后形成完整连接的热塑性材料流出到达其中一个复合部件的邻接边缘与另一复合部件的直接相对面之间。这样是可行的，因为连接性能由热塑性材料决定，没有被证明在这一方面是决定因素的纤维层。因此这一发现可以采用更少的材料形成连接，也就是无需至今常规采用的凸缘，这样满足了对强度和刚度的要求。 
可以流出的热塑性材料例如来自本身要被连接在一起的部件。在热的作用下，部件的热塑性材料以所述热塑性材料在压力作用下流入连接区域的形式变成流体。由于通过这种方式在连接区域获得的热塑性材料的量有限，因此这种方法的变形尤其适用于承受相对较轻载荷的结构。另外，或备选地，可以向连接区域增加额外的热塑性材料。随后采用相对较大的量的热塑性材料形成连接，所以通过这种方式采用额外的热塑性材料形成的连接适用于承受更重载荷的结构。 
通过这种方式获得的连接必须能够满足多项要求。在这一方面必须制定强度要求与刚度要求之间的区别。如果连接必须能够承受最大载荷，则第一要求是关键。对于常规连接，来自腹板的剪切力在檩条(对于I形梁或T形梁来说)表面的较大宽度上传递，该宽度由凸缘或多个凸缘的宽度决定。对于采用本发明的方法制成的产品，该宽度相对较小并被限制在热塑性材料制成的焊道的宽度内。 
根据本发明的方法尤其可以包括以下步骤： 
-由热塑性材料制成焊道， 
-使焊道的宽度从一个结构部件的邻接前缘起始向着另一结构部件的相对表面增大。 
这种方法尤其适用于连接在楼板托梁(floor joist)上的加强件以及用于腹板上的环形加强件。 
对于承受较高载荷的结构部件，一个结构部件的前缘还可以被加宽。这样增大了腹板与檩条之间的边界表面积。这一点的优点在于，对于其他等同的剪切力，边界表面上的剪应力保持更低。 
特别地，还可以包含实施以下步骤： 
-使一个结构部件的前缘分裂开以形成封闭出纵向空腔的两个支脚， 
-利用热塑性材料填充纵向空腔。 
纵向空腔中的热塑性材料优选地被填充有例如量达到60％的纤维。这样提高了纵向空腔中的填充材料的稳定性，从而形成了更稳定的结构。 
还通过以下步骤进一步提高稳定性： 
-使焊道的宽度从大致一个结构部件的前缘的宽度增大到在另一结构部件的表面至多为所述宽度的五倍。特别地，可以使焊道宽度增大到一个结构部件的前缘的宽度的至多三倍。 
根据本发明的方法的另一可行实施方式包括以下步骤： 
-将一个结构部件的前缘布置成接靠另一结构部件， 
-使热塑性材料在连接区域与两个结构部件的外侧相连。 
因此在该方法中，无需去掉相应结构部件的前缘。原始前缘被布置成直接接靠或几乎接靠另一结构部件。在该实施方式中，前缘任一侧的热塑性材料的焊道确保了力的有效传递。 
在连接区域中采用的热塑性材料优选是PEI、PEKK或PEEK。 
可以在根据本发明的方法中采用纤维加强的复合材料。可以采用多种材料作为纤维加强；实例包括金属加强的复合材料、或利用PEI、PEKK或PEEK浸渍的复合材料。 
根据本发明的方法可以通过多种方式实施。根据优选，根据本发明的方法包括以下步骤： 
-将结构部件布置在模具内， 
-使热塑性材料在压力和加热作用下在模具中熔化。 
如上所述，对于承受相对较重的载荷的特定结构来说，可以通过增加热塑性材料来获得结构部件之间的连接。这一点尤其通过引入填充元件形式的热塑性材料来实现。填充元件可以例如通过挤出或压缩来预制，并被定位在连接区域中的所需位置。这一步骤包括例如将两个填充元件施加在邻接结构部件的两侧。根据另一选择，可将一个或多个填充元件施加在邻接结构部件的两一侧以及该邻接结构部件与另一结构部件之间。填充元件可以包括填充有相对较短加强纤维的热塑性材料。 
为了确保实现可靠连接，在连接区域采用与结构部件的复合材料的热塑性材料类似的热塑性材料。根据本发明的方法还包括结构部件在热和压力作用下整体熔合。 
在这一方案中采用的模具紧密贴合待制造产品的轮廓。包括模具和工件的总组件放置在压热器中，工件封装在总组件中并包括复合材料的结构部件，如果合适还包括填充元件。在压热器中，组件作为整体承受加热和过度压力。复合部件和任何填充元件的热塑性材料在这种情况下完全熔化，由此使所述部件全部熔合。 
本发明还涉及采用如上所述的方法制造的结构件。该结构件包括至少两个结构部件，它们以一个结构部件的前缘接靠或邻近另一结构部件表面的方式相互横向定向以形成连接区域，还形成由热塑性材料制成并位于连接区域中的连接。该连接可以是T形型材、I形型材等。 
附图说明
下文参照附图中示出的几个示例性实施方式详细描述本发明，图中： 
图1是根据本发明的I形梁的侧视图； 
图2是沿图1中的线II-II截取的剖视图； 
图3表示结构部件之间的前端连接的变形； 
图4-8表示其他变形； 
图9表示与根据图4的变形相关的模具； 
图10表示与根据图8的变形相关的模具； 
图11表示与根据图7b的变形相关的模具；以及 
图12表示与根据图7a的变形相关的模具。 
具体实施方式
根据本发明的图1和2所示的I形梁包括腹板1、上檩条2和下檩条3、这些檩条2，3通过焊道4连接在一起。在所示的示例性实施方式中，这些焊道4从腹板1的前缘5向上延伸到檩条2，3的面对所述前缘的表面6。在由此确定的连接区域10中，焊道的宽度从腹板1的厚度增大到在檩条2，3的表面6的位置处为所述厚度的三到五倍。这样提供了与檩条2，3的良好连接，这种连接具有相对较低的剪应力。这样的改变是根据本发明的方法的实施方式所特有的，其中由于热塑性材料流出腹板和檩条，因此在焊道中留有相对少量的热塑性材料。鉴于由此获得的连接区域较窄，这种类型的结构尤其适用于相对较轻的载荷。 
还可以应用根据图3的变形。在这种情况下，腹板1的前缘5被去除以形成封闭出纵向空腔8的两个支脚7。该纵向空腔填充有流出的热塑性材料。这样在连接区域10的腹板1的前缘5与檩条2的表面6之间可以获得相对较大的连接表面积。腹板1经由其分开的支脚7到檩条2的连续无阻碍确保了实现坚固的刚性连接。由前缘5宽的属性在与檩条连接的位置形成的低剪应力还防止了热塑性材料的过度载荷。 
根据图4的变形表示腹板1的前缘5未得到加宽的I形梁。腹板1以其前缘5几乎或完全压靠在檩条2的表面6上的方式垂直于檩条2延伸。通过增加额外的热塑性材料(参见下文和图9)获得的焊道9应用在由此形成的连接区域10的任一侧。这样使焊道9具有相对较大的横截面，所以这种连接尤其适用于承受相对较重载荷的结构。 
图5表示与图4相对应的连接，尽管如此在这种情况下没有增加任何额外的热塑性材料。因此，焊道11被认为小于根据图4的变形的焊道。毕竟，因为檩条1和凸缘2本身的热塑性材料的流出获得焊道11，所以这种连接尤其适用于相对较轻的载荷。 
根据图6a和6b的变形涉及一种托梁，其腹板1具有通过圆柱形凸缘12加固的开口13。圆柱形凸缘12通过焊道11被紧固在腹板1上，焊道11也可以仅通过腹板1和圆柱形凸缘12的热塑性材料的流出来获得。另外， 还可以增加额外的热塑性材料以获得更厚的焊道并由此获得能够承受更重载荷的连接。 
根据图7a和7b的变形涉及一种硬化板，其具有加强件15紧固在其上的壳板14。由于这种壳板14是承受相对较高载荷的结构部件，因此通过增加额外的热塑性材料(参见下文和图11，12)获得焊道9。 
图8表示I形梁的变形，其凸缘2，3以与根据图4的变形不同的方式得到紧固。此时在腹板1和上、下檩条2，3的上侧和下侧的前缘5之间存在空间，其中填充有热塑性材料23。该热塑性材料23与位于前缘任一侧的焊道9构成单个整体。 
图9表示借助于模具25制造根据图4的I形梁的方式。模具25包括上和下模具板体16，17以及左手和右手模具件19，18。这些模具板体和模具件封闭成具有根据图4的最终I形梁的轮廓的成形腔24。如图所示，成形腔24容纳下檩条3、腹板1和上檩条2。以它们紧密贴合模具件19，18以及檩条2，3和腹板1的轮廓的方式被挤出或压缩的填充元件20也容纳在檩条2，3与腹板1之间的拐角位置。 
包括模具25、檩条2，3、腹板1和填充元件20的总组件布置在压热器内并承受加热和压力。这样促使檩条2，3、腹板1和填充元件20的热塑性材料熔化。所述部件的热塑性材料以冷却之后获得根据图4的最终I形梁的方式混合。 
图10也表示模具25，但其被用于根据图8的I形梁的制造。该I形梁制造中的过程大体上与图4和9相一致。然而在这种情况下，包括在根据图8的变形中采用的填充元件20以及桥22的填充元件21连接在腹板1的上和下前缘5的位置上。这些填充元件20和桥22在顶部和底部形成例如可以通过挤出或压缩方式而获得的单个整体结构。腹板1的上和下前缘5由此与上和下檩条2，3的相对表面分离。因此在模具25承受过度压力和受热时获得根据图8的I形梁，如图10所示。 
图11和12表示模具26，其包括用于制造根据图7a，b的硬化板的成形腔27。该模具26包括上模具板体28和下模具板体29以及模具件30。壳板14以及包括填充元件20的加强件15容纳在每两个模具件30、模具板体28与模具板体29之间。由此在通过压热器中提供的加热和压力的作用 下获得根据图7a，b的硬化板。 
上述连接可以用在所有类型的结构件中，尤其是在航天和宇宙飞行中采用的桁架。这种应用的实例包括在驾驶舱底板上采用的支承梁。 
附图标记列表 
1.腹板 
2.檩条 
3.檩条 
4.焊道 
5.腹板前缘 
6.檩条表面 
7.腹板支脚 
8.腹板中的纵向空腔 
9.焊道 
10.连接区域 
11.焊道 
12.圆柱形凸缘 
13.腹板上的开口 
14.壳板 
15.加强件 
16，17.模具板体 
18，19模具件 
20.填充元件 
21.填充元件 
22.桥 
23.热塑性材料填充 
24，27成形腔 
25，26模具 
28，29模具板体 
30.模具件。 

Claims (26)

1.一种将结构部件(1，2，3)连接在一起的方法，所述结构部件由嵌入在由热塑性材料制成的基体中的一层或多层纤维构成的复合材料制成并相互横向延伸，所述方法包括以下步骤：
-将要制造的工件的结构部件(1，2，3)相对于彼此布置在模具(25，26)中和在所需位置以形成连接区域(10)，在所述连接区域中，其中一个结构部件(1)的前缘(5)接靠或邻近另一结构部件(2，3)的表面(6)，
-将模具(25，26)和工件放置在过度压力和升高的温度下；
-促使工件的热塑性材料完全熔化；以及
-促使热塑性材料流出到连接区域(10)中，
-使结构部件(1，2，3)在热和压力的作用下熔合在一起，包括在热和压力的作用下使结构部件(1，2，3)整体熔合，使热塑性材料流出到达所述一个结构部件的邻接边缘与另一结构部件的直接相对面之间，
从而形成位于连接区域内的连接，所述连接包括热塑性材料，所述连接位于所述一个结构部件(1)的邻接前缘(5)与另一结构部件(2，3)的表面(6)之间。
2.如权利要求1所述的方法，其特征在于，包括以下步骤：
-形成由热塑性材料构成的焊道(4，9，11)，
-使焊道(4，9，11)的宽度从所述一个结构部件(1)的前缘(5)起始向着相对结构部件(2，3)的相对表面(6)增大，所述前缘以一定距离邻接靠近该相对结构部件。
3.如权利要求1或2所述的方法，其特征在于，包括以下步骤：
-使所述一个结构部件(1)的前缘(5)加宽。
4.如权利要求3所述的方法，其特征在于，包括以下步骤：
-使所述一个结构部件(1)的前缘(5)分裂开以形成封闭出纵向空腔(8)的两个支脚(7)，
-利用热塑性材料(4)填充纵向空腔(8)。
5.如权利要求4所述的方法，其特征在于，包括以下步骤：
-利用纤维将热塑性材料(4)填充在连接区域中。
6.如权利要求4或5所述的方法，其特征在于，包括以下步骤：
-将所述一个结构部件(1)的两个支脚(7)布置成接靠另一结构部件(2，3)。
7.如权利要求2所述的方法，包括以下步骤：
-使焊道(4，9)的宽度从大致所述一个结构部件(1)的前缘(5)的宽度增大到在另一结构部件(2，3)的表面(6)处为至多所述宽度的五倍。
8.如权利要求1或2所述的方法，其特征在于，包括以下步骤：
-将所述一个结构部件(1)的前缘(5)布置成接靠另一结构部件(2，3)，
-在连接区域(10)向两个结构部件(1，2，3)的外侧施加热塑性材料(7)。
9.如权利要求1或2所述的方法，其特征在于，包括采用PEI、PEKK或PEEK作为连接区域(10)中的热塑性材料。
10.如权利要求9所述的方法，其特征在于，采用填充有纤维的热塑性材料。
11.如权利要求1所述的方法，其特征在于，所述结构部件为型材的凸缘(2，3)和腹板(1)。
12.如权利要求10所述的方法，其特征在于，所述纤维为碳纤维。
13.如权利要求10所述的方法，其特征在于，所述纤维为玻璃纤维。
14.如权利要求1或2所述的方法，其特征在于，包括以下步骤：
-在连接区域(10)施加额外的热塑性材料(20，21)。
15.如权利要求14所述的方法，其特征在于，包括以下步骤：
-施加至少一个填充元件(20，21)形式的额外的热塑性材料。
16.如权利要求1所述的方法，其特征在于，包括以下步骤：
-在邻接的结构部件(1)的任一侧施加填充元件(20)。
17.如权利要求15或16所述的方法，其特征在于，包括在邻接的结构部件(1)的任一侧以及在该邻接的结构部件(1)与另一结构部件(2，3)之间施加一个或多个填充元件(20，21)。
18.如权利要求17所述的方法，包括施加由两个相对较厚的半体(20)和将两个半体连接在一起的相对较薄的桥(22)构成的填充元件(20，22)。
19.如权利要求15、16或18所述的方法，包括施加由填充有相对较短加强纤维的热塑性材料构成的填充元件(20，22)。
20.使用如权利要求14-19中任一项所述的方法制造的结构，包括至少两个结构部件(1，2，3)，它们彼此横向定向成使得其中一个结构部件(1)的前缘(5)接靠或邻近另一结构部件(2，3)的表面(6)，从而形成连接区域(10)，和位于所述连接区域内的连接，所述连接包括热塑性材料，
所述连接位于所述一个结构部件(1)的前缘(5)与另一结构部件(2，3)的表面(6)之间，
并且所述连接位于邻接的结构部件(1)的任一侧以及另一结构部件(2，3)的面对该邻接的结构部件(1)的那一侧，
其特征在于，
所述连接包括填充元件(20，22)形式的塑料材料，包括位于所述邻接的结构部件(1)的任一侧以及在该邻接的结构部件(1)与另一结构部件(2，3)之间的填充元件(20，22)，所述填充元件包括两个相对较厚的半体(20)和将两个半体连接在一起的相对较薄的桥(22)。
21.如权利要求20所述的结构，其特征在于，所述填充元件由填充有相对较短加强纤维的热塑性材料构成。
22.如权利要求20或21所述的结构，其特征在于，包括I形梁，所述结构部件形成所述I形梁的腹板(1)、上檩条(2)和下檩条(3)。
23.如权利要求20或21所述的结构，其特征在于，包括硬化板，所述结构部件形成所述硬化板的壳板(14)和至少一个加强件(15)，所述硬化板具有通过增加额外的热塑性材料而获得的焊道。
24.一种在权利要求16-19中任一项所述的方法中采用的填充元件(20，21)和至少两个结构部件(1，2，3)的组合件，所述结构部件由嵌入在由热塑性材料制成的基体中的一层或多层纤维构成的复合材料制成并且适于彼此横向放置成使得其中一个结构部件(1)的前缘(5)接靠或邻近另一结构部件(2，3)的表面(6)，从而形成连接区域(10)，所述填充元件包括额外的热塑性材料，并且适于施加到邻接的结构部件的任一侧以及在该邻接的结构部件与另一结构部件之间，其中结构部件(1，2，3)的热塑性材料和填充元件(20，22)的额外热塑性材料适于完全融化并整体融合到一起。
25.如权利要求24所述的组合件，其特征在于，所述填充元件(20，22)包括两个相对较厚的半体(20)，还包括将半体连接在一起的相对较薄的桥(22)。
26.如权利要求24或25所述的组合件，其特征在于，所述填充元件(20，22)由填充有相对较短加强纤维的热塑性材料构成。
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