CN101778760A - 复合层压制品结构 - Google Patents

复合层压制品结构 Download PDF

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CN101778760A
CN101778760A CN200880102444.9A CN200880102444A CN101778760A CN 101778760 A CN101778760 A CN 101778760A CN 200880102444 A CN200880102444 A CN 200880102444A CN 101778760 A CN101778760 A CN 101778760A
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艾伦·凯伊
李东
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Abstract

一种结构，包括具有边缘(8)的复合层压制品；和由所述边缘(8)承载并包括在撞击下发生破裂的树脂的撞击指示物(9)。该破裂为撞击损伤提供了持久的可视证据，例如开裂或一个或多个块从撞击指示物上脱落。不仅可以为撞击损伤提供这些可视证据，撞击指示物还可以提供撞击保护。典型地，撞击指示物(9)采用比制造复合层压制品的材料易碎和脆弱的树脂制成。例如，制造复合层压制品的材料可以是加强的，而制造撞击指示物的树脂可以是非加强的。

Description

复合层压制品结构
技术领域
本发明涉及一种复合层压制品结构和一种用于在这种结构中指示撞击损伤的方法。特别地，而非排他地，该结构可以形成飞行器部件的一部分。
背景技术
许多飞行器部件由复合层压材料制成。例如，飞行器机翼中的桁条/纵梁(stringer)，加强肋以及翼梁结构都可以采用复合层压结构的形式。虽然这些结构在以已经设计好的承载方式受载时可能是坚固的，它们却非常容易发生撞击损伤，并导致发生分层。分层可能会导致结构变得脆弱，并最终失效。当撞击发生在复合层压结构的边缘时，复合层压结构的边缘(复合层压结构层的末端所在处)特别容易受到伤害，尤其是如果撞击是在端点的话(即，撞击的方向垂直于结构边缘而平行于组成该结构的层压制品的平面)。
如果撞击具有明显的端向方向的力分量的话，撞击可能将损坏包括复合层压结构的层压层之间的结合，引起或加剧分层效应。这些撞击可能是在维修的过程中例如当复合层压结构的端面以与往常不同的方式暴露时，工人们在这些结构上工作的同时掉落工具所导致的。复合层压结构可能遭到损坏的另一方式是随着时间的流逝而磨损，这些磨损例如由工人坐或站在这些结构上，或者直接或通过工具或其他设备接触这些结构所导致。例如，工人在飞行器上工作时，将工具或工具箱搁置在这些结构的端面上是常见的。至少在维护过程中，复合层压结构的边缘通常暴露在受到如上所述的直接磨损和直接撞击的情形下。类似的撞击危险也存在于制造和装配这些复合部件的过程中。
在设计飞行器部件时，要考虑影响飞行器的复合层压结构的强度或其他机械特性的因素，例如上述的那些因素。因此，诸如上述的那些因素通常意味着复合层压结构需要具有额外的强度，从而导致尺寸和重量的增加。
已知的加强层压复合制品的边缘的方法是应用边缘护具——例如在US2006/0234007中所述的。另一解决办法是形成具有卷边/翻边(roll-formedge)——即，由折叠层形成的边缘的复合层压制品。但是这些传统方法的一个问题在于这些传统方法都不能提供充分的关于撞击的可视证据。而这种可视证据对于这些结构而言可能是需要的。
发明内容
本发明的一个目的是提供一种结构，该结构包括具有边缘的复合层压制品；和由所述边缘承载并包括在撞击下发生破裂的树脂的撞击指示物。
本发明的另一目的是提供一种在这种结构中指示撞击损伤的方法，该方法包括使撞击指示物破裂。
该破裂为撞击损伤提供了持久的可视证据，例如裂纹或一个或多个块从撞击指示物上脱落。不仅可以为撞击损伤提供这些可视证据，撞击指示物还可以通过吸收部分冲击能量提供撞击保护。
典型地，撞击指示物包括比制造复合层压制品的材料易碎和脆弱的树脂。例如，制造复合层压制品的材料可以是加强的，而制造撞击指示物的树脂可以是非加强的。
典型地，复合层压制品包括热固性材料例如环氧树脂。形成撞击指示物的材料可以由相同的热固性树脂或由在相近的或更低的温度下固化的树脂形成。
撞击指示物可以限制长度，或者可以包括在边缘的至少大部分长度上延伸的条带。
在本发明的特定实施例中，复合层压制品的多个层的末端位于边缘处。可选地，边缘可以通过折叠层形成卷边。
撞击指示物可以通过共同固化、共同结合或二次结合粘附到边缘上。在撞击指示物通过共同固化粘附到边缘上的情况下，该撞击指示物可以与复合层压制品整体地形成(例如通过形成具有富含树脂的边缘的复合层压制品)。
在一个示例中，通过从喷嘴挤出树脂到边缘上将撞击指示物施加至边缘，然后通过固化所挤出的材料将其与边缘共同结合。
在另一个例子中，通过在凹形模具中提供热固性树脂的珠状物来将撞击指示物施加至边缘；将复合层压制品的边缘插入凹形模具，然后加热珠状物和复合层压制品，从而使得复合层压制品固化，而珠状物共同固化到边缘上。
在另一个例子中，复合层压制品包括加强相和基质树脂相，这样形成撞击指示物：将复合层压制品的边缘插入凹形模具；在边缘和凹形模具之间提供间隙；加热复合层压制品以使得基质树脂相流入间隙并形成撞击指示物。
附图说明
下面将参考附图来说明本发明的实施例，其中：
图1是将撞击指示物应用到桁条/纵梁上的方法的透视图；
图2是带有撞击指示物的桁条的端面图；
图3-5示出桁条的制造过程的三个步骤；
图6是一种可选的带有撞击指示物的桁条的端面图；
图7是另一种可选的带有撞击指示物的桁条的端面图；
图8是带有撞击指示物的卷边桁条的端面图；
图9是共同固化(co-curing)制造工艺的端面图；
图10是将桁条与撞击指示物整体成型的制造工艺的端面图。
具体实施方式
图1中所示的桁条1包括一个托板/刀形板(blade)2和一对凸边3、4。该桁条通过图3至图5中所示的流程来制造而成。在第一步中，将平板填料5a放置在凸的成型工具6上。填料5包括由一叠片材形成的层积结构，其中，各个片材包含大量由热固性环氧树脂浸渍的单向碳纤维。这些片材通常被称为“预浸渍物”。图3中示意性地示出了单独的预浸渍片材，而为了简明起见，在其余各图中不再示出预浸渍片材。
然后，使填料5a在模具上变形，如图4所示，以形成U型部5b。然后U型部5b被切割成如图5中所示的两个L型部5c和5d；L型部5c和5d背对背地放置，如图2所示。一旦L型部5c和5d被背对背地放置，将被共同固化以使桁条硬化并将各部分接合起来。
桁条1的长度方向定义为0度方向，桁条的高度方向定义为90度方向。桁条的铺层(lay-up)方式由代表桁条中分别定向为0度/±45度/90度方向的纤维的百分比含量的符号来表示。一种典型的桁条铺层方式是60/30/10。也就是说，百分之六十的纤维是0度方向，百分之三十的纤维是±45度方向，百分之十的纤维是90度方向。
桁条包括暴露在外的顶部边缘8，通过图1所示的工艺来机械加工和(在固化之后)密封所述边缘。
成型机械切割元件10沿边缘8移动，切除掉材料以制造出图2所示的沟槽11。清洁装置12移走切割过程所产生的废料。通过从喷嘴14中挤压出液态的环氧树脂将珠状物13安置到沟槽中。精加工工具15设有具有预定形状的槽16，使工具15在喷嘴14后面沿着边缘移动，从而从珠状物13除去多余树脂。
应当注意到，这些工艺是在一条线上进行的，从而可以在对边缘8进行机械加工的同时施加珠状物13。
然后，将树脂固化从而使珠状物与边缘8共同结合，形成图2中所示的位于沟槽11中的撞击指示物9。
应当注意到，可以省略机械加工步骤，从而桁条的顶部边缘是平的，如图6中的8a所示。在图7所示的可选实施例中，预浸渍物层在图4所示的变形步骤期间可以相对彼此滑动，从而L型部具有斜边8b，所述斜边处为预浸渍片材的末端。因此，在这种情况下不需要单独的机械切割步骤来制造沟槽。
在图6和图7所示的情况下，桁条和撞击指示物9a，9b可以共同固化而不是在不同的时间固化。
图8中示出了卷边桁条。这通过采用单独的一叠被折叠起来以形成卷边8C的预浸渍物层得到。通过挤出树脂珠状物和将该树脂珠状物与卷边8c共同结合来将撞击指示物9c附着到卷边8c上。
在图9中示出的一种可选的制造工艺中，撞击指示物这样来施加到桁条的边缘上：将未固化的环氧树脂珠状物20提供至凹形模具21中；将桁条托板2插入凹形模具中；加热模具组件，从而通过共同固化来使桁条与珠状物20相互结合。
在图10所示的另一种可选的制造工艺中，撞击指示物这样与桁条整体地形成：将桁条托板插入凹形模具21中；在边缘8和凹形模具之间提供间隙22；加热桁条从而使托板中的环氧树脂基质流入间隙22中以形成撞击指示物。
前述的撞击指示物采用一种材料制成，所述材料在撞击下发生破裂，产生一条或多条的裂缝和/或使一个或多个块脱落。已经发现EA9394环氧树脂具有必要的破裂特性，但也可以设想其他材料。例如该树脂可以在室温下固化，从而不必加热珠状物以固化。
应当注意的是，撞击指示物要采用比形成复合层压制品的材料易碎和脆弱的树脂来制造。例如，非加强的EA9394树脂比用来形成复合层压制品的碳纤维加强预浸渍物要更易碎和脆弱。此外，各个撞击指示物可具有弯曲凸起的外表面和在边缘的宽度方向上变化的厚度。这可以具有以下的优点：
●使得撞击指示物比平的条带更容易破裂；
●破裂后，一个或多个块更容易脱落；
●破裂后产生的裂纹或空缺更容易从侧面看到。
尽管已经参考一个或多个优选实施例来说明本发明，应该意识到在不脱离本申请所附的权利要求限定的本发明的范围的情况下，本发明可以有多种变化与变型。

Claims (19)

1.一种结构，包括具有边缘的复合层压制品；和撞击指示物，所述撞击指示物由所述边缘承载并包括在撞击下发生破裂的树脂。
2.如权利要求1所述的结构，其特征在于，所述撞击指示物包括比制造所述复合层压制品的材料易碎和脆弱的树脂。
3.如前面任何一项权利要求所述的结构，其特征在于，所述撞击指示物包括环氧树脂。
4.如前面任何一项权利要求所述的结构，其特征在于，所述树脂是非加强的。
5.如前面任何一项权利要求所述的结构，其特征在于，所述树脂包括在低于100℃，优选的是低于50℃的温度下固化的热固树脂。
6.如前面任何一项权利要求所述的结构，其特征在于，所述层压的结构包括在第一温度下固化的热固性材料；所述树脂包括在比所述第一温度低的第二温度下固化的热固性材料。
7.如前面任何一项权利要求所述的结构，其特征在于，所述撞击指示物安置在所述边缘的沟槽中。
8.如前面任何一项权利要求所述的结构，其特征在于，所述撞击指示物具有在边缘的宽度方向上变化的厚度。
9.如权利要求8所述的结构，其特征在于，所述撞击指示物的外表面是凸的。
10.如前面任何一项权利要求所述的结构，其特征在于，所述撞击指示物包括沿所述边缘的至少大部分长度延伸的条带。
11.如前面任何一项权利要求所述的结构，其特征在于，所述复合层压制品的多个层的末端位于所述边缘。
12.如权利要求1到10中任何一项所述的结构，其特征在于，所述边缘是由所述层压的结构的折叠层形成的卷边(roll-form edge)。
13.一种具有如前面任何一项权利要求所述的结构的飞行器部件。
14.一种在前面任何一项权利要求所述的结构中指示撞击损伤的方法，该方法包括使所述撞击指示物破裂。
15.如权利要求14所述的方法，还包括使一个或多个块从所述撞击指示物上脱落。
16.一种制造如权利要求1到12中任一项所述的结构的方法，该方法包括通过从喷嘴挤出树脂来将所述撞击指示物施加到所述边缘。
17.一种制造如权利要求1到12中任一项所述的结构的方法，该方法包括将所述撞击指示物共同固化到所述边缘。
18.如权利要求17所述的方法，其特征在于，这样来施加所述撞击指示物：在凹形模具中提供热固性树脂珠状物；将所述复合层压制品的所述边缘插入所述凹形模具；加热所述珠状物和所述复合层压制品从而固化所述复合层压制品和将所述珠状物共同固化到所述边缘。
19.一种制造如权利要求1到12中任一项所述的复合层压制品结构的方法，其特征在于，所述复合层压制品的各层具有加强相和基质树脂相，该方法这样来制造所述撞击指示物：将所述复合层压制品的边缘插入凹形模具；在所述边缘和所述凹形模具之间提供间隙；加热所述复合层压制品从而使所述基质树脂相流入所述间隙中，形成所述撞击指示物。
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