CN101835602A - 制造复合材料的加强面板的方法 - Google Patents

制造复合材料的加强面板的方法 Download PDF

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CN101835602A
CN101835602A CN200880113008A CN200880113008A CN101835602A CN 101835602 A CN101835602 A CN 101835602A CN 200880113008 A CN200880113008 A CN 200880113008A CN 200880113008 A CN200880113008 A CN 200880113008A CN 101835602 A CN101835602 A CN 101835602A
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synusia
stiffening element
composite
panel
groove
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CN101835602B (zh
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拉里·J·阿什顿
迈克尔·G·阿尔曼
特洛伊·L·怀特
本科·S·塔阿拉
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Spectrum Aeronautical LLC
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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
    • B29C66/50—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
    • B29C66/63—Internally supporting the article during joining
    • 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
    • B29C70/02—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers
    • B29C70/021—Combinations of fibrous reinforcement and non-fibrous material
    • B29C70/023—Combinations of fibrous reinforcement and non-fibrous material with reinforcing inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • B29C66/01—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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    • B29C66/40—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
    • B29C66/438—Joining sheets for making hollow-walled, channelled structures or multi-tubular articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
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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
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    • B29C66/636—Internally supporting the article during joining using a support which remains in the joined object
    • 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
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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
    • B29C66/70—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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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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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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    • 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
    • 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
    • B29C66/7394—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 thermoset
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91411—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the parts to be joined, e.g. the joining process taking the temperature of the parts to be joined into account
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91431—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature the temperature being kept constant over time
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/92—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools
    • B29C66/924—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools
    • B29C66/9241—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force or the mechanical power
    • 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
    • B29C66/90—Measuring or controlling the joining process
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    • B29C66/929—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools characterized by specific pressure, force, mechanical power or displacement values or ranges
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/94—Measuring or controlling the joining process by measuring or controlling the time
    • B29C66/949—Measuring or controlling the joining process by measuring or controlling the time characterised by specific time values or ranges
    • 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
    • B29C70/30—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
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    • B29D99/0014—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings provided with ridges or ribs, e.g. joined ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

一种用于制造由复合材料制成的刚性面板的方法，其需要具有光滑表面的垫板，该光滑表面形成有多个凹槽。第一层复合材料放置在垫板上，且进行切割而形成延伸入相应凹槽中的翼片。复合材料条带然后沿凹槽的边缘定位，以便在凹槽中延伸且彼此交叠。接下来，单向层片沿凹槽的长度放置，且该组合然后由第二层复合材料覆盖。第一层和第二层、条带和单向层片的组合在一起共同固化，以便形成具有一体式加劲构件的刚性面板。

Description

制造复合材料的加强面板的方法
发明领域
本发明主要涉及由复合材料制成的坚硬且刚性的面板。更具体而言，本发明涉及具有由用来制造面板的相同复合材料制成的加劲构件的刚性面板。本发明尤其但非排他地用作加强面板及其制造方法，其中，加劲构件为基部面板的结构性延续部。
发明背景
在过去的几年间，使用复合材料制造结构部件取得了较大的发展。具体而言，由碳纤维和环氧树脂制成的复合材料已经成功地用来制造各种类型的交通工具(例如，汽车、船舶和飞机)。在某种程度上，这种情况的发生是由于这些材料的重量相对较轻，且它们在张力和压缩方面表现出很高的强度。它们还相当耐破坏和抗穿刺。此外，它们禁止水分迁移。尽管有这些许多优点，但当复合材料制造成面板且它们没有适当的支承时，它们就易弯曲，并且会松软。
从结构观点看来，公知的是可通过将材料添加到横梁的弯曲平面上来提高横梁抗弯曲的能力。工字梁在这里就是一个好的例子，并且在许多方面，面板基本上都是相同的。例如，当力只对准面板上材料所处的面板位置时，面板就表现出很高的抗弯强度。另一方面，面板在其所受力的方向横切于面板平面时就趋于起皱和滑移。在该后一种情况下，面板中没有材料可有效地对力作出反应。这里的解决方案在于通过将反应材料定位成离面板平面一定距离来加强面板。
加强和加固复合材料面板的早期尝试通常涉及使用由该材料制成的隔离层。更具体而言，这些层通过蜂窝构造进行保持和与彼此间隔开。尽管大体上是有效的，但这些加强复合材料面板易于经受复合材料层和蜂窝构造之间的分离。众所周知，此类分离将使面板变弱。还会发生的是，此类面板会变为多孔的，且因此易于经受穿过结构的水分迁移。在交通工具的情形中，这种水分迁移会导致其它结构部件的腐蚀，这可不利地影响交通工具的工作。
鉴于上文，本发明的一个目的在于提供一种由复合材料制成的加强面板及其制造方法，其中，该面板为刚性且坚硬的。本发明的另一个目的在于提供一种抵抗材料分离的加强面板及其制造方法，材料分离否则将会降低面板的结构强度。本发明的又一个目的在于提供一种加强面板及其制造方法，其中，该面板为无孔的，且有效地防止面板中的水分迁移。本发明的又一个目的在于提供一种用于制造加强面板的方法，该面板完全由复合材料制成，其中，该方法易于执行且成本效益合算。
发明概述
根据本发明，用于制造加强面板的方法需要使用垫板。重要的是，垫板需要形成有作为加强面板所期望的表面的镜像(即，负片)的表面。对于本发明而言，垫板将具有大致光滑的表面，其可为弯曲或平坦的，且表面将形成有多个大致平直的凹槽。更具体而言，各凹槽将具有第一边缘和第二边缘。每个边缘还将具有长度“l”和深度“h”。如本发明所设计的，第一组多个大致平行的凹槽定向为在垫板的表面上横切于第二组多个大致平行的凹槽。利用此定向，凹槽就为加强面板的加劲构件形成了等距网格(isogrid)。
为了制造加强面板，将第一层复合材料放置在垫板的表面上。最初，该第一层跨置(即，在上方延伸)在垫板的凹槽上。然而，一旦就位，第一层然后就在其中间跨距处沿每个凹槽发长度“1”切开。结果是，翼片就形成在第一层中，该第一层从相应凹槽的相对边缘延伸。这些翼片然后沿凹槽的第一边缘和第二边缘折入凹槽中。
在翼片已经折入垫板上的各凹槽中之后，复合材料条带就沿凹槽的第一边缘定位。该条带从垫板的表面延伸到凹槽中。条带还在先前折入凹槽中的翼片上延伸。重要的是，条带需要延伸超过翼片，更具体而言是其需要延伸超过凹槽底部处的中点。另一复合材料条带然后沿每个凹槽的第二边缘定位。像第一条带一样，第二条带也从垫板的表面延伸到凹槽中。其也在先前折入凹槽中的翼片上延伸，且延伸超过翼片。最重要的是，该第二条带需要延伸超过凹槽底部处的中点，直到其与第一条带交叠。然后将尼龙管沿其整个长度“l”放置到每个凹槽中。
单向层片(ply)(即，其所有丝束均大致平行于彼此的层片)位于在凹槽中适当位置上的尼龙管上。重要的是，单向层片的放置使得其丝束沿凹槽的长度对齐。此外，单向层片放置成其将与已经分别沿凹槽的相对边缘定位的条带接触。第二层复合材料然后放置在垫板上的第一层复合材料上。此布置还覆盖了单向层片。因此，单向层片、尼龙管和条带全部都位于第一层复合材料与第二层复合材料之间。这些复合材料部件的组合然后准备进行共同固化。
本发明的备选实施例中，使用了附加的单向层片。这里的目的在于将两个不同的单向层片定位成大致与彼此隔开距离“h”，以便交替地抵抗加强面板弯曲期间所产生的张力。为了制造该实施例，基部单向层片沿凹槽的底部放置。该布置可在第一层复合材料放置在垫板表面上之前完成。在此情况下，在翼片已经形成之后，它们就分别折入凹槽中，以便与预先放置的基部单向层片交叠。作为备选，可首先形成翼片，且如上文所公开的折入凹槽中。基部单向层片然后放置到凹槽底部中，以便与先前折叠的翼片交叠。在任一情况下，条带、尼龙管和第一层中的单向层片随后都将如上文所公开的那样构造。
在固化过程期间，复合材料部件的组合被定位在垫板与基部构件之间。它们然后经受在大约30psi至大约100psi之间的范围内的压力。同时，以在大约30psi至大约100psi之间的范围内的压力对位于垫板的凹槽中的尼龙管施压。在这些相应的压力得到保持的同时，在200°F至300°F之间的范围内的温度下对复合材料部件的组合进行固化。此固化将延续一定时间周期，该时间周期持续大约120分钟。在完成固化过程时，就除去垫板和基部构件，而加强面板就已经制成。
需要注意用于本发明的复合材料的一些附加方面。首先，复合材料优选为由环氧树脂中的碳纤维制成。更具体而言，这些纤维合并成通常称为“丝束”的东西。就上文所公开的单向层片而言，丝束大致彼此平行地对齐。另一方面，本发明的其它复合材料部件(如第一层和第二层，以及条带)中的丝束是以定向为横切于彼此的相应多根丝束制成。多根丝束之间的定向角可根据所期望的结果而变化。在任何情况下，丝束通常定向成提供在所期望的方向范围内的最大实用抗拉强度。
附图说明
本发明的新颖特征以及本发明自身两者均关于其结构及其操作，这将从结合所附描述的附图中最佳地理解到，在附图中，相似的附图标记表示类似的部分，并且在附图中：
图1为根据本发明由复合材料制成的加强面板的透视图；
图2为用于制造根据本发明的加强面板的垫板的一部分的透视图；
图3A至图3F共同地呈现了沿图1中的线3-3看到的截面内的一系列透视图，示出了在制造根据本发明的加强面板期间将复合材料层放置在垫板上的顺序步骤；
图4为在图3E中所示的步骤中使用的单向层片的透视图，为了清楚起见，截取了一部分；
图5为准备固化的复合材料部件的组件的透视图；
图6为如沿图1中线3-3看到的，用于根据本发明的由复合材料制成的加强面板的加劲构件的截面透视图；
图7A至图7B为如沿图1中的线3-3看到的截面透视图，示出了在制造根据本发明的加强面板备选实施例期间使用基部单向层片的步骤；以及
图8为如沿图1中线3-3看到的根据本发明的由复合材料制成的加强面板加劲构件的备选实施例的截面透视图。
具体实施方式
首先参看图1，示出了根据本发明制造的加强面板，且其大体上指定为10。在图1中，可看到的是，加强面板10包括具有表面14的基层12。就本发明而言，表面14可为弯曲或平坦的。此外，图1示出了面板10包括第一组多个加劲构件16，其中的加劲构件16a和16b仅为示例性的。而且，图1示出了面板10包括第二组多个加劲构件18，其中的加劲构件18a和18b也仅为示例性的。如图所示，第一组多个加劲构件16大致彼此平行。同样，第二组多个加劲构件18也大致彼此平行。如图所示，加劲构件16定向为横切于加劲构件18，它们之间的角为“α”。当角“α”为直角时，多个加劲构件16，18就形成正交网格。当角“α”为锐角时，多个加劲构件16，18就形成等距网格。
仍参看图1，且具体参看加劲构件16a，应当认识到，所有加劲构件16，18将分别包括基部20，且该基部20定位成离基层12的表面14有距离“h”。此外，每个加劲构件16，18形成有一对相对的支腿22a和22b，支腿22a和22b从基部20延伸至相应的边缘24a和24b。这些支腿22a和22b分别附接到基层12的表面14上，且它们在其间限定通道26。
图2中示出了垫板28的一部分。如本领域的技术人员所认识到的，整个垫板28可相当大，且如上文所述，可为多种构造中的任何一种。然而，图2中示出的垫板28的部分就足够用于本公开内容的目的。出于此目的，所示的垫板28形成为具有凹槽30，凹槽30具有相对的边缘32a和32b，其分别标记从垫板28的表面34至凹槽30的过渡部分。如上文所提到的，实际上很可能有多个此类凹槽30。图2还示出了凹槽30具有宽度“w”和深度“h”。此外，图2指出了凹槽30具有长度“l”，该长度由垫板28的要求确定。
现在参看图3A至图3F，按照它们被执行的次序示出了用于制造加强面板10的顺序步骤。从图3A开始，复合材料的第一层36制造成覆盖垫板28的表面34。最初，第一层36跨置在凹槽30上。然而，一旦形成第一层36，其就沿虚线38切开。更具体而言，是在凹槽30的跨距中心处且沿凹槽30的整个长度“l”进行此切割。结果是，形成了图3B中所示的翼片40a和40b。如图3B中所示，翼片40a和40b两者均在相应边缘32a和32b处折叠，且向下折入凹槽30中。
图3C示出了在翼片40a和40b已经折入凹槽30之后，复合材料的条带42a和42b沿凹槽30的相应边缘32a和32b定位。条带42a和42b然后在翼片40a和40b上折叠。更具体而言，在这样折叠时，每个条带42a和42b延伸到了凹槽30中，且越过凹槽30底部处的中点。这里重要的是条带42a和42b的端部彼此交叠。接下来，如图3D中所示，尼龙管44然后放置到形成在凹槽30中的通道26内。应当认识到的是，层片(未示出)可加到管子44周围，以提供额外的强度。
在尼龙管44放置到通道26中之后，单向层片46就放置到管子44的顶部上，以便大致如图所示地跨过凹槽30。如本发明所意图的，该单向层片46由复合材料制成，且包括大量丝束48，这些丝束48全部都彼此平行地相互对齐(见图4)。重要的是，当层片46放下时，丝束48就沿凹槽30的长度“l”对齐。如图3F中所示，复合材料的第二层50然后放在层片46上。具体而言，除覆盖层片46之外，该第二层50还覆盖整个垫板28。结果是，复合材料构件的组合(即，第一层36、条带42a和42b、层片46和第二层50)将共同固化，以形成加强面板10。
图5示出了一旦复合材料部件(即，第一层36、条带42a和42b、层片46和第二层50)的组合已经组装好，其定位在垫板28与基部构件52之间。然后，其在垫板28与基部构件52之间受到在大约30psi与大约100psi之间的范围内的压力的压制。同时，对在层片46与条带42a和42之间的通道26中的尼龙管44以大约30psi与大约100psi之间的范围内的压力施压。当施加这些压力时，复合材料部件(即，第一层36、条带42a和42b、层片46和第二层50)的组合就在200°F至300°F之间的范围内的温度下固化持续大约120分钟的时段。这里应当注意的是，在固化之后，尼龙管44就保持与面板10结合。还应当注意的是，尽管层片46为单向复合材料(即，其丝束48相互平行)，但用于第一层36、条带42a和42b和第二层50的复合材料将通常并非为单向的。作为替代，它们将分别具有横切于彼此(例如，以90°)延展的第一组多根丝束和第二组多根丝束。
图6示出了在其制造之后的加强面板10的一部分。如图6中所示，且交叉参看图5而最佳认识到的，基层12是第一层36与第二层50共同固化的结果。同时，条带42a和42b，以及翼片40a和40b的共同固化形成了加劲构件16。同样，单向层片46与第二层50共同固化而形成层片46的一体式结构。结果是，使加强面板10具有光滑表面54，其适用于许多应用场合。如为本发明可构想出的的，表面54将用于形成飞机机身(未示出)的外部表层。
对于加强面板10及其制造方法的可替代实施例，图7A指出了基部单向层片56定位在垫板28上的凹槽30底部内。在其所有重要方面中，基部单向层片56在结构上类似于上文所公开的单向层片46。另外，与单向层片46相似，基部单向层片56定位在凹槽30中，而其丝束48大致沿凹槽30的长度“l”对齐。
在基部单向层片56如图7A中所示定位在垫板28上的情况下，翼片40a和40b折叠到凹槽30中，以便如图7B中所示的与基部单向层片56交叠。本领域的技术人员将认识到，基部单向层片56在凹槽30中的放置以及将翼片40a和40b折入凹槽30中可为相反的(即，先将翼片40a、40b折入凹槽30中，而然后将基部单向层片56放置在凹槽30中而与翼片40a、40b交叠)。在任一情况下，在第一层36中条带42a、42b的放置、尼龙管44的放置和单向层片46的放置均如上文所公开地构造。固化过程也正如上文所公开的。
上述可替代构造的结果在于大致在图8中示出的加强面板10′。重要的是，对于本发明的加强面板10′而言，面板10′的基部20中的基部单向层片56离位于基层12中的单向层片46大致有距离“h”。在结构上，该构造的结果在于，单向层片46和基部单向层片56两者均定位成交替地抵抗加强面板10′弯曲期间所产生的张力。重要的是，所提供的阻力克服了在任一相对方向上可能经受的弯曲力。
尽管本文所示和详细公开的用于制造复合材料的加强面板的特定方法完全能够达到目的且提供前文所述的优点，但应当理解的是，其仅仅示出了本发明的当前优选实施例，且除所附权利要求中所述之外，没有意图对本文所示的构造或设计的细节进行限制。

Claims (20)

1.一种用于制造用以加强由复合材料制成的面板的加劲构件的方法，其包括以下步骤：
提供具有形成有凹槽的表面的垫板，其中，所述凹槽具有第一边缘、第二边缘和预定长度“l”；
制造所述复合材料的第一层来覆盖所述垫板的所述表面，并跨置在所述凹槽上；
在跨距中心处沿所述凹槽的长度“l”切割所述第一层，以形成一对相对的翼片；
将所述第一层的所述翼片沿所述凹槽的相应的第一边缘和第二边缘折入所述凹槽；
沿所述凹槽的所述第一边缘定位所述复合材料的第一条带，以便从所述第一层延伸且进入所述凹槽中；
沿所述凹槽的所述第二边缘定位所述复合材料的第二条带，以便从所述第一层延伸且进入所述凹槽中，从而与所述第一条带交叠并与所述第一条带一起形成所述第一层的延续部；
将层片放置在所述垫板的所述表面上，其中，所述层片与所述第一条带和所述第二条带接触，以便在所述层片与所述延续部之间形成通道；以及
制造所述复合材料的第二层，以便覆盖所述第一层，而所述通道处于所述第一层和所述第二层之间，以构造用于加强所述面板的所述加劲构件。
2.根据权利要求1所述的方法，还包括以大约30psi至大约100psi之间的范围内的压力压制所述垫板与基部构件之间的所述面板的步骤。
3.根据权利要求2所述的方法，还包括将尼龙管放置在所述层片与所述延续部之间的所述通道中的步骤。
4.根据权利要求3所述的方法，还包括在所述压制步骤期间以大约30psi至大约100psi之间的范围内的压力对所述尼龙管施压的步骤。
5.根据权利要求4所述的方法，还包括在大约200°F至300°F之间的范围内的温度下以持续大约120分钟的时段对所构造的面板进行固化的步骤。
6.根据权利要求1所述的方法，其中，所述层片为具有多根丝束的单向复合材料，所述复合材料的丝束大致沿所述凹槽的长度对齐。
7.根据权利要求1所述的方法，其中，所述复合材料由碳纤维和环氧树脂制成。
8.一种用于制造由复合材料制成的加强面板的方法，包括以下步骤：
形成由所述复合材料制成的基层，所述基层具有表面；
将细长的单向层片嵌入所述基层中，其中，所述层片由所述复合材料制成，且具有多根大致平行的丝束，并且其中，所述层片沿预定路径放置在所述基层的所述表面上，而所述丝束在所述路径上大致对齐；
沿所述路径定位加劲构件，其中，所述加劲构件具有大致为U形的截面，并具有基部和一对大致平行且相对的支腿，所述支腿从所述基部延伸至相应边缘以限定所述支腿之间的通道，其中，所述加劲构件的每个边缘一体地附接到所述基层的所述表面，以便将所述加劲构件的所述基部定位成与所述基层中的层片相距距离“h”；
将细长的基部单向层片放置在所述加劲构件的所述基部中；以及
共同固化所述基层、所述层片和所述加劲构件来制造所述面板。
9.根据权利要求8所述的方法，其中，对多个层片实施所述嵌入步骤，以及对相应的多个加劲构件实施所述定位步骤。
10.根据权利要求9所述的方法，其中，第一组多个层片及其相应的加劲构件横切于第二组多个层片及其相应的加劲构件。
11.根据权利要求10所述的方法，其中，所述第一组多个层片及其相应的加劲构件和所述第二组多个层片及其相应的加劲构件形成等距网格。
12.根据权利要求8所述的方法，其中，所述基层具有第一组多根丝束和定向成与所述第一组多根丝束大致成直角的第二组多根丝束。
13.根据权利要求12的方法，其中，所述单向层片的丝束定向成大致平分所述基层中的第一组多根丝束与第二组多根丝束之间的所述直角。
14.根据权利要求13所述的方法，其中，所述加劲构件的所述基部具有第一组多根丝束和第二组多根丝束，而所述第二组多根丝束定向成与所述第一组多根丝束大致成直角。
15.根据权利要求8所述的方法，其中，所述复合材料由碳纤维和环氧树脂制成。
16.根据权利要求8所述的方法，其中，在大约200°F至300°F之间的范围内的温度下以大约120分钟的持续时间实施所述共同固化步骤。
17.一种用于制造由复合材料制成的加强面板的方法，包括以下步骤：
形成多个面板部分，其中，每个面板部分均具有边界；
布置每个面板部分，使每个面板部分的边界与至少一个其它面板部分相距距离“w”，以便在其间形成间隙；
沿所述间隙定位加劲构件，其中，所述加劲构件具有大致为U形的横截面，并具有基部和一对大致平行且相对的支腿，所述支腿从所述基部延伸至相应边缘以限定所述支腿之间的通道，其中，所述加劲构件的每个边缘一体地附接到相应面板部分的所述边界上，以便将所述加劲构件的所述基部定位成与所述间隙相距距离“h”；以及
共同固化所述面板部分和所述加劲构件以制造所述面板。
18.根据权利要求17所述的方法，其特征在于，所述方法还包括沿所述间隙且跨过所述间隙定位单向层片以使相应的面板部分的相邻边界互连的步骤，其中，所述单向面板的丝束沿所述间隙延伸，且定位成与所述加劲构件的基部相距所述距离“h”，以产生对所述加劲构件中的力的反作用力来加强所述面板。
19.根据权利要求17所述的方法，其中，每个面板部分的所述边界延伸到所述加劲构件的通道中。
20.根据权利要求19所述的方法，还包括在加劲构件的所述相应边缘与相应面板部分的所述边界之间的界面处添加附加的复合材料，以便进一步加强所述面板。
CN200880113008.1A 2007-09-14 2008-09-12 制造复合材料的加强面板的方法 Expired - Fee Related CN101835602B (zh)

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