CN102006993A - 用于制造在两侧带有覆盖层的芯复合部件的方法 - Google Patents

用于制造在两侧带有覆盖层的芯复合部件的方法 Download PDF

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CN102006993A
CN102006993A CN2009801131074A CN200980113107A CN102006993A CN 102006993 A CN102006993 A CN 102006993A CN 2009801131074 A CN2009801131074 A CN 2009801131074A CN 200980113107 A CN200980113107 A CN 200980113107A CN 102006993 A CN102006993 A CN 102006993A
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core
folded form
honeycomb core
cover layer
form honeycomb
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CN102006993B (zh
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迈克尔·科拉克斯
沃尔夫-迪特里希·多尔辛斯基
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Airbus Operations GmbH
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Abstract

本发明涉及一种用于制造平坦的、单次或两次弯曲的芯复合部件(1，23)的方法，该芯复合部件具有至少一个折叠型蜂窝芯(4，19)。在折叠型蜂窝芯(4，19)的贯通的、有排水能力的通道(5，6)中，在涂覆最初还未硬化的覆盖层(2，3，13，22)之前，引入硬化的并且稍后可移除的芯填料(15，16)，以便在覆盖层(2，3，13，22)的布置和/或硬化的情况下防止覆盖层(2，3，13，22)渗入折叠型蜂窝芯的通道(5，6)中并且实现芯复合部件(1，23)的无边棱或无多边形的表面。

Description

用于制造在两侧带有覆盖层的芯复合部件的方法
技术领域
本发明涉及一种用于制造芯复合部件的方法，该芯复合部件具有在两侧带有覆盖层的折叠型蜂窝芯，其中折叠型蜂窝芯具有平行于覆盖层延伸的有排水能力的通道。
背景技术
在飞机制造业中以卷绕方法分开制造CFK-夹层-机舱。为此使用的芯复合部件利用具有小容积的小室的蜂窝芯构成，以便避免涂覆的覆盖层在蜂窝的区域中发生凹陷以及由此避免受限制的、特别是结构性的、气体动力学的和光学的缺陷。
这种小室状的蜂窝芯不适合于卷绕用于现代的大型客机的一个整体式的机身部段。一方面，所使用的蜂窝芯缺乏排水能力。由此，渗入芯复合部件中的和/或在芯复合部件内部产生的冷凝水可能导致例如通过在很高的飞行高度中的结冰过程而引起的巨大的损害，这可能显著地损害在日常的飞机运行中的结构性的强度并且因此成为不合理的安全风险。另一方面，蜂窝芯的小容积的小室结构使得重量增大。此外，利用蜂窝芯，相对于平行于覆盖层作用的负载，仅仅可以困难地调节各向异性的性能，从而即使当完全仅仅在非常狭窄的界限中，也可以实现常规地利用蜂窝芯构成的芯复合部件的负载流量合适的设计方案。
在这里，作为补救办法，提出了带有贯通的通道的、有排水能力的折叠型蜂窝芯。通过该通道确保将水快速和安全地导出。此外，例如通道的梯形的或蜿蜒曲折形的取向允许了折叠型蜂窝芯的与蜂窝芯相比在负载流量方面改进的设计方案。此外，这种折叠型蜂窝芯可以单次或两次弯曲地设计，从而原则上可以制造完整的机身部段或者至少可以在形成多个纵缝的情况下制造用于接合机身部段的壳形区段。
然而，这样的折叠型蜂窝芯仅仅是困难地能卷绕和/或铺设覆盖层，这是因为在此未产生至少逐段连续弯曲的表面，而是产生了一个具有多个多部分的多边形特征的表面几何形状。然而，具有这样的不连续的表面几何形状的芯复合部件出于各种原因不能用于飞机的机身部段的蒙皮。因为带有边棱的表面使得特别是利用该芯复合部件制成的部件的气体动力学的性能变差并且与平坦的结构相比还导致了大大降低的机械的结构负荷能力。
由以前公开的DE 10 2006 050 823 A1已知了一种复合部件，其由此制成：在支承结构上涂覆至少一个纤维层；将填料引入支承结构的至少一个空腔中；将基体材料注入纤维层中；使纤维增强层硬化；以及从至少一个空腔中移除填料。
由DE 10 2005 016 654 A1已知了一种用于吸收声音的内衬的夹层元件，具有在两个覆盖层之间的设计成三维形式的芯结构，其中芯结构和/或覆盖层至少局部地具有用于传输声音的通路，其中在至少一个覆盖层的区域中，至少局部地布置了吸收声音层。
由DE 10 2006 056 353 B3已知了一种用于制造用于芯复合部件的折叠型蜂窝芯的方法，该方法具有以下步骤：提供具有软化温度的表面材料；将表面材料在预定的折叠线的区域中局部地加热到至少软化温度；以及将表面材料沿着折叠线的加热的区域折叠成折叠型蜂窝结构。
由DE 843 890 B已知了一种板状的空心体，其具有多个由含有层状的、可热硬化的树脂的纤维制成的纵向壁和横杆，其中每个横杆属于具有通道或空腔的多个主体中的至少一个，这些主体由折叠的或卷绕的纤维组成并且借助于可热硬化的树脂与纵向壁连接，以及在制造时，层状的纵向壁和横杆在热作用期间经受了在其厚度方向上的压力，从而产生了一个紧凑的、坚硬和均匀的整体。
发明内容
因此，本发明的目的在于提出一种用于制造芯复合部件的方法，该方法没有前述的缺点。
该目的通过一种根据权利要求1所述的方法实现。从属权利要求的内容是该方法的优选的实施方式。
根据本发明的方法具有以下步骤：
a)在工具上布置利用湿的预浸料-材料形成的下部的覆盖层；
b)将芯填料至少局部地引入折叠型蜂窝芯中；
c)在下部的覆盖层上布置至少一个折叠型蜂窝芯；
d)将预浸料-材料布置在折叠型蜂窝芯上以形成上部的覆盖层；
e)在应用压力和/或温度的情况下使整个芯复合部件硬化；和
f)移除该芯填料。
在方法步骤a)中，将“湿的”、也就是说利用可硬化的塑料材料浸透的、预浸渍的增强纤维布置(所谓的“预浸料”-材料)取决于工具几何形状布置或放置或展开在工具上，用于制成稍后的芯复合部件的下部的覆盖层。在此通过工具的表面几何形状预定了稍后的芯复合部件的形状。步骤a)和b)的顺序在一定条件下也可以交换。作为预浸料-材料，例如可以使用渗透了可硬化的环氧树脂的碳纤维织物、碳纤维针织物、或碳纤维无卷曲材料，其可以具有带状的或轨道状的几何形状。
随后或者提前地，在步骤b)中将芯填料至少局部地引入折叠型蜂窝芯中。由此实现了，即在折叠型蜂窝芯的一侧或两侧上为了产生覆盖层而涂覆的预浸料-材料在形成槽的情况下不卷入折叠型蜂窝芯的大容积的、贯通的通道(空穴)中(所谓的“暴露”)，从而使稍后的芯复合部件在气体动力学、静力学和光学方面具有理想的、也就是说首先是平滑的、连续弯曲的(无多边形的)表面。
在方法步骤c)中，将至少一个折叠型蜂窝芯安放在已经放置在工具上的下部的覆盖层上。折叠型蜂窝芯与常规的蜂窝芯相反不具有封闭小室形式的重复单位，而是具有贯通的通道。这种贯通的通道例如可以具有蜿蜒曲折形的、弯曲形的或梯形的取向并且能够实现芯的排水能力。通过合适地折叠最初的平坦的下料(Zuschnitten)，折叠型蜂窝芯可以具有单次的或两次的弯曲部，因此折叠型蜂窝芯可以以理想的方式匹配于飞机机舱的预定的表面几何形状。折叠型蜂窝芯可以利用任意的增强纤维布置或纸张来制造，其利用热固性的(可硬化的)塑料材料进行浸渍(浸透，渗透)，该塑料材料在根据本发明的应用时已经完全硬化，以便确保在处理期间的必需的固有硬度。用于实施当前方法的折叠型蜂窝芯例如可以利用已知的Nomex
Figure BPA00001237989900041
-纸张或另一种渗透了适合的环氧树脂、酚醛树脂或聚酯树脂的碳纤维织物、碳纤维无卷曲材料或玻璃纤维织物来制成。可替换地，折叠型蜂窝芯也可以利用金属薄膜构成。
此外可能的是，首先将折叠型蜂窝芯以不含有各种芯填料的形式安放在下部的覆盖层上并且随后将芯填料至少局部地引入到折叠型蜂窝芯的还可触及的上侧。对于这种情况，即应用旋转的卷绕心轴(“阳性”-工具)作为工具，芯填料可以借助于通向旋转的折叠型蜂窝芯的、具有用于填料的集成的定量给料装置的刮铲进行涂敷和处理平滑。在芯填料硬化之后，跟随的是方法步骤d)。
在方法步骤d)中，将另外的预浸料-材料布置在折叠型蜂窝芯上以形成芯复合部件的上部的覆盖层。预浸料-材料可以以狭窄的带形式或作为宽轨道形的半成品进行处理。在旋转的卷绕心轴作为工具的情况下，优选为带状的预浸料-材料随后可以以层形式地卷绕在旋转的折叠型蜂窝芯上。由于芯填料，确保了至少是上部的覆盖层的无多边形的布置。
在方法步骤e)中，通过应用压力和/或温度，在应用了已知的硬化程序的情况下，使整个芯复合部件最后实现硬化。
在最后的方法步骤f)中，将芯型完全从折叠型蜂窝芯中移除，以便减少制成的芯复合部件的重量并且再次产生排水能力。如果作为芯填料例如使用了材料“Aqua-Core”，则硬化的芯填料可以简单地利用作为溶剂的水完全地从有排水能力的折叠型蜂窝芯中冲洗出来。原则上，也可以在合适的温度时使用熔化的蜡和/或金属合金作为芯填料。
根据该方法的一个有利的设计方案，将下部的和/或上部的覆盖层利用粘合剂与折叠型蜂窝芯至少局部地粘合。
由此防止了折叠型蜂窝芯的覆盖层的脱落并且提高了损坏公差以及芯复合部件的负载能力。如果用于制造覆盖层的“预浸料”-材料的利用可硬化的塑料材料(热固性塑料)、特别是环氧树脂、聚酯树脂、酚醛树脂或BMI-树脂的浸透可能不足以实现将覆盖层以能够充分负载的、带粘性的方式连接到折叠型蜂窝芯上，则这种操作方式可能是必需的。
根据本发明的方法的另一个设计方案设计为，将折叠型蜂窝芯的上侧和/或下侧这样地填满芯填料并且成型，即出现了芯复合部件的在其上布置的稍后的覆盖层的无多边形的外轮廓和内轮廓。
由此实现了稍后的芯复合部件的无边棱的上侧和/或下侧，其具有最佳的结构机械的和气体动力学的以及美观的性能。因此，根据本发明制成的芯复合部件可以在不需要附加的和可能提高重量的精整步骤、如磨平、磨光等等的情况下直接用于制造机身部段或飞机的另外的主要结构部件。
为了获得芯复合部件的平滑的和连续的上侧和下侧所需要的、被引入的芯填料的造型例如可以通过(视芯复合部件的期望的几何形状而定)平坦的以及单次的或球形的(两次的)弯曲的压板或工具实现。此外可能的是，对已经略微被拉动的芯填料通过合适的拆卸工具进行平整和造型，其中这种方法可以有利地特别在已经放置在旋转的卷绕心轴上的折叠型蜂窝芯中应用。
根据另一个有利的改进方案设计为，工具是旋转的卷绕心轴，在该卷绕心轴上层状地展开了预浸带材料以形成至少一个覆盖层。
由此可能的是，在应用有排水能力的折叠型蜂窝芯的情况下，将用于大飞机的完整的机身部段与芯复合部件制成一个整体。在这种情况下通常值得推荐的是应用多个彼此对接的、预先制成的、带有相应的自身弯曲部的折叠型蜂窝芯，它们接合在接缝处以实现机械的连接。
可替换地，用于实施该方法的工具也可以具有平坦的、一维的或二维的弯曲的表面几何形状(球形弯曲的或单轴弯曲的)。在这种情况下可以制造例如用于飞机的机身部段的壳形区段或板状的部件。飞机机身部段随之在常规的铝结构形式的情况下在飞机制造业中由多个壳形区段在形成纵缝的情况下接合起来。
该方法的另一个改进方案设计为，借助于工具为芯复合部件提供了壳形区段形状的几何形状，用于制造机身部段。
通过平坦的、单次的或两次的(球形的)弯曲的工具可以借助于该方法将用于制造飞机机身部段的壳形区段制造为芯复合部件，其中各自的机身部段随后通过多个壳形区段的接合，在形成纵缝的情况下制成。利用平坦的工具可以在一定条件下也利用该方法制成板状的、不弯曲的芯复合部件。
附图说明
本发明的其它特征和优点由下面对优选实施例的参照附图的说明给出。
图1在透视图中示意性地示出了按照根据本发明的方法制造的、具有折叠型蜂窝芯的芯复合部件。
图2至5分别示意性地示出了根据本发明的方法流程的实施方式。
具体实施方式
图1示出了按照根据本发明的方法制造的、具有夹层结构的芯复合部件，其在空间方向上具有弯曲部。两个覆盖在折叠型蜂窝芯两侧的覆盖层仅仅被示出轮廓，然而其余部分显示为透明的，以便露出折叠型蜂窝芯的内部构造。
芯复合部件1具有上部的覆盖层2和下部的覆盖层3，在这些覆盖层之间布置了折叠型蜂窝芯4。覆盖层2，3和折叠型蜂窝芯4都在空间方向上弯曲。原则上可以利用该方法制成具有非常高负载能力的、平坦的、单次或两次(球形的)弯曲的芯复合部件。折叠型蜂窝芯4具有多个平行布置的、贯通的和梯形延伸的(排水-)通道5，6。通道5，6通过基线7至9以及顶点线10至12限定，其同样示出梯形取向。通道5，6原则上也可以具有大约是矩形的、梯形的或波形的(正弦形的)取向。
在进一步的描述中根据图2至5同时使用标号进一步说明制造方法的流程。
首先根据图2在步骤a)中，将下面的、还是“湿的”覆盖层13涂覆在工具14上。下部的覆盖层13利用任意的、利用可硬化的塑料材料进行预浸渍的增强纤维布置、例如浸透了环氧树脂的碳纤维织物或碳纤维无卷曲材料(“预浸料”-材料)构成。该“预浸料”-材料可以轨道形地放置在工具14上或在转动的、然后基本上旋转对称的工具14的情况下也卷绕到该工具上。在足够狭窄的带形的“预浸料”-材料的情况下，其也可以布置在TFP-(合适的纤维布置-)布置过程中。工具14的表面几何形状至少限定了稍后的芯复合部件的内部造型。
在另一个方法步骤b)中(见图3)，将可移除的芯填料15，16引入折叠型蜂窝芯19的上侧17和下侧18中，其中折叠型蜂窝芯19已经在制造厂商方面这样预先成型，即折叠型蜂窝芯相应于稍后的芯复合部件的预定的额定几何形状。在此需要考虑，即外轮廓20和内轮廓21连续弯曲(也就是说平滑)并且无多边形地形成期望的额定几何形状，随后得到要制造的芯复合部件。芯填料15，16可通过溶剂或在一定条件下通过熔化再次从折叠型蜂窝芯19中移除。
将芯填料15，16至少局部地引入折叠型蜂窝芯19的一侧或两侧，这例如可以通过利用合适的工具拉动还未完全硬化的芯填料15，16实现。作为芯填料15，16例如可以使用水溶性的材料“Aqua-Core
Figure BPA00001237989900091
”。通过芯填料15，16，覆盖层的拉入(所谓的“暴露”)在折叠型蜂窝芯19的相对大容积、贯通的通道中被阻止。由此在可实现的静力学的硬度方面得到了气体动力学的性能以及稍后的芯复合部件两侧最佳性能的外部的视觉效果。
在步骤c)中，如在图4中所示，将至少一个在步骤b)中预备的或准备的折叠型蜂窝芯19放置在下面的、已经安放在工具14上的覆盖层13上。
可替换地，当限制了将芯填料15，16引入折叠型蜂窝芯19的上侧时，至少局部地引入芯填料15，16以及它们的轮廓形成或造型也仅仅在该方法步骤中实现。
在步骤d)中，如在图5中所示，将用于形成完整的芯复合部件23的第二个上部的覆盖层22布置在折叠型蜂窝芯19上。该上部的覆盖层22也利用合适的湿的“预浸料”-材料通过放置或卷绕(假设有相应的工具14)制造。
按照方法步骤e)，借助于常规的方法、例如在压煮器中在同时使用压力和温度的情况下实现了芯复合部件23的硬化，其中可以利用真空薄膜覆盖该结构。
可替换地也可以在大气压力下实现硬化。在这种情况下，工具14例如可以可电加热的设计。为了实现芯复合部件23的均匀和快速的硬化，上部的覆盖层22可以利用跟随芯复合部件的期望的外部几何尺寸的、同样优选地也是可电加热的工具而压在折叠型蜂窝芯19上。
最后的方法步骤f)涉及了从制成的、硬化的芯复合部件23中移除芯填料15，16，这例如可以通过利用合适的溶剂溶解或通过熔化实现。
不同于工具14的四分之一圆形的横截面几何形状，其例如也可以设计为卷绕心轴，带有大约圆形的、椭圆形的、卵形的横截面形状或任意弯曲的横截面几何形状以用于卷绕或放置覆盖层13，22以及至少一个折叠型蜂窝芯19。原则上，工具14可以为了制造板状的芯复合部件而也具有平坦的形状。
根据本发明的方法提出了轮廓准确、特别是无多边形地制造特别是单次或两次弯曲的芯复合部件。原则上，整个飞机机身部段可以和这样的芯复合部件制成一个整体，其中可以基于芯复合部件的高的自身硬度至少逐段地取消利用纵梁和/或环形隔壁的附加的紧固。
可替换地也可以制成至少两个具有芯复合部件的壳形区段，其随后与完整的机身部段沿着纵缝彼此连接。
参考标号表
1芯复合部件                23芯复合部件
2上部的覆盖层(芯复合部件)
3下部的覆盖层(芯复合部件)
4折叠型蜂窝芯
5通道(有排水能力的)
6通道(有排水能力的)
7基线
8基线
9基线
10顶点线
11顶点线
12顶点线
13下部的覆盖层(芯复合部件)
14工具
15芯填料
16芯填料
17上侧(折叠型蜂窝芯)
18下侧(折叠型蜂窝芯)
19折叠型蜂窝芯
20外轮廓(折叠型蜂窝芯)
21内轮廓(折叠型蜂窝芯)
22上部的覆盖层(芯复合部件)

Claims (9)

1.一种用于制造芯复合部件(1，23)的方法，所述芯复合部件具有在两侧带有覆盖层(2，3，13，22)的折叠型蜂窝芯(4，19)，其中所述折叠型蜂窝芯(4，19)具有平行于所述覆盖层(2，3，13，22)的延伸的有排水能力的通道(5，6)，所述方法具有以下步骤：
a)在工具上布置利用湿的预浸料-材料形成的下部的覆盖层(3，13)；
b)将芯填料(15，16)至少局部地引入所述折叠型蜂窝芯(4，19)中；
c)在所述下部的覆盖层(3，13)上布置至少一个折叠型蜂窝芯(4，19)；
d)将所述预浸料-材料布置在所述折叠型蜂窝芯(4，19)上以形成上部的覆盖层(2，22)；
e)在应用压力和/或温度的情况下使整个所述芯复合部件(4，19)硬化；和
f)移除所述芯填料(15，16)。
2.根据权利要求1所述的方法，其特征在于，将所述下部的和/或所述上部的覆盖层(2，3，13，22)利用粘合剂与所述折叠型蜂窝芯(4，19)至少局部地粘合。
3.根据权利要求1或2所述的方法，其特征在于，将所述折叠型蜂窝芯(4，19)的上侧(17)和/或下侧(18)这样地利用所述芯填料(15，16)填满并且成型，即出现了布置的所述覆盖层(2，3，13，22)的无多边形的外轮廓和内轮廓(20，21)。
4.根据权利要求1至3中任一项所述的方法，其特征在于，所述工具(14)是旋转的卷绕心轴，在所述卷绕心轴上展开了所述预浸料-材料以形成至少一个覆盖层(2，3，13，22)。
5.根据权利要求1至4中任一项所述的方法，其特征在于，借助于所述工具(14)为所述芯复合部件(1，23)提供了基本上为壳形区段形状的几何形状，特别用于制造飞机机身部段。
6.根据权利要求1至5中任一项所述的方法，其特征在于，借助于所述卷绕心轴为所述芯复合部件(1，23)提供了基本上为空心圆柱形的几何形状，特别用于一个整体式的飞机机身部段。
7.根据权利要求1至6中任一项所述的方法，其特征在于，将利用可硬化的塑料材料、特别是利用环氧树脂进行预浸渍的、带有增强纤维、特别是碳纤维的半成品应用为预浸料-材料，其中进行预浸渍的所述半成品在处理之后、特别是在展开和/或放置之后才硬化。
8.根据权利要求1至7中任一项所述的方法，其特征在于，至少一个折叠型蜂窝芯(4，19)利用最初是平坦的平面的增强布置形成，所述增强布置利用可硬化的塑料材料进行浸渍并且多次折叠。
9.根据权利要求1至8中任一项所述的方法，其特征在于，通过熔化或通过利用溶剂的溶解从所述折叠型蜂窝芯(4，19)中移除所述芯填料(15，16)。
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