CN102006995A - 用于制造集成雷击防护材料的系统和方法 - Google Patents

用于制造集成雷击防护材料的系统和方法 Download PDF

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CN102006995A
CN102006995A CN2009801130226A CN200980113022A CN102006995A CN 102006995 A CN102006995 A CN 102006995A CN 2009801130226 A CN2009801130226 A CN 2009801130226A CN 200980113022 A CN200980113022 A CN 200980113022A CN 102006995 A CN102006995 A CN 102006995A
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layer
lightning protection
paper
inch
composite structure
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CN102006995B (zh
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A·O·沙夫
A·H·源
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Boeing Co
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Abstract

本发明涉及适于自动敷设在复合材料结构上的集成的雷击防护系统，该系统包括由有机聚合物树脂构成的铺面层、延展金属箔的导电层、隔离/附着层和载体纸层。在本发明另一实施例中，提供集成的雷击防护系统，其包括集成的雷击防护材料，所述材料由安置于载体纸上的封装在有机聚合物树脂中的延展金属箔构成，以及自动敷设机，其适于将所述材料敷设于航空器的复合材料零件上以保护该复合材料零件免于雷击影响。在本发明另一实施例中，提供用于制造具有雷击防护能力的复合材料结构的方法。

Description

用于制造集成雷击防护材料的系统和方法
技术领域
本发明提供用于制造集成雷击防护材料的系统和方法。更具体地说，本发明提供用于将集成的金属树脂雷击防护材料在复合材料结构上的自动敷设制造的系统和方法。
背景技术
航空器和航天器结构的制作开始越来越多地使用复合材料，例如碳纤维增强塑料(CERP)，而不是使用先前的铝合金和类似的金属材料，这很大程度上是因为复合材料改进了结构性能，提供了良好的强度和刚度特性，并降低了飞行器重量。但是，复合材料导电能力不如金属材料，并且抗雷击能力不如金属。复合材料不能像金属材料那样将来自于雷击的电流和热迅速地分散开，在50,000伏时该电流通常可达约100,000安培。为了给复合材料结构(例如航空器和航天器结构)提供雷击防护，发展出一些已知的系统和方法。有些已知的系统和方法将金属导体附加于或者将不同结构的金属箔系统结合于航空器的复合材料外表面，例如机翼和机身上的蒙皮板上，以提供改进的导电性能，并将电流从飞行关键区域和下层飞机部件上分散和转移出去，以此最小化来自于雷击事件的物理损害。金属导体附加物可以包括基于贴面的系统(appliqué-based system)，所述基于贴面的系统使用施加于复合材料结构表面并且用粘合剂固定到表面上的交替的绝缘材料层和导电材料层。这将下层飞机部件从雷击中隔离出来，并为快速分散和耗散雷电电流和热量提供了传导通路。金属箔系统的结合可以包括铜箔或者铝箔的使用，铜箔或者铝箔既可以是实心形式的也可以是板网(expanded mesh)形式的，它们被层压入复合材料或者与复合材料一起被固化(co-cured)。这一系统为雷电电流的转移和分散提供了传导通路，结合特殊紧固件和其它特征，为复合材料结构提供了一定程度的雷击防护。但是，这类已知的系统和方法经常包含手工的、繁琐的并且耗时的多种材料部件敷设工作，这些敷设工作对于雷击防护系统的有效集成是必需的。
此外，用于雷击防护的已知系统和方法通常通过下面的方式制作：分别铺设表面修整顶层，其为后续的顶涂层完成系统提供一光滑的表面；铺设传导雷电电流的金属箔层；和铺设可选的隔离层，其通常为树脂增强纤维玻璃板，以防止电偶腐蚀并改善导致油漆开裂和层间开裂的热膨胀失配。例如，在美国专利US_5,225,265中公开的用于复合材料结构的雷击防护材料，其中，环氧树脂层和金属箔层并不是集成的，而是分别被铺设于彼此的顶部。但是，这些已知的多层系统的分层铺设耗时而且劳动强度高。此外，随着材料起皱、污染和处理不当会出现一些问题。当材料被分别施加时，材料对工具或者对复合材料基材如何附着也是一个挑战。
有些材料供应商提供了集成的延展金属箔和环氧基薄膜，它们最低限度地改善了制造流程的耗时和处理。例如，美国专利US 5,470,413公开了一种已知的(防)雷击复合材料的加工过程，其提供了一种多层复合材料，所述多层复合材料包括延展金属箔层，单独的环氧基树脂薄膜层和载体层。另一已知的复合材料结构雷击防护系统在美国专利US7,277,266中被公开，所述系统涉及一种雷电防护贴面。但是，这一已知系统使用了非共同固化的贴面，并且使用了压敏粘合剂。而且，这些已知的系统不允许应用支持大批量生成过程的自动制造过程，特别是自动处理、切割和敷设过程。此外，已知的集成系统还需要附加的铺面层或表面修整层，例如环氧铺面层，以提供足够的修整、密封和光滑性来满足宇航应用的环境要求。而有些已知系统可以被设计为满足环境要求，它们在自动化能力和最小重量的限制方面没有被优化。为雷击防护和/或环境耐久性而设计的集成系统在制造时没有考虑挠性和附着性的要求。它们的两侧均没有粘性(tack)，所以它们不能容易地被安放于曲面形状的表面上。此外，为将材料稳定地盘绕于自动敷设系统上，在两侧上均有粘性是必需的。如果有些次要的集成系统，其可以仅在一侧有粘性。
由此可见，需要一种制造集成雷击防护材料的系统和方法，其没有那些与已知系统和方法相关联的问题。
发明内容
对制造集成的雷击防护材料的系统和方法的需求通过本发明得以满足，本发明的方法和系统没有与已知系统和方法相关联的问题，同时又是独特、非显而易见和先进的系统和方法。没有已知的系统和方法提供了在这里讨论的全部多种优点。不同于已知的系统和方法，本发明提供了下列优点中的一个或者多于一个：所述系统和方法提供了对通常是环氧基的树脂薄膜、延展金属箔和在纸基载体纸上的附着层的集成，以使得其能够在各种不同的自动敷设机上被加工，以对大批量加工过程，例如处理、切割和敷设提供支持，并支持雷电防护复合材料蒙皮系统的大批量铺设；所述系统和方法提供将延展金属和通常是环氧基的树脂薄膜材料部件集成为一单独的集成产品，其可与现有的复合材料带和织物自动敷设机一起使用，以用于快速和有效地在扁平和有曲面的复合材料蒙皮结构上的材料敷设或安置，以提供对诸如雷击等电磁影响的防护；所述系统和方法提供了一种两侧带有粘性的材料，所述粘性对于稳定地盘绕材料是必需的；所述系统和方法提供了一种集成的材料，其既是环境耐久性的，又是能够无缝地与曲面料带铺设机、真空辅助整体敷设或安置系统和其它自动敷设机配合工作的；所述系统和方法提供了改善的制造流程耗时、改善的材料一致性、减少的劳动工时和资源以及最小化的处理和污染关注；所述系统和方法提供了作为独立系统的自动化，该自动化使独立系统能够满足应对电磁影响、防护和环境性能要求而不需要附加额外的表面、额外的隔离层或者额外的金属；所述系统和方法提供具有改善的挠性的材料，该挠性使得在x-y平面内弯曲或者在z平面内弯曲更容易；所述系统和方法提供了来自于错误处理、污染、起皱或者其它制造缺陷的废弃零件或者材料的数量的减少；所述系统和方法没有或者只有最低限度的对于将材料敷设于复合材料结构上所需的附加设备的开发要求；并且，所述系统和方法提供了在外观和潜在缺陷和不规则的数量方面的全面改进的复合材料零件，同时提供了改进了的对雷击和电磁影响的防护，和改进了的使用寿命期间的环境耐久性。
在本发明一实施例中，提供适于在复合材料结构上进行自动敷设的集成的雷击防护系统，其包括：由有机聚合物树脂组成的铺面层、延展金属箔导电层、隔离层和载体纸层。
在本发明另一实施例中，提供了集成的雷击防护系统，其包括：集成的雷击防护材料，所述材料由安置于载体纸上的封装在有机聚合物树脂中的延展金属箔构成；自动敷设机，其适于将材料敷设于航空器复合材料零件上，以保护复合材料零件免受雷击的影响。
在本发明另一实施例中，提供制造具有雷击防护功能的复合材料结构的方法，其包括：将集成的雷击防护材料装入自动层压机，其中雷击防护材料包括安置于载体纸上的封装在有机聚合物树脂中的延展金属箔；和，将材料层压在复合材料蒙皮的暴露表面上，以形成具有雷击防护功能的复合材料结构。
附图说明
前述的和其它的优点和特征以及实现它们的方式，在考虑结合了介绍优选和示例性实施例的附图的下面的详细描述后，将变得显而易见，但是所述附图不是必需按照比例绘制，其中：
图1是显示航空器上不同雷击区域的航空器顶视图；
图2是显示本发明的多层雷击防护材料系统的示意图；
图3是显示前体材料的示意图，该前体材料被转换成本发明的多层雷击防护材料系统集成产品；
图4是曲面料带铺设机的后视透视图，该曲面料带铺设机将本发明的集成雷击防护材料系统铺设于复合材料结构上；
图5是图4中曲面料带铺设机的侧视透视图，该曲面料带铺设机将本发明的集成雷击防护材料系统铺设于复合材料结构上；
图6是图4中曲面料带铺设机的前视透视图，该曲面料带铺设机将本发明的集成雷击防护材料系统铺设于复合材料结构上；
图7是本发明的集成雷击防护材料系统在复合材料结构上最终或完成敷设的前视透视图；
图8是本发明的两个集成雷击防护材料系统在复合材料结构上完成敷设的前视透视图。
具体实施方式
参考附图，本发明的实施例将在下面被充分描述，在附图中，本发明实施例被示出，但并未被全部示出。事实上，可以提供一些不同的实施例，并且不应认为本发明仅限于此处所列的实施例。确切地说，提供这些实施例以使得本公开彻底和完整，并且将向本领域技术人员充分地传递关于本发明范围的信息。
本发明涉及雷击防护系统和方法，所述系统和方法适于在复合材料结构或者零件上的自动敷设或者层压，例如在航空器和航天器的复合材料结构或者零件上的自动敷设或者层压。现参考附图，图1是显示航空器上不同雷击区域的航空器10的顶视图。航空器10上这些有高直接雷击概率的区域可以包括机翼区域12、翼尖区域14、机鼻区域16、机身区域18和机尾区域20。
图2是显示本发明的集成的多层雷击防护系统的示意图，所述系统适于自动敷设在复合材料结构上，例如航空器机翼区域、翼尖区域、机身区域、机尾区域或者机鼻区域上。本发明包含了集成的金属树脂雷击防护材料系统，所述系统由几个部件组成，其中每一部件均对理想的雷电防护、环境性能以及自动化制造进行了具体优化。系统包括由有机聚合物树脂构成的铺面层或表面修整层22。优选地，有机聚合物树脂包括部分固化的酚醛环氧树脂，例如可从马里兰州Havre de Grace的西塔克工程材料公司(Cytec Engineered Materials，Inc.)得到的Cytec Metlbond 1515-3或者Cytec SurfaceMaster 905。但是，其它合适的有机聚合物树脂也可被采用。优选地，铺面层是环氧基的并且其被设计成封装导电层24并对导电层24的环境加以保护，如下所述，并且其可被设计作为表面准备和喷漆系统施加的牺牲层和提供牺牲层。优选地，铺面层的厚度在0.002英寸到0.075英寸范围内。优选地，铺面层的重量在0.015磅每平方英尺(psf)到0.070psf范围内。
如图2所示，集成的多层雷击防护系统进一步包括与铺面层22相邻的导电层24。所述导电层包括延展的箔。导电层24引导雷电电流离开连接点，和/或保护电子/电气系统不受干扰信号影响。优选地，导电层的延展金属箔包括铜、铝、钛、镍、青铜、金、银和它们的合金或者其它导电金属。优选地，导电层的厚度在0.0015英寸到0.006英寸范围内。优选地，导电层的重量在0.086psf到0.100psf范围内。延展金属箔优选地是实心金属箔，因为它们重量轻并且由于它们在x-y平面及z平面上的屈伸能力从而提供自动化性的潜力。
如图2所述，集成的多层雷击防护系统进一步包括一隔离或者附着层或粘接层26，以便在需要时将导电层从下层的碳纤维增强塑料层压板流电隔离开(即，铝合金)。隔离或者附着层与导电层相邻。优选地，隔离或者附着层包括环氧基树脂材料、玻璃纤维环氧预浸材料、薄粘接材料或者其它有机聚合物树脂。隔离或者附着层上的粘合剂提供了粘性，所以隔离或者附着层可以粘在载体纸层28的一侧，并且能够改善相邻的碳纤维增强塑料层的施加。在特定实施例中，隔离或者附着层可以与铺面层有相同的成分。优选地，隔离或者附着层的厚度在0.0015英寸到0.005英寸范围内。优选地，隔离或者附着层的重量在0.015psf到0.060psf范围内。
如图2所示，集成的多层雷击防护系统进一步包括与隔离或者附着层相邻的载体纸层28。优选地，载体纸层包括带有可变粘性的合适的纸。更为优选地，载体纸层有低的或者中等的粘性。优选地，载体纸层具有有机硅脱离剂。有机硅提供了光滑的表面以从纸上移除雷击防护材料。优选地，载体纸层的厚度在0.004英寸到0.008英寸范围内。当材料被敷设在复合材料结构上时，载体纸层优选地被移除和丢弃。这样，当载体纸层被从隔离或者附着层上移除时，当材料被敷设或者铺设在复合材料结构上时，隔离或者附着层的暴露出的粘性侧被贴在了复合材料结构的表面。
尽管挠性是使得可自动化性成为可能的主导特性，整个系统的厚度、材料粘性以及载体纸粘性和厚度也是重要的。有些实施例会要求非常特定的纸张特性。例如，较薄的箔-树脂薄膜系统要求较厚的载体纸。根据对金属系统和自动敷设机的适当性和兼容性来选择隔离或者附着层，该金属系统为该自动敷设机或贴片机而设计。优选地，延展金属箔被树脂封装，并被安置于载体纸上，并按自动敷设机要求的宽度被卷在一芯轴上。所用的箔和树脂的类型取决于雷击和耐久性要求。为使得系统能够实现自动化，如粘性和挠性等这些参数被优化。集成材料优选地被通过在树脂被制成薄膜的同时将延展金属箔同步(in-line)地嵌入聚合物树脂中而制成，或者，用后加工的方式制成，其中部分固化的树脂已经被制成薄膜而延展金属箔被夹在树脂薄膜层和隔离或者附着层之间，或者树脂薄膜层和树脂薄膜层之间
图3是显示前体材料“A”的示意图，所述前体材料“A”包括铺面层22以及纤维增强材料层30，例如稀织品载体，其通常包括玻璃纤维或者碳增强纤维、织席或者针织聚酯纤维。前体材料“A”进一步包括导电层24、隔离或者附着层26和载体纸层28。前体材料被组合并集成以形成一集成的产品“B”，B包括由铺面层22与纤维增强材料层30、导电层24和隔离或者附着层26集成的多层，隔离或者附着层26被铺设于载体纸层28上。
优选地，集成的多层雷击防护系统在复合材料结构上的自动敷设通过自动敷设或者层压机执行，例如通过曲面料带铺设机或者真空辅助整体敷设系统执行。优选地，本发明所使用的曲面料带铺设机可从俄亥俄州辛辛那提的MAG Cincinnati、法国图卢兹的Forest-Line或者西班牙潘普洛纳的M.Torres获得。优选地，曲面料带铺设机能够以高速率将复合材料料带铺设于大型曲面零件上并且通常可容纳宽度为6英寸或者12英寸的雷击防护材料。真空辅助整体敷设系统具有较大的表面面积并能够容纳宽度达48英寸的雷电防护材料。雷击防护系统被装载于自动敷设机上，并且自动敷设机将雷击防护系统铺设或者层压于复合材料结构或者工具上。具有集成的雷击保护材料的被层压加工的复合材料结构或者零件稍后可被装配在航空器中。
图4显示根据本发明的系统和方法的集成的雷击防护材料32，其通过传统的曲面料带铺设机或靠模料带铺设机(contour tape laying machine)36被敷设或者铺设在复合材料蒙皮34的暴露表面上。图4显示沿方向40铺设材料32的曲面料带铺设机或靠模料带铺设机36的后端38的后视透视图。图5是图4中的沿方向40将本发明的集成的雷击防护材料32铺设于复合材料蒙皮34之上的曲面料带铺设机36的侧面42的侧视透视图。图6是图4中的沿方向40将本发明的集成雷击防护材料32铺设于复合材料蒙皮34之上的曲面料带铺设机36的前端44的前视透视图。图7是通过曲面料带铺设机将两片本发明的集成雷击防护材料32最终敷设或者层压在复合材料蒙皮34之上的前视透视图。最终或完成敷设或者层压材料32具有开始端48，在此处，材料32中一片的开始端48轻微地与材料32中另一片的开始端相重叠。最终敷设材料32中的每一片均具有以微小角度铺设的间隔开的侧端50。最终敷设材料32中的每一片都具有结束端52，在此处，材料32中一片的结束端52与材料32中另一片的结束端52形成一小的缝隙46。通过本发明能够精确地控制在何处和如何将材料敷设或者铺设在复合材料蒙皮上或者工具上。
图8是将本发明的两个集成的雷击防护材料32、54中的几片通过曲面料带铺设机(未显示)最终敷设在复合材料蒙皮34上的前视透视图。最终敷设或者层压材料32、54具有开始端56，在此处，材料32的开始端56与材料54的开始端56相重叠。最终敷设材料32、54中的每一片均具有结束端58，在此处，材料32的结束端58与材料54的结束端58间隔开。材料32、54的结束端58形成曲线60，并且由于从开始到结束每一片被连续地铺设，曲率半径随着随后被铺设的片而减小。通过本发明能够精确地控制在何处和如何将材料敷设或者铺设在复合材料蒙皮上或者铺设工具上。本发明的雷电防护材料和系统的优点包括其顺应曲面的能力和在x-y平面上和z平面上弯曲的能力，这是由于在树脂薄膜间的延展金属箔的几何特性所致。
在另一实施例中，本发明涉及的集成的雷击防护系统包括：集成的雷击防护材料，所述材料由安置于载体纸上的封装在有机聚合物树脂中的延展金属箔构成，以及自动敷设机，其适于将材料敷设于航空器的复合材料零件上以保护该复合材料零件免于雷击。优选地，自动铺设包括曲面料带铺设机。应注意到，如上所述并联系附图的与本发明实施例相关的细节，同样适用于本发明这一实施例的细节。
在另一实施例中，本发明涉及用于制造具有雷击防护的复合材料结构的方法。所述方法包括将集成雷击防护材料装载于自动层压机中的步骤。优选地，雷击防护材料包括被安置于载体纸上的封装在有机聚合物树脂中的延展金属箔。所述方法进一步包括将雷击防护材料层压在复合材料蒙皮的暴露表面上以形成具有雷击防护能力的复合材料结构的步骤。优选地，自动层压机包括曲面料带铺设机。优选地，所述复合材料结构包括航空器机翼区域、机身区域、机尾区域或者机鼻区域。优选地，所述方法在环境温度下进行，并且优选地，取决于要进行层压的复合材料的大小，所述方法的执行时间能够以小时为量级。应注意到，如上所述并联系附图的与本发明实施例相关的细节，同样适用于本发明这一实施例的细节。
本发明提供一种集成的材料，该材料既是环境耐久的又能够无缝地与曲面料带铺设机和其它自动敷设机配合工作。本发明所涵盖的材料系统的设计有明确的自动化目的，并且被设计成为能够满足电磁影响防护(例如对雷击的防护)和环境防护性能要求的独立系统。本发明提供了改进的制造流程时间、减少的劳力和资源(要求)、最小化的处理和污染关注，并且提供了在外观和潜在缺陷和不规则的数量方面而言的改进了的复合材料零件，同时提供了改进的雷击和电磁影响防护以及改进了的使用寿命期间的环境耐久性。
本发明的许多改进和其它实施例可被本发明所属领域的技术人员所意识到，这些改进和实施例也具有在前面描述和附图中所展示的教导所带来的益处。因此，应理解本发明不限于所公开的具体实施例，并且改进和其它实施例也意在包括于所附权利的范围内。尽管此处用到了具体的术语，它们仅仅是在一般意义和描述意义上被使用的，并且没有限制的目的。

Claims (15)

1.一种集成的雷击防护系统，其适于自动敷设在复合材料结构上，包括：
铺面层，其由有机聚合物树脂构成；
延展金属箔的导电层；
隔离层；和
载体纸层。
2.根据权利要求1所述的系统，其中所述有机聚合物树脂包括酚醛环氧树脂。
3.根据权利要求1所述的系统，其中所述铺面层的厚度在0.002英寸到0.075英寸范围内。
4.根据权利要求1所述的系统，其中所述铺面层的重量在0.015psf到0.070psf范围内。
5.根据权利要求1所述的系统，其中所述延展金属箔包括从铜、铝、钛、镍、青铜、金、银和它们的合金所组成的组中选择的金属。
6.根据权利要求1所述的系统，其中所述导电层的厚度在0.0015英寸到0.006英寸范围内。
7.根据权利要求1所述的系统，其中所述导电层的重量在0.086psf到0.100psf范围内。
8.根据权利要求1所述的系统，其中所述隔离层包括从环氧基树脂材料、玻璃纤维环氧预浸材料、薄粘合剂材料和有机聚合物树脂所组成的组中选择的材料。
9.根据权利要求1所述的系统，其中所述隔离层的厚度在0.0015英寸到0.005英寸范围内。
10.根据权利要求1所述的系统，其中所述隔离层的重量在0.015psf到0.060psf范围内。
11.根据权利要求1所述的系统，其中所述载体纸层包括具有可变粘度的纸。
12.根据权利要求1所述的系统，其中所述载体纸层的厚度在0.004英寸到0.008英寸范围内。
13.一种用于制造具有雷击防护能力的复合材料结构的方法，该方法包括：
将集成的雷击防护材料装载于自动层压机中，其中所述雷击防护材料包括安置于载体纸上的封装在有机聚合物树脂中的延展金属箔，和
将所述材料层压在复合材料蒙皮的暴露表面，以形成具有雷击防护能力的复合材料结构。
14.根据权利要求13所述的方法，其中所述自动层压机包括曲面料带铺设机。
15.根据权利要求13所述的方法，其中所述复合材料结构包括航空器机翼区域、翼尖区域、机身区域、机尾区域或者机鼻区域。
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CN104853910B (zh) * 2012-12-05 2017-03-22 塞特工业公司 用于复合结构的传导性表面材料
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CN104901008A (zh) * 2014-03-04 2015-09-09 波音公司 防雷天线罩系统
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