CN102076475B - 用于制造纤维增强热塑性复合结构的方法和设备 - Google Patents

用于制造纤维增强热塑性复合结构的方法和设备 Download PDF

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CN102076475B
CN102076475B CN200980124260.7A CN200980124260A CN102076475B CN 102076475 B CN102076475 B CN 102076475B CN 200980124260 A CN200980124260 A CN 200980124260A CN 102076475 B CN102076475 B CN 102076475B
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fiber
reinforced thermoplastic
thermoplastic
ultrasonic
temperature
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CN102076475A (zh
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大卫·因斯通
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Airbus Operations Ltd
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Airbus Operations Ltd
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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
    • 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
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/0261—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould using ultrasonic or sonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/0266—Local curing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/081—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations having a component of vibration not perpendicular to the welding surface
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/10—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using hot gases (e.g. combustion gases) or flames coming in contact with at least one of the parts to be joined
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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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
    • B29C66/01—General aspects dealing with the joint area or with the area 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
    • B29C66/01—General aspects dealing with the joint area or with the area 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
    • 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
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    • 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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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

提供一种制造纤维增强热塑性复合结构的方法，该方法包括：将第一层纤维增强热塑性材料放置在第二层纤维增强热塑性材料的顶部上；提供局部加热源并且局部地加热至少上层热塑性复合材料的一部分；以及提供超声换能器并且将超声能波局部地进入到所述热塑性材料的被加热的部分，使得所述纤维增强热塑性材料的超声固化发生。

Description

用于制造纤维增强热塑性复合结构的方法和设备
背景技术
现在复合材料通常在各行各业中用作结构材料。一个这种领域是航空和航天工业，其中结构复合材料用来形成飞机机构的比例日益增加。关于这一点，复合材料被认为是用纤维或网增强，最典型的是碳纤维但是可能是其他材料的纤维或金属网增强的聚合物基体。复合材料趋于属于两个主要材料家族中的一个，即那些具有热塑性基体的复合材料和那些具有热固性基体的复合材料。热固性复合材料需要被硫化，通过该硫化工艺聚合物基体的化学结构通常通过施加热和可选的压力被不可逆地改变。一旦被硫化，热固性复合材料就具有它最终的刚性、硬度以及强度的性质并且不能回到其未硫化柔软状态。相反，热塑性复合材料不需要硫化，当冷却时具有它们所需的结构性质并且当被加热时软化。热塑性复合材料可以通过加热被重复地软化并通过冷却被硬化，这是因为当被加热时，它们基本上经历物理变化而非化学变化。
热塑性复合材料和热固性复合材料都可以形成薄软片或纤维。这允许通过将复合材料铺放在模具中而形成复合部件，并且部件的厚度根据铺设的复合材料层的数量而局部地变化并且一个或更多个层的方向是可控制的，从而控制形成的复合部件的最终结构性质。然后铺叠成型的部件被“固化”，在两种情况下该工艺包括加热复合结构使得热固性或热塑性基体软化到足够程度从而形成单个一体的基体，并且将足够的压力施加于软化的基体以从基体排出所有捕获的空气，并且还允许增强纤维能够在基体内“沉淀”。
在最终的结构性质方面，热塑性复合材料具有优于热固性复合材料的抗冲击性和抗破坏性并且通常更坚固并更耐化学腐蚀，所有这些都是航空应用中优选的性质。此外，热塑性复合材料可以被重复地再热和改铸，所以它们自然地可循环再用，这是日益重要的考虑因素。
在铺叠成型的叠层被固化之前，“铺叠”纤维增强复合材料的单个层的动作可以手工进行。然而，这是非常费时的并且需要熟练工人以获得好的结果，因此是相对昂贵的并且不适合复合结构的大规模生产。为解决该问题，已经开发了自动铺带(ATL)和自动纤维铺放(AFP)技术和设备，其中复合材料带或纤维被连续地从一大卷材料供给到带或纤维铺放头，该铺放头自动地将复合材料放在希望的位置。因为该工艺是自动化且机械化的，所以比起手动铺叠复合材料，大大提高了速度和精确性。在本技术的另一个改进中，当与纤维增强热固性复合材料一起使用时，在纤维或带已被铺放之后，例如利用红外线激光器或热气焊枪执行纤维或带的局部加热，局部加热导致在铺放复合材料时热固性基体完全或局部固化。由于已经通过局部加热实现了局部固化而可以完全除去随后的固化工艺或可以在缩短的时间内实现该固化工艺，所以该技术进一步减少了制造热固性复合结构所需的时间。在该技术的具体改进中，通过利用超声换能器将超声波能引入热固性复合基体实现局部加热。超声波能导致热固性基体材料在超声频率下振动并且这些振动自身引起热固性材料内的局部加热，因此实现希望的完全或局部固化。然而，如所提及的，当和热塑性复合材料一起使用时，该超声铺带技术必须约定不能以有效且迅速的方式实现。因此，希望提供一种用于对热塑性复合材料执行超声铺带的方法和设备，该方法和设备实现希望的速度和效率。
发明内容
根据本发明的第一方面，提供一种制造纤维增强热塑性复合结构的方法，该方法包括：将第一层纤维增强热塑性材料放置在第二层纤维增强热塑性材料的顶部上，提供局部加热源并且局部加热上层和下层的一部分，以及提供超声换能器并将超声能量波局部地引入所述热塑性材料的被加热的部分，使得所述纤维增强热塑性材料发生超声固化。
优选地一方面在所述第一层纤维增强热塑性材料和所述超声换能器之间，另一方面在所述局部加热源和所述超声换能器之间，发生相对运动。
所述第一层纤维增强热塑性材料优选地以连续长度提供，并且可以以连续方式放置在所述第二层纤维增强热塑性材料上。优选地，所述局部加热和所述超声波能量的引入发生在所述热塑性层的接近于所述第一层纤维增强热塑性材料被放置在所述第二层上的点的一部分处。
所述纤维增强热塑性材料层的所述部分优选地被加热到所述纤维增强热塑性材料的玻璃化过渡相范围内的温度。另外所述纤维增强热塑性材料的所述部分可以被局部加热到以下范围内的温度，即基本上从玻璃化转变温度升高并且升高到超出与热塑性材料的损耗因子(Tan delta)的峰值对应的温度以上5℃的温度。最优选地，所述纤维增强热塑性材料的所述部分可以被局部加热到基本上等于与所述热塑性材料的损耗因子的峰值对应的温度的温度。
所述局部加热源可以包括红外线激光器。
根据本发明的另一方面，提供一种根据本发明的第一方面的所述方法制造的纤维增强热塑性复合结构。
根据本发明的第三方面，提供一种用于制造纤维增强热塑性复合结构的设备，该设备包括：局部热源，该局部热源布置成加热一叠层的纤维增强热塑性层的一部分；和超声换能器，该超声换能器布置成将超声能量波局部地引入所述纤维增强热塑性材料层的被加热的部分，使得所述层发生超声固化。
所述局部加热源或所述超声换能器优选地布置成相对于所述一叠层的纤维增强热塑性层移动。
在优选实施方式中所述局部加热源包括红外线激光器。
优选地，所述设备包括与所述局部热源结合的超声铺带设备。
附图说明
现在将参照附图仅通过示例性实施例在下文描述本发明的实施方式，其中：
图1示意性地示出根据现有技术的超声铺带；
图2示意性地示出用于纤维增强基体复合材料的动态模量振幅和对照温度的损耗因子(tanδ)的普通关系图；以及
图3示意性地示出根据本发明的实施方式的超声铺带。
具体实施方式
参照图1，示意性地示出了用于执行热固性复合材料的超声铺带的典型装置。热固性带的上层10被放置在现有的热固性复合材料的下层12上。下层12可以是单层热固性带材料或可以是先前已经沉积的多层的叠层。超声换能器14设置成将超声波能引入热固性复合材料的上层和下层在图1所示的画圈部分16内。热固性复合材料的上层和下层沿图1所示的方向相对于超声换能器14移动，并且上层和下层的接收来自超声换能器的超声波能的部分接近于热固性复合材料的上层10被放置在材料的下层12之上的点。
热固性复合材料的超声固化通过下面的机构发生，并且可以参照图2说明与该机构有关的材料的关键特征，图2示意性地示出了施加有超声能的材料的某些性质随温度的变化。图2所示的实心迹线示意性地表示粘弹性材料的弹性模量随温度的变化，热固树脂和热塑树脂都是这种粘弹性材料的实例。材料的弹性模量是当受到振动力时材料中应力和应变的比的量。诸如热固性聚合物和热塑性聚合物的粘弹性材料通常以两个截然不同的状态存在。在低温下它们以“玻璃”相存在，在该玻璃相中材料通常是硬的和“象玻璃的”并且显示高模量值。该相在图2所示的迹线中由竖轴和由点划线A表示的点之间的部分表示。粘弹性材料在高得多的温度下以弹性相存在，在该弹性相中它们显示弹性材料的性质并且具有低模量值。该相在图2所示的迹线中由点划线B的右手侧的区域表示。在这两相之间粘弹性材料经过由图2中的点划线A和B之间的区域表示的过渡相，在过渡相期间它们的模量在它们的玻璃相的上限值和它们的弹性相的下限值之间变化。与图2的点A对应的、过渡相开始的温度通常被称为玻璃化转变温度(Tg)。
由图2中的虚迹线22表示的第二值是损耗因子(Tanθ)值。该值是施加的振动力和在实际的粘弹性材料中引起的振动之间的相位滞后的量，并且可以被解释为由材料吸收的机械能的量。如图2所示，损耗因子的最大值与玻璃化过渡相的中心相对应。如应当理解的，损耗因子的值越高由粘弹性材料吸收的能量越大，该粘弹性材料将自身表示为局部加热，从而导致聚合物树脂材料软化和流动(固化)，而同时被给予适当的操作条件的超声波振动将导致材料内的增强纤维沉淀或“嵌套”成希望的厚度。
对于通常用来制造纤维增强复合结构的热固性复合材料，玻璃转化通常与环境温度或室温一致。因此，损耗因子的值在室温或环境温度下位于或接近其峰值，因此由超声换能器施加的最大能量被热固性聚合材料吸收，导致上述的局部加热和固化。这是热固性复合带的超声固化如此有效的主要原因。
相比之下，热塑性复合带的玻璃化转变温度Tg显著地更高。例如PEEK的Tg是大约145℃。因此，在室温或环境温度下，热塑性材料很好地保持在损耗因子相对低的初始玻璃相内，并且因此热塑性材料从超声换能器吸收非常小的能量，使得很少或没有局部加热发生。
本发明的实施方式提供一种方法和设备以克服该问题并且图3示意性地示出了一个实施方式。以类似于图1所示的装置的方式，优选地利用自动铺带技术和设备将热塑性复合材料的上层10放置在现有的下层12之上。超声换能器14设置成在接近于上层10被放置在下层12之上的点的点处将超声波能引入上热塑性层的一部分16。在优选实施方式中是红外线激光器的局部加热源18被进一步提供，并且布置成使得它局部地加热与超声换能器14将超声波能注入其中的热塑性材料的上层的相同部分16(图3所示)，或者可替代地在上热塑性材料层和下热塑性材料层通过超声换能器14和局部加热源18的相对运动之前立即局部地加热热塑性材料的上层的一部分，使得在超声波能被注入到热塑性材料的上层10的待固化的该部分之前或同时立即实现加热。在替代性实施方式中可以包括热气焊枪或加热滚筒的局部加热源18的动作优选地通过加热源的选择和待提供的热能被布置成足以将热塑性材料的所选择的部分16局部加热到在热塑性材料的玻璃化过渡相内的温度。由于在通过超声换能器14注入超声能之前立即将热塑性复合材料的该部分预加热到在玻璃化过渡相内的温度，所以很大比例的超声能可以被热塑性材料吸收，并且超声波振动允许热塑性材料流动和固化，同时也允许热塑性基体内的增强纤维以类似于热固性复合带在室温下的超声固化的方式“嵌套”成希望的厚度。优选地，预热动作被布置成将复合材料的温度提高到玻璃化转变温度Tg以上达到与损耗因子的峰值一致的温度，使得最大量的超声能随后可以被吸收。然而将复合材料预热到包括损耗因子峰值的温度范围内，例如从玻璃化转变温度Tg到超出峰值损耗因子温度大约5℃的范围，将引起由复合材料吸收的超声能的量的提高并且允许有效的超声固化。
虽然已经在超声铺带或铺纤维的背景下描述了本发明的上述实施方式，即连续铺放热塑性带并且当带被铺放时执行超声固化，但是本发明的原理可以应用于其他实施方式，在其他实施方式中，热塑性带可以被手工应用，或者手工地应用在较大片材中，并且结合的热固化和超声固化作为随后的单独的工序执行。还应当理解，虽然因为碳增强复合材料是深色的并因此很好地吸收红外线能，所以红外线激光器加热特别适于导致热塑性复合带的局部加热，但是任何其他可以以希望的速度执行所需的局部加热以便使用的局部加热技术都可以被利用并且落在本发明的实施方式的范围内。

Claims (11)

1.一种制造纤维增强热塑性复合结构的方法，该方法包括：
将第一层纤维增强热塑性材料放置在第二层纤维增强热塑性材料的顶部上，所述第一层纤维增强热塑性材料和所述第二层纤维增强热塑性材料包括位于热塑性聚合物基体内的增强纤维；
提供局部加热源并且局部地加热所述第一和第二层纤维增强热塑性材料的一部分；以及
提供超声换能器并且将超声能量波局部地引入到所述第一和第二层纤维增强热塑性材料的被加热的部分，使得所述第一和第二层纤维增强热塑性材料发生超声固化，其中所述纤维增强热塑性材料的所述部分被局部地加热到在以下范围内的温度，该范围即基本上从玻璃化转变温度升高并且升高到超出与所述纤维增强热塑性材料的损耗因子的峰值对应的温度以上5℃的温度，其中所述第一和第二层纤维增强热塑性材料的所述固化包括形成内部沉淀有增强纤维的单个一体的热塑性聚合物基体。
2.根据权利要求1所述的方法，其中，一方面在所述第一层纤维增强热塑性材料和所述超声换能器之间，另一方面在所述局部加热源和所述超声换能器之间，发生相对运动。
3.根据权利要求1或2所述的方法，其中，所述第一层纤维增强热塑性材料以连续长度设置，并且以连续方式放置在所述第二层纤维增强热塑性材料上。
4.根据权利要求3所述的方法，其中，所述局部加热和所述超声能的引入发生在接近于所述第一层纤维增强热塑性材料被放置在所述第二层上的点的一部分处。
5.根据权利要求1所述的方法，其中，所述第一和第二层纤维增强热塑性材料的所述部分被局部地加热到基本上等于与所述纤维增强热塑性材料的损耗因子的峰值对应的温度的温度。
6.根据权利要求1所述的方法，其中，所述局部加热源包括红外线激光器。
7.一种根据任一前述权利要求所述的方法制造的纤维增强热塑性复合结构。
8.一种用于制造纤维增强热塑性复合结构的设备，该设备包括：局部热源（18），该局部热源布置成加热一叠层的纤维增强热塑性材料层的一部分，其中第一层纤维增强热塑性材料和第二层纤维增强热塑性材料包括位于热塑性聚合物基体内的增强纤维；和超声换能器（14），该超声换能器布置成将超声能量波局部地引入所述纤维增强热塑性材料层的被加热的部分，由此所述层发生超声固化，其中所述第一和第二层纤维增强热塑性材料的所述固化包括形成内部沉淀有增强纤维的单个一体的热塑性聚合物基体，其中所述局部热源布置成将所述叠层的所述部分加热到在以下范围内的温度，该温度即基本上从玻璃化转变温度升高并且升高到超出与所述纤维增强热塑性材料的损耗因子的峰值对应的温度之上5℃的温度。
9.根据权利要求8所述的设备，其中，所述局部热源和所述超声换能器布置成相对于所述一叠层的纤维增强热塑性层移动。
10.根据权利要求8或9所述的设备，其中，所述局部热源包括红外线激光器。
11.根据权利要求8所述的设备，该设备包括与所述局部热源结合的超声铺带设备。
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BRPI0915407A2 (pt) 2015-11-03
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