CN102105296A - 用于制造三维梁类型的复合材料元件的装置和方法 - Google Patents
用于制造三维梁类型的复合材料元件的装置和方法 Download PDFInfo
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Abstract
本发明涉及一种用于从铺放、预切割且未聚合的层压件(21、22)制造三维部件—例如由聚合树脂预浸渍的增强纤维构成的复合材料梁—的装置,所述装置包括头部(15),头部(15)又包括滚轮组(17),头部(15)能够沿固定座板纵向运动,使得当头部(15)运动时,滚轮组作用在未聚合的层压件(21、22)上,压紧和成型层压件(21、22),因此使层压件(21、22)一次性成型为最终形状。由此,所述层压件(21、22)能够用于随后的一体化。本发明还涉及一种用于制造三维部件例如复合材料梁的方法。
Description
技术领域
本发明涉及用于制造尤其是飞行器用的复合材料元件的装置,以及涉及用于制造所述复合材料元件的方法。
背景技术
基于重量节约和机械性能的提高,航空航天主结构中新式复合材料的大量应用已成为结构优化的一种重要方法,因此正成为新一代飞行器的设计和制造中的主要目标之一。
由于改进了用于层压件/层压材料-从由聚合树脂预浸渍的增强纤维构成的片层获得该层压件-的自动堆叠和切割的技术和设备,这种复合材料的大量应用已成为可能。然而,制造过程的自动化几乎专门地被限制用于大的二维层压件的生产(大的翼面例如机翼、安定面的蒙皮或机身的蒙皮),而对于适用于这些航空结构的整体式构造的增强元件和加强杆(桁条和加强杆)的制造和一体化仍包括相当大比率的手工制造。
迄今为止,飞行器桁条和加强杆的制造基本上通过与蒙皮制造相类似的带铺放和切割过程来实现,其包括:配备有头部的数字控制机,该头部与进给预浸渍材料的卷轴一体地形成;滚轮,该滚轮将材料堆放和压紧在层压件所堆叠的台上;一个或多个将所述材料切割成所要求尺寸的刀片,因此获得二维的层压件。
通过上述方法获得的二维层压件尽管未聚合,但是通过类似于金属冷冲压的方法被热成型,以便生产可展开或可近似展开的三维梁类型的元件,该元件具有呈L、J、C等形状的开口截面。这些开口截面以单独或联接在一起的方式使得梁型元件具有T、I等形状的截面。
挤拉成型是传统成型工艺过程的一种代替方案,挤拉成型借助下述系统实现梁型元件的成型与连续固结:该系统包括一组向该系统进给原材料的卷轴,所述原材料呈预浸渍材料带或片层的形式;滚轮组,该滚轮组堆叠、压紧一系列的原材料带或片层并逐渐地和连续地成型系列的原材料带或片层而不进行聚合;和加热系统,该加热系统使因此成型的层压件固结--也是连续的,由此生产出与通过传统的成型方案获得的元件相类似的三维梁类型元件。
然而,挤拉成型工艺过程的应用对于桁条和加强杆--所述桁条和加强杆具有航空结构中常用的构造:层压件是厚度大的、厚度可变的、曲率相当大的、其与厚度可变的蒙皮连接的面是变化的等--的生产是过度复杂的。
本方面的目的是解决这些缺点。
发明内容
本发明涉及一种用于由铺放和被切割但未聚合的层压件制造三维梁类型的复合材料(复合材料包括聚合树脂预浸渍的增强纤维)元件--桁条或加强杆--的装置,将所述层压件放置在为成型提供支承的模中,所述模可以是桁条或加强杆的硫化模,本发明还涉及一种用于制造所述元件的方法。根据本发明的装置包括装备有运动头部的装置,该运动头部又包括一组可运动的滚轮,所述滚轮用于抵靠前述的模压紧和成型桁条或加强杆的未聚合的层压件,使桁条或加强杆处于其最终的几何形状并能够集成在飞行器的蒙皮中。
根据本发明的方法允许对未聚合的层压件进行铺放和切割,以便产生具有所有复杂度的桁条和加强杆,其中将这些层压件放置在对成型操作起支承作用的模(该模可以是桁条或加强杆的硫化模)中,通过一组可运动的滚轮抵靠所述模来压紧和成型桁条或加强杆的层压件。
参考附图,通过下面对应用示例的详细描述可清楚地得出本发明的其它特征和优点。
附图说明
图1a、1b和1c示意性示出为成型飞行器的桁条或加强杆通常所采用的方法的三个步骤;
图2a和2b示意性示出根据本发明第一实施方式的用于制造复合材料元件的装置的正视图和侧视图;图2c、2d和2e以剖视图示出根据本发明第一实施方式的制造复合材料元件的方法成型层压件的三个依次的状态;
图3a、3b和3c示意性示出根据本发明第一实施方式的复合材料层压件成型过程的操作的三个步骤;
图4a和4b示意性示出根据本发明第一实施方式的用于制造复合材料元件的装置的可运动头部的基本元件的平面图和正面图;
图5示意性示出根据本发明第二实施方式的成型复合材料层压件的系统的固定座板的一部分的等轴立体图;
图6以剖视图示意性示出根据本发明第二实施方式的复合材料层压件成型过程的依次的阶段;
图7示意性示出根据本发明第三实施方式的成型复合材料层压件的系统的固定座板的一部分的等轴立体图;
图8a和8b示意性示出根据本发明第三实施方式的用于制造复合材料元件的装置的可运动头部的基本元件的平面图和正面图;
图9以剖视图示意性示出根据本发明第三实施方式的复合材料层压件成型过程的依次的阶段;
图10示意性示出根据本发明的第一、第二或第三实施方式的成型复合材料层压件的系统的可行的实际实施。
具体实施方式
本发明涉及从堆叠片层开始--该片层由聚合树脂预浸渍的、具有限定取向的增强纤维构成--由复合材料制造结构的领域。根据本发明,在压力和温度作用下的固结过程实现了:压紧材料、除去过多的树脂和挥发物、以及固结(如果是热固性的,则借助树脂的交联,如果是热塑性的,则借助熔接),使得面板具有高的机械性能。
如图1a至1c示出地,根据现有技术的为成型桁条或加强杆通常所采用的方法的三个示意性阶段被描述如下。
在第一阶段中,如图1a中可观察到地,将平的层压件1、2--从该层压件得到桁条或加强杆、所述层压件1和2已预先被堆叠和切割好--放置在成型模3、4上,借助于凸缘5、6来保持所述层压件1、2的与桁条或加强杆的支腿相对应的区域。成型模3、4又位于真空台7上,真空台7由带孔的板构成,该带孔的板与真空系统相连接以允许通过该板进行抽吸。在真空台7上设有罩8,罩8装备有加热和冷却系统9和弹性膜,加热和冷却系统9允许对层压件1、2进行加热以有助于成型,弹性膜优选由有机硅形成、可与位于真空台7上的成型模3、4的几何形状相适配。
在第二阶段中,如图1b中观察到地,罩8下降到真空台7上,抵靠台7密封弹性膜10的边缘。随后启动加热系统9,因此加热层压件1、2并相应地减小树脂的粘度,这有助于使树脂流动,在这个操作之后启动台7的真空系统。在通过真空台7抽气的情况下,弹性膜1然后与由台7和成型模3、4形成的组件的几何形状相适配,拉动层压件1、2并使层压件1、2变形,以及使层压件1、2成型为具有最终的L形截面11、12。
在第三阶段中,根据图1c,一旦层压件11、12已经被成型,则在不除去弹性膜10或由台7生产的真空的情况下使层压件11、12冷却(正常地,借助于强制通风或借助于一些等同的冷却机理),因此使获得的层压件11、12的截面能够稳定。一旦这(上述操作)完成之后,除去真空并且除去罩8。接下来,接合成型模3、4,从而又接合L形截面的层压件11、12。从而,最终被成型的桁条的支腿成型为一适合用于粘合的连续表面,加入填料13--填料13与位于桁条11、12支腿和贴靠在支腿上的直线之间的类三角形的几何形状相适配,因此获得了桁条或加强杆14的最终截面,所获得的桁条或加强杆11已可用于与外壳的蒙皮集成到一起。
图2a和2b示意性示出根据本发明第一实施方式的用于制造复合材料结构的装置,该装置包括可沿着固定座板纵向运行的可运动头部15,固定座板由支承件33形成,在该支承件33上搁置有两个成型模19、20,成型模19、20将两个平的层压件21、22锁定在一起、位于垂直位置中。可运动的头部15基本包括:加热系统16,该加热系统16用于加热滚轮组17和两个待成型的层压件21、22;以及冷却系统18,该冷却系统18基于冷的空气或气体的注入、或基于允许层压件21、22一旦成型就能够被冷却的任何其它的等同系统。另外,图2c、2d和2e示出了图2a的三个截面A-A’、B-B’和C-C’,其示出层压件21、22成型的三个依次的状态。
如图3a-3c中示意性示出地,根据本发明第一实施方式的层压件21、22成型过程的操作可分成三个步骤或阶段:第一阶段,抵靠成型模19、20放置平的层压件21、22并使模19、20闭合(图3a);第二阶段,借助滚轮组17进行成型(图3b);以及第三阶段,布置填料13并使模19、20分开以取出桁条/加强杆(图3c)。
如从图4a和4b清楚看到地,根据本发明第一实施方式的成型装置的滚轮组17执行层压件21、22的渐进成型,使层压件21、22从其最初的平的截面成型至最终的L形截面,借助罗马数字I至VII来标记每个滚轮,7被认为是最适于实现中间厚度层压件的逐级成型的滚轮的数量,不排除根据各过程的特殊特征增加或减少滚轮数量的可能性。
因此,本发明的目的是:简化通常用于成型由预浸渍层压件制成的复合材料桁条或加强杆的工具和过程操作,并如图1a至1c中描述地,所述工具和过程操作使层压件21、22一次性热成型以制成最终的T形加强杆。
因此,本发明的目的在于提供一种包括可运动滚轮组17的装置,其用于抵靠上述的成型模19、20压紧和成型层压件21、22而不聚合桁条或加强杆,使桁条或加强杆保留它们的最终几何形状,并可与飞行器的蒙皮集成一体。
因此,在本发明的第一实施方式中提及的装置和方法--如图2a-2e中示意性示出地--可代替在图1a至1c中描述的传统过程中使用的许多装置。其结果是,在传统方法中必须使用真空台7、装备有加热和冷却系统9以及有机硅膜10的可运动的罩8,所有的尺寸都略大于待成型的桁条的尺寸,而根据本发明的方法仅需要尺寸减小的可运动头部15,该头部15以渐进的方式实现层压件21、22的成型过程。
在图3a、3b和3c中示意性描绘了根据本发明第一实施方式的、使用图2a-2e中的装置的成型过程的操作,并且该操作可概括为下面的步骤或阶段:在第一阶段中,如图3a所示,抵靠成型模19、20放置平的层压件21、22并闭合所述模19、20;在第二阶段中,如图3b所示,将滚轮组17移到所述两个层压件21、22的一个端部处,开始加热并通过第一滚轮I抵靠成型模19、20成型该端部(图3b中的截面D-D’),通过纵向运动,加热和成型以渐进的方式持续地进行并张开层压件21、22,直到层压件21、22获得最终的T形截面为止(图3b中的截面E-E′),该阶段如此地进行,即一旦滚轮组17的所有滚轮I至VII都已经越过/经过了一个截面,则定位在可运动头部15的端部处的冷却系统18就对层压件21、22进行冷却,从而层压件21、22维持所获得的最终截面;最后,根据第三阶段,如图3c所示,实现填料13的布置以及成型模19、20的分开,以取出位于其最终形状的桁条/加强杆。
根据本发明第一实施方式,可在成型模19、20上进行成型过程--所述成型模19、20具有这种唯一的功能,或者根据本发明第二实施方式,可直接在图5中示意性示出的角式硫化模24(该硫化模24随后用于使物件硫化)上进行成型过程,因此,节省了桁条制造过程中的数个操作(从成型工具19、20取出桁条和将桁条传送至硫化模24)。根据本发明第二实施方式的工艺过程的机理与所描述的用于第一实施方式的工艺过程的机理相同,并在图6中示意性示出该工艺过程的机理;图6示出了当由滚轮组17的各滚轮作用时桁条截面的几何形状的变化--其通过字母A至G标记,另外,根据本发明第二实施方式这些滚轮可具有可变的截面。
根据本发明第三实施方式,所述工艺过程必须考虑到桁条截面的变化:桁条尺寸设计的要求之一是要求在桁条的腹板中引入一中间层压件23。根据这个第三实施方式的成型过程与先前已描述的成型过程相同,能够在成型滚轮的两个半体之间引入一间隙25,成型装置因此与桁条截面的几何形状相适配,如从图7和8a-8b可观察到地。因此,所述系统允许中间层压件23的厚度的逐渐变化。
如从图7可观察到地,根据本发明第三实施方式,可成型出不同的桁条截面,其中除平的层压件21、22之外还引入第三层压件23,第三层压件23插入在上述层压件21、22之间并形成桁条腹板的一部分。进行层压件--该层压件具有如图7所描述的新截面--的渐进成型的滚轮组17包括位于滚轮的两个半体之间的间隙25,间隙25的宽度等于中间层压件23的宽度,以使工艺过程与所需要的桁条的新截面相适配。
最后,图9以剖视图示意性示出根据本发明第三实施方式的已闭合的成型和硫化角24。图9还示出在新桁条截面--在桁条的腹板中具有中心层压件23--的成型过程的相继阶段中的层压件21、22和23。
可在已描述的实施方式中引入落在由所附权利要求限定的范围内的修改。
Claims (14)
1.一种用于从铺放和预切割但未聚合的层压件(21、22)开始制造三维梁类型的复合材料元件的装置,所述复合材料具有聚合树脂预浸渍的增强纤维,其特征在于,所述装置包括头部(15),所述头部(15)又包括滚轮组(17),所述头部(15)能够沿固定座板纵向运动,使得当所述头部(15)运动时,所述滚轮组作用在未聚合的层压件(21、22)上,压紧和成型所述层压件(21、22),因此使所述层压件(21、22)一次性成型为最终的几何形状,由此所述层压件(21、22)能够用于随后的一体化。
2.根据权利要求1所述的用于制造三维梁类型的复合材料元件的装置,其特征在于,所述头部(15)包括加热系统(16),所述加热系统(16)用于加热所述滚轮组(17)和待成型的层压件(21、22)。
3.根据上述权利要求中任一项所述的用于制造三维梁类型的复合材料元件的装置,其特征在于,所述头部(15)包括冷却系统(18),所述冷却系统(18)用于使所述层压件(21、22)一旦成型就被冷却。
4.根据权利要求3所述的用于制造三维梁类型的复合材料元件的装置,其特征在于,所述冷却系统(18)基于冷的空气或气体的注入。
5.根据上述权利要求中任一项所述的用于制造三维梁类型的复合材料元件的装置,其特征在于,所述滚轮组(17)的滚轮具有可变的截面。
6.根据上述权利要求中任一项所述的用于制造三维梁类型的复合材料元件的装置,其特征在于,所述装置包括两个成型模(19、20),所述头部(15)抵靠作用在所述两个成型模(19、20)上,以成型所述层压件(21、22)。
7.根据权利要求1至5中任一项所述的用于制造三维梁类型的复合材料元件的装置,其特征在于,直接在硫化模(24)上进行所述层压件(21、22)的成型,所述硫化模(24)随后用于硫化所述三维元件。
8.根据权利要求1至5中任一项所述的用于制造三维梁类型的复合材料元件的装置,其特征在于,连同所述层压件(21、22),还引入第三层压件(23),所述第三层压件(23)插入前述层压件(21、22)之间,使得进行所述层压件(21、22)的渐进成型的滚轮组(17)具有一位于滚轮的两个半体之间的间隙(25),所述间隙(25)的宽度等于所述中间层压件(23)的宽度,从而所述工艺与要求的新截面相适配。
9.根据上述权利要求中任一项所述的用于制造三维梁类型的复合材料元件的装置,其特征在于,所述三维元件是航空结构的T形桁条或加强杆。
10.一种用于从铺放和预切割但未聚合的层压件(21、22)开始利用如权利要求1所述的装置制造三维梁类型的复合材料元件的方法,所述复合材料具有聚合树脂预浸渍的增强纤维,其特征在于,所述方法包括下列阶段:
(a)将所述层压件(21、22)放置在成型装置上,随后闭合所述装置;
(b)将所述滚轮组(17)移到所述层压件(21、22)的一个端部处,通过第一滚轮开始所述端部的成型,成型以渐进的方式连续地进行,直到所述滚轮组(17)的所有滚轮都经过一截面并将该截面成型为其最终的形状;
(c)稳定所获得的层压件(21、22)的最终形状,以及
(d)分开所述成型装置,以取出所获得的处于其最终形状的三维元件。
11.根据权利要求10所述的用于制造三维梁类型的复合材料元件的方法,其特征在于,所述成型装置是两个成型模(19、20),所述头部(15)的滚轮组(17)抵靠作用在所述两个成型模(19、20)上,以使所述层压件(21、22)成型。
12.根据权利要求10所述的用于制造三维梁类型的复合材料元件的方法,其特征在于,所述成型装置是现有的硫化模(24),所述硫化模(24)随后用于硫化所述三维元件。
13.根据权利要求10所述的用于制造三维梁类型的复合材料元件的方法,其特征在于,所述成型过程还包括在所述成型滚轮的两个半体之间引入一间隙(25),以允许插入在所述层压件(21、22)之间的中间层压件(23)的厚度逐渐地变化。
14.根据权利要求10至13中任一项所述的用于制造三维梁类型的复合材料元件的方法,其特征在于,所述三维元件是航空结构的T形桁条或加强杆。
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US11135789B2 (en) * | 2018-04-26 | 2021-10-05 | The Boeing Company | Methods and devices of forming a tensioned stringer for a vehicle |
US10780971B2 (en) | 2018-04-26 | 2020-09-22 | The Boeing Company | Methods of manufacturing a panel having a composite stringer for a vehicle |
CN111099035B (zh) * | 2018-10-29 | 2023-07-14 | 中国商用飞机有限责任公司 | 一种t形复合材料工件的加工方法 |
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EP3744511A1 (en) * | 2019-05-29 | 2020-12-02 | Airbus Operations, S.L.U. | Composite forming station |
DE102019125498A1 (de) * | 2019-09-23 | 2021-03-25 | Airbus Operations Gmbh | Vorrichtung und Verfahren zur Herstellung eines T-förmigen Halbzeugs aus einem mehrlagigen Gelege von Verstärkungsfasern |
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JP2954836B2 (ja) * | 1994-09-14 | 1999-09-27 | 川崎重工業株式会社 | 繊維強化樹脂系型材の成形方法 |
US20040265536A1 (en) * | 2003-05-30 | 2004-12-30 | Toshikazu Sana | Method and apparatus for shaping section bar made of composite material and shaped product and I-shaped stringer thereof |
US20050056362A1 (en) * | 2003-08-01 | 2005-03-17 | Benson Vernon M. | Apparatus and methods for forming composite stiffeners and reinforcing structures |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN105881933A (zh) * | 2016-04-01 | 2016-08-24 | 西北工业大学 | 适用于rtm的t型带筋壁板复合材料的成型模具及成型方法 |
CN105881933B (zh) * | 2016-04-01 | 2017-10-10 | 西北工业大学 | 适用于rtm的t型带筋壁板复合材料的成型模具及成型方法 |
Also Published As
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ES2341828A1 (es) | 2010-06-28 |
WO2009156548A1 (es) | 2009-12-30 |
US20090320995A1 (en) | 2009-12-31 |
JP2011525865A (ja) | 2011-09-29 |
ES2341828B1 (es) | 2011-05-26 |
EP2327537A1 (en) | 2011-06-01 |
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