CN102137748B - 用于利用微波聚合制造由纤维加强的复合材料制成的部件的方法 - Google Patents

用于利用微波聚合制造由纤维加强的复合材料制成的部件的方法 Download PDF

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CN102137748B
CN102137748B CN200980124359.7A CN200980124359A CN102137748B CN 102137748 B CN102137748 B CN 102137748B CN 200980124359 A CN200980124359 A CN 200980124359A CN 102137748 B CN102137748 B CN 102137748B
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surface section
parts
microwave
layer
fiber
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CN102137748A (zh
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G·A·马伦戈
T·M·赫克纳
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GKN Aerospace Services 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
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    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1403—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the type of electromagnetic or particle radiation
    • B29C65/1425—Microwave radiation
    • 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
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    • 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
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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  • Mechanical Engineering (AREA)
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  • Oral & Maxillofacial Surgery (AREA)
  • Thermal Sciences (AREA)
  • Composite Materials (AREA)
  • Chemical & Material Sciences (AREA)
  • Moulding By Coating Moulds (AREA)
  • Reinforced Plastic Materials (AREA)
  • Heating, Cooling, Or Curing Plastics Or The Like In General (AREA)
  • Treatments Of Macromolecular Shaped Articles (AREA)

Abstract

根据本发明的用于制造具有至少一个带有吸收微波(3)的纤维加强的复合材料(4)的层(2)的部件(1)的方法至少包括以下步骤：a)布置至少一个带有外形(5)的层(2)；b)利用微波(3)处理该至少一个层(2)的第一表面区段(6)，其中，用于限制该至少一个层(2)的温度的器件至少暂时地与至少一个相邻的第二表面区段(7)共同作用。尤其地，同样如此执行该方法，即，对多个部件(1，11)执行步骤a)和b)，并且至少根据以下步骤进一步处理该部件(1，11)：c)如此使多个部件(1，11)彼此定位，即，相应地第二表面区段(7)至少部分地形成至少一个重叠区域(12)，d)利用微波(3)处理该至少一个重叠区域(12)。

Description

用于利用微波聚合制造由纤维加强的复合材料制成的部件的方法
技术领域
本发明涉及一种用于制造具有至少一个带有吸收微波的纤维加强的复合材料的层的部件(Bauteil)的方法。本发明尤其应用于制造飞机的机身和/或外流动面的结构性构件(Komponente)。
背景技术
在致力于提供符合未来的生态要求的、且可成本适宜地制造和运行的飞机但满足严格的安全要求的方面，越来越多地寻求这样的可能性，即，不再由铝而是由纤维加强的复合材料制造必要的主要结构(例如，机翼、机身构件、驱动机组的罩壳等)。尤其地，利用该轻型结构技术可显著地减小飞机的重量。在制造这种必要的主要结构时需要注意的是，该主要结构呈现相当大的规模，例如着陆襟翼部件，其在数米之上延伸。此外，在运行中这些部件遭受高负载，并且由此为安全方面危险的部件，在这些部件中，必须尤其遵守质量要求。
通常，这种纤维加强的复合材料包括两种基本组分，即，一方面为纤维以及另一方面为围绕该纤维的聚合体基质(Polymermatrix)。该基质包围纤维并且通过热处理使该基质硬化(聚合)，从而实现三维的交联(Vernetzung)。利用该聚合实现，使纤维固定地相互连接，并且因此可将力引入到纤维中，即，主要通过剪应力。除了碳纤维外，如有可能同样考虑玻璃纤维作为纤维。当前仍然相对昂贵的碳纤维按重量计算通常至少90％由碳组成。纤维直径例如为4.5至8μm(微米)。这种碳纤维的特性为各向异性的。与此相反，玻璃纤维具有无定形(amorphe)结构并且具有各向同性的特性。玻璃纤维主要由氧化硅(Siliciumoxid)组成，其中，如有可能可混合有其它氧化物。虽然玻璃纤维相对便宜，但是碳纤维由其高的强度和刚性而出众。
尤其在飞机制造中采用所谓的预浸处理技术(Prepreg-Technik)。在该工艺中，例如将预浸渍的织物或其它纤维形态(Faserform)(预成型件)浸泡在人造树脂中，并且对其进行热处理仅仅至轻度的硬化(凝胶化)，以使得可以层的方式对其进行加工。这种预浸处理材料表现出一定的粘性，并且由此可良好地布置在相应的成型模具中或逐层地重叠布置，直至构造成期望的部件形状。如果已布置期望的预浸处理材料的层，则可(以热的方式)将其硬化。为了硬化该预浸处理部件，目前应用所谓的高压釜(Autoklave)，即，烘炉，如有可能必须利用超压(直至10bar)在数小时之上加热该烘炉，以使得部件实现完全硬化。
此外，从文件DE 10 2005 050 528 A1中已知一种微波高压釜，利用该微波高压釜提出借助于微波辐射制造纤维复合部件。在该文件中提出的装置使以下成为可能，即，使微波辐射耦合到高压釜的压缩室中。在利用微波激励预浸处理材料时优点在于，不必加热位于高压釜中的空气或位于高压釜中的保护气体，由于部件的尺寸该保护气体具有相当大的体积。通过使用微波工艺待硬化的材料自身可直接升温，相应地剩余环境区域保持相对较冷。在利用微波加热预浸处理材料时，可根据应用的材料应用以下作用机理：电介质(dielektrisch)加热和电阻加热。长链的烃分子(例如在环氧树脂中)为偶极子(Dipol)(即，具有不规则的电荷分布)，并且在由微波产生的电磁场中被激励成以高频振动。然后，该偶极子的动能通过内摩擦转化成热，该热直接在材料中产生(电介质加热)。此外，同样可能的是，通过感应产生涡流，以使得材料的电的阻抗最终引起温度升高(电阻加热)。由此，例如可将材料加热到温度高于130℃或甚至高于160℃，通常在该温度时在预浸处理材料中开始(einsetzen)聚合或硬化。
从文件DE 103 29 411 A1中所描述的微波共振器同样适合于执行这种热处理。该微波共振器一般不在超压的情况下运行。但是，如有可能，该微波共振器还可结合到压力容器(高压釜)中。
在用于这种大型部件(如其应用在飞机制造中)的硬化过程中有问题的是，这些构件的如有可能较复杂的几何结构需要这种纤维加强的复合材料的附加的接合过程。为此通常地，在应用粘结剂情况下将硬化的部件以接合技术的方式相互连接。如有可能，为此对硬化的部件进行表面处理，例如磨光和/或清洁。之后，可能将增粘剂施加到处理过的表面上。随后施覆粘合剂，利用该粘合剂然后可将待相互连接的部件固定。不仅该方法使得必须对大型部件进行繁琐的加工，此外，部件的预处理以及接合过程本身必须非常精确地实施，因为在此误差重复地导致部件削弱，这尤其在飞机制造中不应接受。
发明内容
基于此，本发明的目的为，至少部分地解决参考现有技术所描述的问题。尤其地应给出这样的方法，利用该方法可实现成本适宜地、以可变化的方式且以在整个截面上带有均匀的部件性能的方式制造飞机部件。
该目的利用根据权利要求1的特征的方法实现。在撰写的从属权利要求中给出其它有利的设计方案和应用领域。需指出的是，在撰写的从属权利要求中给出的特征可以技术上合理的方式任意地相互组合，并且指出本发明的其它设计方案。尤其地，与附图相结合的描述列举出本发明的其它实施方案。
根据本发明的用于制造具有至少一个带有吸收微波的纤维加强的复合材料的层的部件的方法包括至少以下步骤：
a)布置至少一个带有外形的层；
b)利用微波处理该至少一个层的第一表面区段，其中，用于该至少一个层的温度限制的器件(Mittel)至少暂时地与至少一个相邻的第二表面区段共同作用。
在此应用的纤维加强的复合材料可吸收微波。由此尤其表示，可利用微波辐射加热该复合材料，即，该复合材料适合用于电介质加热和/或电阻加热。
纤维加强的复合材料尤其为碳纤维加强的复合材料。优选地，该碳纤维实施成在初始状态中无端部的(endlos)长纤维，并且这些长纤维逐层地、以纤维纵向的不同的取向布置在部件中。尤其地，下者之一可考虑作为树脂：环氧树脂、酚醛树脂、双马来酰亚胺树脂或聚酯树脂。
为了制造部件现在可应用这种层，但是同样可能的是，至少局部地重叠地安置多个这种层，以使得如有可能可产生部件的变化的厚度。尤其地，在此一个“层”代表一个预浸处理材料的层。
现在根据步骤a)以期望的外形布置层。如果涉及平面型部件，则如有可能可以平整的(eben)外形布置层。对于期望为弯曲的外形的情况，则可将层以相应的方式布置并固定。因此，尤其地，这样的外形(即，在步骤a)中以该外形布置层)基本上涉及期望的部件的最终形状。
在步骤b)中现在提出利用微波局部限制地处理第一表面区段。为了该目的可能的是，利用微波辐射整个部件，但是，如有可能同样可在第一表面区段或附近周围的区域中进行集中的微波处理。尤其地，在此，为了可靠地引起复合材料的聚合，借助于已提到的加热，温度可达到至少80℃、至少130℃以上或甚至160℃以上。
现在在第一表面区段附近设置有用于限制该至少一个层的温度的器件。该器件在整个微波处理的过程中可为有效的，但是，这不是必须的。该用于温度限制的器件如此与相邻的第二表面区段共同作用，即，在该处使温度不超过50℃。
最终这导致，在执行步骤b)之后，相比于在第二表面区段中，在第一表面区段的区域中可确定在纤维加强的复合材料方面明显更高的交联度。交联度为这样的参数，即，其描述了在所考虑的复合材料的区段中，非聚合的材料组分相对于完全聚合的材料组分的体积份额。
因此，例如，在第一表面区段中(第一)交联度平均为至少80％，而在第二表面区段的区域中，(第二)交联度为最大20％或甚至最大10％或甚至最大4％。
在此，尤其优选的是，在非常狭窄的过渡区域中达到在第一表面区段的区域中的第一交联度和在第二表面区段中的第二交联度，例如，在最大30mm或甚至最大10mm或甚至最大5mm的过渡区域中。在根据步骤b)的首次处理之后，第一表面区段的基本特性为，用于部件的后续加工和处理的足够的强度或交联。这种可得到的交联可从各个基质类型、纤维半成品的种类、纤维的定向以及层或部件厚度中推出或获得。应如此完成根据b)处理的第一表面区段，即，如在传统地制造的部件中那样可实现至少部分地进行再加工。
结果，优选地，因此存在这样的部件，即，该部件基本上在第一表面区段的区域中硬化，而在相邻的第二表面区段中该部件还可变形或可继续借助于微波硬化。根据在此描述的处理可同样通过已知的传统的硬化方法(例如高压釜或空气循环加热炉)实现最终的聚合度或交联度。这适用于部件的全部区域，与在每个部位处实现的聚合度无关。
为了完整性还需指出的是，在执行步骤b)之后可存在多个第二(未(完全地)硬化的)表面区段。同样清楚的是，参考表面区段所考虑的是，微波从部件的一侧起作用但可如此程度地穿透复合材料，即，在部件的整个厚度上或在至少一层上均匀地存在交联度。
同样需指出的是，微波的引入可简单地通过空气或其它气体引导，从而尤其地不必在部件周围提供液态的载体介质(例如水)。
因此，对于具体地可预设的第二表面区段，利用在此描述的方法如此限制微波的作用，即，(很大程度上)不进行硬化或聚合。因此，可在步骤b)之后继续以热的方式处理该第二表面区段，从而改变在第二表面区段中的交联度。
根据该方法的改进方案建议，在步骤b)中作为用于温度限制的器件使至少一个散热元件与第二表面区段接触。例如，这种散热元件包括由铝或带有类似的良好的导热特性的材料制成的(板形的)散热元件。例如，可将这种散热元件(直接地)以与第二表面区段碰触接触的方式定位。尤其地，散热元件的目的为，减小或限制从第一表面区段向第二表面区段的热传导。为此，散热元件也可配备有冷却设备，即自身具有(主动的)冷却。该冷却可为可调节的和/或持续可用的。
此外，同样提出，在步骤b)中作为用于温度限制的器件使至少一种冷却流体与第二表面区段接触。在此，相当尤其优选的是，使温度明显低于100℃、尤其地低于40℃并且如有可能甚至低于20℃的气体和/或液体直接地和/或间接地与第二表面区段接触。相当尤其优选的是，使冷的空气与第二表面区段接触。冷却流体同样具有这样的功能，即，导出如有可能在第二表面区段的区域中产生的热，并且由此防止或限制纤维加强的复合材料的交联。
根据根据本发明的方法的改进方案提出，在步骤b)中作为用于限制温度的器件将至少一个微波屏蔽件定位在第二表面区段处。尤其地，可利用板形的元件提供这种微波屏蔽件，微波不可穿透该屏蔽件。如果没有设置在两侧成型的表面模具在相应的成型时反射微波辐射的金属的薄膜或金属气相淀积的薄膜优选地作为柔性的支撑(Auflage)。金属的织物或针织物(例如网(Netz))同样适用于在步骤b)中的处理(其中，同时在第二表面区段中对部件进行通风)期间使用，其中，具体的设计方案(例如网孔宽度)必须与所应用的微波频率相匹配，从而实现需求的屏蔽。
现在通过将微波屏蔽件定位在微波源和第二表面区段之间，使微波辐射不可到达第二表面区段，并且由此在该处不导致温度升高和聚合。以这种方式，还在期望的范围中阻止聚合。如有可能，可同样直接使这种微波屏蔽件与第二表面区段接触，以使得其附加地作为散热元件起作用。
因此，根据该方法的改进方案，在多个部件处执行步骤a)和b)，并且根据至少以下步骤进一步处理这些部件：
c)如此使多个部件彼此定位，即，相应地第二表面区段至少部分地形成至少一个重叠区域，
d)利用微波处理该至少一个重叠区域。
现在该方法尤其地涉及多个这种部分地硬化的部件的接合或这种部分地硬化的部件与未处理的部件或层的接合。在此，在步骤c)中如此使部件彼此对准或重叠地放置部件，即，第二表面区段(直接地)彼此贴靠。在此，尤其地可取消传统所需的表面区段的准备工作或取消施覆附加的粘合剂。现在在第二表面区段彼此贴靠之后，可借助于微波再次开始部件的处理。如有可能在能量方面有意义的是，仅仅利用微波针对地处理重叠区域，然而这不是必须的，从而同样可处理已经硬化的第一表面区段或可进一步提高在该处的交联度。结果，然而因此可由多个部件制造构件，该构件在所有横截面中具有相同的交联度，其中，尤其地，即使在复杂的形状几何结构(Formgeometrie)中也可保证均匀的材料特性。
就此而言同样视作有利的是，至少在步骤b)和c)之间或在步骤c)期间，在第二表面区段的区域中使部件中的至少一个变形。尤其地，该变形导致部件的不同的外形。例如，这使得以下成为可能，即，首先以一定的外形制造部件并且之后使其匹配于具体的部件。由此，尤其显著地减小了用于执行步骤a)和b)的加工成本。优选地，在步骤c)期间发生变形，其中，如有可能通过相应的保持装置使部件彼此固定。在任何情况下该变形还导致，重叠的第二表面区段可靠地且以彼此对准的方式接触。
此外，同样视作有利的是，在步骤d)中在重叠区域中构造多个部件的直接的材料配合的连接。换句话说，尤其地，在步骤d)之后在材料配合连接部的区域中不可识别出材料过渡、强度区别和/或在交联度方面的明显区别。
相当尤其优选地，在此建议的方法用于制造包括这种部件的飞机的机体或外流动面的构件。该构件尤其涉及以下分组之一：着陆襟翼、襟翼导轨臂、机头部分、方向舵组、升降舵组、扰流板、机顶元件、喷嘴罩壳悬臂(Ausleger)、结构框架。需指出的是，在此“飞机”仅仅作为优选的应用方案给出，同样在其它飞行器(例如直升飞机)中存在其它应用范围。
根据以下示例说明在此描述的方法的作用：
初始状态
预浸处理材料：在树脂含量为35％的情况下带有
              环氧树脂基质和145g/m2的单位面
              积重量的单向的12K HTS碳纤维
              预浸处理料坯
层厚度：0.145mm
层数：16
其它薄膜：脱模布(Abreiβgewebe)、分离薄膜、
          通风毛毡(Belüftungsvlies)、真空薄
          膜
起始温度：25℃
步骤b)：
用于温度限制的器件：铝板
定位：覆盖一半预浸处理板
冷却流体：压缩空气
微波频率：2.45GHz
微波功率：约10kW
处理时间：约3小时45分钟
在第一表面区段中的温度：135℃
在第二表面区段中的温度：42℃
结果：
第一交联度：大于80％
第二交联度：低于20％
过渡区域：小于18mm
附图说明
下面根据附图进一步解释本发明以及技术环境。需指出的是，附图显示了本发明的尤其优选的实施方案，但是不应将本发明限制于这些实施方案。其中：
图1示意性地显示了用于执行根据本发明的方法的结构，
图2示意性地显示了飞机，以及
图3至6示意性地显示了根据根据本发明的实施方案的单独的方法步骤。
具体实施方式
在图1中示意性地示出了用于执行根据本发明描述的方法的装置20。例如，该装置20可涉及传统的高压釜，该高压釜构造成带有大量微波热源，该微波热源包括微波源。例如，该微波源辐射带有在30兆赫至50千兆赫范围内的频率的微波，典型的频率例如为0.913千兆赫、2.45千兆赫或5.8千兆赫。尤其地，根据当前的现有技术可利用磁电管以成本适宜的方式提供2.45千兆赫的频率，其中，微波功率尤其适合用于使能量耦合到纤维复合材料的基质中。原则上，装置20也可在提高的环境压力下工作。
在中央示出了第一部件1，该第一部件1由单个的由复合材料4制成的第一层2制造，并且具有平面型外形5。在此，尤其涉及所谓的预浸处理材料，在该预浸处理材料中碳纤维存在于环氧树脂基质中。
第一部件1具有第一表面区段6和第二表面区段7，这两个表面区段布置成彼此相邻。在图1的图示中，微波3从上方作用于第一部件1，从而现在同样在第二表面区段7之上(如有可能同样在其之下)设置有散热元件8。此外，散热元件8具有冷却系统，利用该冷却系统可将冷却流体9朝向第二表面区段7引导。附加地散热元件8(例如根据铝板的方式)使得，微波3不可到达第二表面区段7，即，该散热元件8附加地根据微波屏蔽件10的方式起作用。在利用微波3对第一部件1进行处理时，第一表面区段6硬化直至期望的交联度。由于以上描述的措施，与第一表面区段6相邻布置的第二表面区段7未达到这种交联度，而是实际上保持(几乎)交联度不增加。
应指出的是，尤其对于这样的情况(即，装置20在压力下工作)，可利用薄膜或微层(其例如应保证从(在此未示出的)部件容纳部中的可脱模性)包围第一部件1。例如，该微层涉及多个真空薄膜(真空薄膜)、热的绝缘体、分离薄膜以及类似者。在此，真空薄膜为用于第一部件1的外部包围覆层，从而用于这种结构的根据本发明的方法的相应的应用也被包括在内，并且不会偏离本发明的对象。
图2再次说明了飞机17的机身或流动面16的构件14，这些构件14可根据在此根据本发明描述的方法利用部件制造。可看出，可利用提出的方法制造飞机17的恰好大面积的主要结构部件，其中，可同样显著减小飞机17的重量。由此得到的更小的燃油消耗量和/或更高的载重量为本发明的主要优点。
现在图3至6说明了根据本发明的方法的实施方案的不同步骤。在图3中重新示意性地示出了第一部件1，但是在此该第一部件1构造成多层的，即，带有第一层2、第二层18以及第三层19。在此，这些层可为不同的和/或相同的预浸处理材料的层。在这种情况中同样提出利用微波3辐射吸收微波的、纤维加强的复合材料4以用于使第一表面区段6硬化。散热元件8以直接接触的方式位于(较小的)第二表面区段7的区域中，从而如有可能使在该处产生的热量从第一部件1中除去，并且由此限制或阻止硬化过程。
现在图4显示了两个部件彼此的布置，即，第一部件1和第二部件11。两个部件都具有第二表面区段7(在此为了强调以白色示出)，这两个表面区段7尚可变形且未硬化。现将两个部件布置成如此部分地重叠，即，构造带有尚未硬化的复合材料的重叠区域12。在右边示出的第二部件11方面，同样地存在外形5的变化。
利用微波3处理如此准备的第一部件和第二部件11的布置，其中，如有可能同样可有针对性地进行该处理，如在图5中通过外部仅由虚线指出的微波3说明的那样。在此，直接的材料配合的连接部13构造在重叠区域12中。
结果，最终制造出构件14，该构件14在整个横截面上具有相同的材料特性，如在图6中通过均匀地涂色而说明的那样。
参考标号列表
1     第一部件
2     第一层
3     微波
4     复合材料
5     外形
6     第一表面区段
7     第二表面区段
8     散热元件
9     冷却流体
10    微波屏蔽件
11    第二部件
12    重叠区域
13    连接部
14    构件
15    机身
16    流动面
17    飞机
18    第二层
19    第三层
20    装置

Claims (8)

1.一种用于制造具有至少一个带有吸收微波(3)的纤维加强的复合材料(4)的层(2)的部件(1)的方法，所述方法至少包括以下步骤：
a)布置至少一个带有外形(5)的层(2)；
b)利用微波(3)处理所述至少一个层(2)的第一表面区段(6)，其中，用于限制所述至少一个层(2)的温度的器件至少暂时地与至少一个相邻的第二表面区段(7)共同作用；
其中，在步骤b)中作为用于温度限制的器件使自身具有主动冷却的至少一个散热元件(8)与所述第二表面区段(7)接触。
2.根据权利要求1所述的方法，其特征在于，在步骤b)中作为用于温度限制的器件使至少一种冷却流体(9)与所述第二表面区段(7)接触。
3.根据权利要求1所述的方法，其特征在于，在步骤b)中作为用于温度限制的器件将至少一个微波屏蔽件(10)定位在所述第二表面区段(7)处。
4.根据权利要求1所述的方法，其特征在于，为多个部件(1，11)执行步骤a)和b)，并且至少根据以下步骤进一步处理所述部件(1，11)：
c)如此使多个部件(1，11)彼此定位，即，相应地第二表面区段(7)至少部分地形成至少一个重叠区域(12)，
d)利用微波(3)处理所述至少一个重叠区域(12)。
5.根据权利要求4所述的方法，其特征在于，至少在步骤b)和c)之间或在步骤c)期间，在第二表面区段(7)的区域中使所述部件(1，11)中的至少一个变形。
6.根据权利要求4所述的方法，其特征在于，在步骤d)中在所述重叠区域(12)中构造所述多个部件(1，11)的直接的材料配合的连接部(13)。
7.根据权利要求5所述的方法，其特征在于，在步骤d)中在所述重叠区域(12)中构造所述多个部件(1，11)的直接的材料配合的连接部(13)。
8.一种具有至少一个部件(1，11)的飞机(17)的机身(15)或外流动面(16)的构件(14)，所述部件(1，11)根据权利要求1至7中任一项所述的方法制造。
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