CN102137749B - 组装并成形层压板 - Google Patents
组装并成形层压板 Download PDFInfo
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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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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract
一种组装和成形层压板的方法。将中间构件(3)安装在铺设台(4)上,并且通过将一系列层铺设在所述铺设台(4)上的所述中间构件(3)上来组装叠层。然后将所述中间构件(3)和所述叠层从所述铺设台去除并且将它们放置在成形表面上。然后以改变所述叠层的形状的方式通过所述中间构件(3)将所述叠层紧压在所述成形表面上,以形成成形层压板(3)。最后将所述成形层压板从所述中间构件去除。因此在组装期间所述铺设台(4)可以支撑所述柔性中间构件(3),并且可以是相对平坦的,以能够通过自动工艺组装所述叠层。
Description
技术领域
本发明涉及一种用于组装并成形层压板的方法和设备。
背景技术
WO2004054735描述了在形成成形面板中“中间构件”的使用。虽然主要涉及金属面板的制造,但是述及所述设备可以用来形成复合材料,例如,部件由树脂中的大量纤维层形成的复合材料。
关于使用WO2004054735的装置形成层压板的问题在于,难以通过将一系列层放置在中间构件上来组装面板。这是因为中间构件具有复杂的弯曲形状,这使得难以在不形成皱褶的情况下组装叠层。该问题的一个解决方案是手工组装叠层,但是这可能费时且昂贵。WO2004054735确实述及中间构件可以是平坦的。然而即使中间构件是平坦的,但由于中间构件的固有柔性,因此当组装层时该中间构件也会弯曲。
发明内容
本发明的第一方面提供一种组装和成形层压板的方法,所述方法包括:将中间构件安装在铺设台上;通过将一系列层铺设在所述铺设台上的所述中间构件上来组装叠层;将所述中间构件和所述叠层从所述铺设台去除并且将它们放置在成形表面上;以改变所述叠层的形状的方式通过所述中间构件将所述叠层紧压在所述成形表面上,以形成成形层压板;以及将所述成形层压板从所述中间构件去除,其中,所述叠层借助于空气压差被紧压在所述成形表面上,所述空气压差至少部分地通过吸力提供,其中,通过在所述中间构件上的所述叠层上铺设真空袋并且在所述真空袋和所述成形表面之间产生部分真空而产生所述吸力,并且其中所述方法还包括通过在所述中间构件和真空箱之间形成气密密封以便形成真空室,并且通过在所述真空室中产生部分真空而在所述真空袋被去除之后将所述中间构件紧压在所述成形表面上,所述真空室包含所述成形表面。
因而在组装期间所述铺设台可以支撑所述柔性中间构件,并且可以是相对平坦的以能够容易地组装所述叠层。可以用手或更优选地通过自动工艺进行所述叠层的组装。
任选地,可以在所述真空袋和所述叠层之间设置隔板。
在所述叠层成形之后,因而可能希望将一个或更多个复合部件,诸如桁条共同固化到所述成形层压板。在使用所述真空袋的情况下,因而必须去除所述真空袋以使所述面板易接近。然而,随之带来的问题在于,当真空被解除时所述面板可能弹回到其初始形状。该问题通过以下方式解决,即,通过在所述中间构件和真空箱之间形成气密密封以便形成真空室,并且通过在所述真空室中产生部分真空而在所述真空袋被去除之后将所述中间构件紧压在所述成形表面上,所述真空室包含所述成形表面。
所述气密密封例如可以通过系到所述中间构件和所述真空箱的制袋材料,或者通过使所述中间构件和所述真空箱之间的密封构件充气来形成。
所述叠层中的每一层均可包括用基体(诸如环氧树脂)浸渍的一系列纤维(诸如碳纤维)。可选地,每一层均可以包括随后用树脂浸渍的干纤维层。
通常,在成形步骤之后,所述成形层压板例如通过在炉中加热所述面板或者通过红外加热,或通过任何其他固化技术被固化。在该情况下,所述成形步骤可以在炉中或炉外进行。
本发明的第二方面提供一种用于组装和成形层压板的设备,所述设备包括:柔性中间构件;铺设台,该铺设台可以支撑所述柔性中间构件;成形表面,叠层可以通过所述中间构件以改变所述叠层的形状的方式被紧压在所述成形表面上,从而形成成形层压板;真空箱;以及密封构件,该密封构件用于在所述中间构件和所述真空箱之间形成气密密封。
一种组装和成形层压板的方法,所述方法包括:将中间构件安装在铺设台上;通过将一系列层铺设在所述铺设台上的所述中间构件上来组装叠层;将所述中间构件和所述叠层从所述铺设台去除并且将承载有所述叠层的所述中间构件放置在成形表面上,使得所述中间构件的与放置有所述叠层的表面对置的那个表面面对所述成形表面,并且所述成形表面位于真空箱中;以改变所述叠层的形状的方式通过所述中间构件将所述叠层紧压在所述成形表面上,以形成成形层压板;以及将所述成形层压板从所述中间构件去除,其中,所述叠层借助于空气压差被紧压在所述成形表面上,所述空气压差至少部分地通过吸力提供,其中,通过在所述中间构件上的所述叠层上铺设真空袋并且在所述真空袋和所述成形表面之间产生部分真空而产生所述吸力,并且其中所述方法还包括通过在所述中间构件和所述真空箱之间形成气密密封以便形成真空室,并且通过在所述真空室中产生部分真空而在所述真空袋被去除之后将所述中间构件紧压在所述成形表面上,所述真空室包含所述成形表面。
进一步地,该方法还包括:将所述真空袋从所述成形层压板去除;在所述真空袋被去除之后,使所述成形层压板与一个或更多个复合部件接合;并且将所述复合部件共同固化到所述成形层压板。
进一步地,所述气密密封通过使所述中间构件和所述真空箱之间的密封构件充气来形成。
进一步地,该方法还包括:改变所述成形表面的形状以形成改变的成形表面。
进一步地,所述成形表面包括两个或更多个成形构件,并且其中所述成形表面的形状通过用具有不同形状的新成形构件代替所述成形构件中的一个或更多个成形构件来改变。
进一步地,每一层均包括用基体浸渍的一系列纤维。
一种用于组装和成形层压板的设备,所述设备包括:柔性中间构件;铺设台,该铺设台可以支撑所述柔性中间构件;成形表面,承载有叠层的所述中间构件放置在该成形表面上,使得所述中间构件的与放置有所述叠层的表面对置的那个表面面对所述成形表面,所述叠层可以通过所述中间构件以改变所述叠层的形状的方式被紧压在该成形表面上,以形成成形层压板;真空箱,所述成形表面位于该真空箱中;以及密封构件,该密封构件用于在所述中间构件和所述真空箱之间形成气密密封。
进一步地,所述成形表面包括所述真空箱中的多个成形构件。
进一步地,每个所述成形构件均具有:接合所述真空箱的底板的基底;以及限定所述成形表面的一部分的成形上表面。
附图说明
现在将参照附图描述本发明的实施方式,其中:
图1示出通过自动铺带(ATL)机组装的叠层;
图2示出被从铺设台去除并且放置在真空箱中的成形表面上的中间构件和叠层;
图3示出被放置在叠层上的隔板;
图4示出在真空袋被装配之后的组件;
图5是沿图4中的线A-A剖取的组件的剖视图;
图5a是示出第一密封布置的详细视图;
图5b是示出第二密封布置的详细视图;
图6是在真空形成层压板期间沿线A-A剖取的组件的剖视图;
图7示出正被插入压热器中的成形层压板、中间构件以及真空箱;以及
图8是具有铺设在成形层压板上的一系列桁条的组件的剖视图。
具体实施方式
图1示出了由自动铺带(ATL)机2组装的用于层压板的叠层1。ATL机2通过将一系列层铺设在安装于铺设台4上的中间构件3上来组装叠层1。
中间构件3由诸如不胀钢(Invar)、不锈钢或其他含铁材料的柔性材料或者复合材料制成,并且具有基本上不变的厚度。
ATL机2包括安装在一对轨道6上的框架5。框架5承载ATL头7,该ATL头7以一系列窄条的方式铺设“预浸”带,条的方向由ATL头在框架5上的运动和框架5沿轨道6的运动控制。因此叠层1的每层均由带的一系列条形成。“预浸”带包括用环氧树脂基体浸渍的单向碳纤维。通常纤维方向在层之间变化以赋予沿不同方向的面板强度。
中间构件3和铺设台4基本上是平坦的使得相对容易以这种自动方式铺带。
图2示出了承载有叠层的中间构件,该承载有叠层的中间构件被从铺设台去除并且放置在真空箱10中的成形表面上。真空箱10包括底板11、左侧壁12、右侧壁13、前端壁14以及后端壁15。成形表面包括一系列肋板16,在图2中示出三个这样的肋板。每个肋板16均具有基底20和成形上表面22,基底20接合真空箱的底板11。因此肋板16与真空箱形成敞开结构,并且相邻肋板之间具有间隙。
当中间构件3和叠层1在真空箱10上就位时,如图3所示,在叠层1上放置隔板30。然后装配图4中所示的柔性真空袋31。真空袋31可以是可重复使用的真空袋或者是一次性的卡普纶(Capran)(R)真空袋。
图5是沿穿过肋板16中的一个肋板的线A-A的剖视图。通过图5a和5b所示的密封带环33在真空袋31和真空箱10之间形成气密密封。
另外,在中间构件3和真空箱10的顶部之间形成气密密封。可以以图5a和5b所示的两种可选方式中的一种方式形成该密封。
在图5a所示的布置中,中间构件3和真空箱10之间的密封由制袋材料环23产生,该制袋材料环23通过一对密封带环24附接至中心构件3和真空箱10。这产生了两个密封真空室,即:
·真空箱10和中间构件3之间的、在图5中标出的下真空室26;和
·中间构件3和真空袋31之间的、在图5a中标出的上真空室25。
然后真空室25、26分别通过真空袋31的第一真空口(未示出)和真空箱中的第二真空口(未示出)被部分抽空。这产生了压差,该压差以如图6所示改变叠层的形状的方式通过中间构件3将叠层1紧压在成形表面上。真空袋31和隔板30也压靠叠层并且使该叠层压实。制袋材料密封件23具有一些松弛,这允许中间构件3在其弯曲时抵靠真空箱10横向地滑动。
然后如图7所示,将成形层压板、中间构件以及真空箱输送到压热器40。然后面板以一步式固化工艺或两步式固化工艺在压热器40中被固化。
在一步式固化工艺的情况下,真空袋31和隔板30在真空箱被输送到压热器40之前或之后被去除。密封件23、24保持就位,使得下真空室26中维持部分真空。这确保了中间构件3保持被紧压在肋板16上,因此即使在真空袋31被去除之后,也可以如图8所示保持中间构件3的变形形状。
然后,如图8所示,在成形层压板的上表面上铺设一系列桁条50。然后,将真空袋31放回图8所示的组件上,位于桁条的顶部上。然后将上真空室25部分抽空以压实桁条,并且面板和桁条在压热器40中通过温度和压力的结合被共同固化。
在两步式固化工艺中,当真空箱被输送到压热器时,真空袋和隔板被置留就位。然后面板在第一固化阶段中通过温度和压力的结合被部分固化。在第一固化阶段之后,如图8所示,去除真空袋和隔板并且将桁条50铺设在部分固化的面板之上。然后将真空袋31放回组件上,位于桁条的顶部上。然后面板和桁条在第二固化阶段中通过温度和压力的结合被固化。
在固化(通过一步式固化工艺或两步式固化工艺)之后,从压热器40去除固化的层压板、中间构件以及真空箱,解除真空,去除隔板和真空袋,并且使中间构件返回到铺设台。固化的层压板在其返回到铺设台之前或之后可以从中间构件3去除。
可以通过用具有不同于肋板16的上表面22的形状的新肋板代替肋板中的一个或更多个肋板来改变成形表面的形状。然后可以重复该工艺以利用新的成形表面制造另一种成形层压板。
在图5b所示的可选密封布置中,中间构件3和真空箱10之间的密封通过取代制袋材料环23的可充气式密封环27形成。密封环27为了初始面板成形工艺而在压热器外被放气。这使空气能够在上室25和下室26之间流动,因而仅需要单个真空口(位于真空袋31中或真空箱10中)。还允许在成形工艺期间中间构件3抵靠真空箱10横向地滑动而不会损坏密封环27。
在成形步骤之后(并且任选地在第一固化阶段之后),密封环27被充气以密封抽空的下真空室26,使真空袋31能被去除并且能够将桁条50放置在叠层上,而面板和中间构件不弹回到平坦形状。然后将真空袋31放回到组件上,位于桁条的顶部上。然后面板和桁条在压热器中被固化。密封环27在共同固化工艺期间可以被充气或放气。
尽管上面已经参照一个或更多个优选实施方式描述了本发明,但是应理解,在没有脱离如附随的权利要求所限定的本发明的范围的情况下,可以进行各种改变或修改。
Claims (10)
1.一种组装和成形层压板的方法,所述方法包括:将中间构件安装在铺设台上;通过将一系列层铺设在所述铺设台上的所述中间构件上来组装叠层;将所述中间构件和所述叠层从所述铺设台去除并且将承载有所述叠层的所述中间构件放置在成形表面上,使得所述中间构件的与放置有所述叠层的表面对置的那个表面面对所述成形表面,并且所述成形表面位于真空箱中;以改变所述叠层的形状的方式通过所述中间构件将所述叠层紧压在所述成形表面上,以形成成形层压板;以及将所述成形层压板从所述中间构件去除,其中,所述叠层借助于空气压差被紧压在所述成形表面上,所述空气压差至少部分地通过吸力提供,其中,通过在所述中间构件上的所述叠层上铺设真空袋并且在所述真空袋和所述成形表面之间产生部分真空而产生所述吸力,并且其中所述方法还包括通过在所述中间构件和所述真空箱之间形成气密密封以便形成真空室,并且通过在所述真空室中产生部分真空而在所述真空袋被去除之后将所述中间构件紧压在所述成形表面上,所述真空室包含所述成形表面。
2.根据权利要求1所述的方法,该方法还包括:将所述真空袋从所述成形层压板去除;在所述真空袋被去除之后,使所述成形层压板与一个或更多个复合部件接合;并且将所述复合部件共同固化到所述成形层压板。
3.根据权利要求1所述的方法,其中,所述气密密封通过使所述中间构件和所述真空箱之间的密封构件充气来形成。
4.根据权利要求2所述的方法,其中,所述气密密封通过使所述中间构件和所述真空箱之间的密封构件充气来形成。
5.根据权利要求1至3中任一项所述的方法,该方法还包括:改变所述成形表面的形状以形成改变的成形表面。
6.根据权利要求5所述的方法,其中,所述成形表面包括两个或更多个成形构件,并且其中所述成形表面的形状通过用具有不同形状的新成形构件代替所述成形构件中的一个或更多个成形构件来改变。
7.根据权利要求1或2所述的方法,其中,每一层均包括用基体浸渍的一系列纤维。
8.一种用于组装和成形层压板的设备,所述设备包括:柔性中间构件;铺设台,该铺设台可以支撑所述柔性中间构件;成形表面,承载有叠层的所述中间构件放置在该成形表面上,使得所述中间构件的与放置有所述叠层的表面对置的那个表面面对所述成形表面,所述叠层可以通过所述中间构件以改变所述叠层的形状的方式被紧压在该成形表面上,以形成成形层压板;真空箱,所述成形表面位于该真空箱中;以及密封构件,该密封构件用于在所述中间构件和所述真空箱之间形成气密密封。
9.根据权利要求8所述的设备,其中,所述成形表面包括所述真空箱中的多个成形构件。
10.根据权利要求9所述的设备,其中,每个所述成形构件均具有:接合所述真空箱的底板的基底;以及限定所述成形表面的一部分的成形上表面。
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US20150192919A1 (en) * | 2015-03-24 | 2015-07-09 | Caterpillar Inc. | Support members for three dimensional object printing |
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US10773464B2 (en) | 2017-11-21 | 2020-09-15 | General Electric Company | Method for manufacturing composite airfoils |
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US11654647B2 (en) | 2018-03-12 | 2023-05-23 | Cytec Industries Inc. | Fabrication of three-dimensional composite structures |
US11633927B2 (en) * | 2020-05-26 | 2023-04-25 | Spirit Aerosystems, Inc. | System and apparatus for manufacturing simple curvature thermoplastic composite parts |
CN113715366A (zh) * | 2020-05-26 | 2021-11-30 | 势必锐航空系统有限公司 | 用于制造复合零件的系统和方法 |
US11628628B2 (en) * | 2020-05-26 | 2023-04-18 | Spirit Aerosystems, Inc. | Method of manufacturing simple curvature thermoplastic composite parts |
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