CN102196962B - 使用复合模件制造结构的方法以及由此制成的结构 - Google Patents

使用复合模件制造结构的方法以及由此制成的结构 Download PDF

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CN102196962B
CN102196962B CN2009801426757A CN200980142675A CN102196962B CN 102196962 B CN102196962 B CN 102196962B CN 2009801426757 A CN2009801426757 A CN 2009801426757A CN 200980142675 A CN200980142675 A CN 200980142675A CN 102196962 B CN102196962 B CN 102196962B
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D·D·琼斯
A·J·伯格
J·D·布里南
T·J·谢伍德
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    • B29C31/04—Feeding of the material to be moulded, e.g. into a mould cavity
    • B29C31/08—Feeding of the material to be moulded, e.g. into a mould cavity of preforms to be moulded, e.g. tablets, fibre reinforced preforms, extruded ribbons, tubes or profiles; Manipulating means specially adapted for feeding preforms, e.g. supports conveyors
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    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C70/28—Shaping operations therefor
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/545—Perforating, cutting or machining during or after moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64C—AEROPLANES; HELICOPTERS
    • B64C1/00—Fuselages; Constructional features common to fuselages, wings, stabilising surfaces or the like
    • B64C1/06—Frames; Stringers; Longerons ; Fuselage sections
    • B64C1/12—Construction or attachment of skin panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64F—GROUND OR AIRCRAFT-CARRIER-DECK INSTALLATIONS SPECIALLY ADAPTED FOR USE IN CONNECTION WITH AIRCRAFT; DESIGNING, MANUFACTURING, ASSEMBLING, CLEANING, MAINTAINING OR REPAIRING AIRCRAFT, NOT OTHERWISE PROVIDED FOR; HANDLING, TRANSPORTING, TESTING OR INSPECTING AIRCRAFT COMPONENTS, NOT OTHERWISE PROVIDED FOR
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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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    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
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    • B29K2307/00—Use of elements other than metals as reinforcement
    • B29K2307/04—Carbon
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3076—Aircrafts
    • B29L2031/3082—Fuselages
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64C—AEROPLANES; HELICOPTERS
    • B64C1/00—Fuselages; Constructional features common to fuselages, wings, stabilising surfaces or the like
    • B64C2001/0054—Fuselage structures substantially made from particular materials
    • B64C2001/0072—Fuselage structures substantially made from particular materials from composite materials
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Abstract

通过形成多个复合层压模件(208d、208e)并沿其边缘(210)使用楔面接头将模件连接在一起，制造大型复合结构。

Description

使用复合模件制造结构的方法以及由此制成的结构
技术领域
本公开一般地涉及制造复合结构的技术，更特别地涉及通过将复合模件连接在一起制造大型复合结构的方法。
背景技术
可以使用能够以较高速率将复合材料放下的高级纤维铺放(高级铺丝，AFP)机制造大型复合结构如航空器机身外壳。获得较高的单位产率的一种方法可以通过提供较多数量的AFP机来完成，但是，就机器成本、加工和工厂房屋面积而言，使用额外的AFP机可能导致需要大量的资金投资。
因此，需要以较低的资金投资和生产费用来获得相对高的产率的制造方法。还需要相对灵活并依靠比AFP机更简单的设备的制造方法。
发明内容
依据所公开的实施方式，提供了制造复合结构、尤其是大型复合结构的方法，其使用较低成本的设备提供较高的产率。通过以单独制造然后连接在一起并共固化的模件制造大型结构，可以减少生产时间。所述结构的单个模件可以使用合适大小的设备并行制造，总地来说，其相较于传统的AFP机器可以能够有更高的材料铺放速率。所公开的方法也允许使用能够操作可能需要的多种形式的材料的设备，以满足结构的特定区域的负载要求。
依据一个公开的实施方式，提供了制造复合结构的方法，所述方法包括：形成多个复合模件，每个模件都具有边缘；和，沿其边缘连接所述模件。可以使用所述模件边缘之间的、可以包括一个或多个搭接斜面(overlapping ramps)的楔面接头(嵌接)来连接所述模件。可以通过形成小圆齿状图案的多个楔面接头将相邻模件连接在一起，其中所述模件包括单向的、方位不是0或90度的增强纤维。
依据另一公开的方法实施方式，制造复合结构包括：形成多个多层复合模件；将所述复合模件组装在一起，包括在至少某些模件之间形成楔面接头；和，在形成所述楔面接头之后共固化所述模件。可以通过邻接类似层的相邻模件或通过搭接所述类似层形成所述楔面接头。
依据进一步公开的实施方式，用于航空器的复合结构包括：多个复合层压模件，每个复合层压模件都具有边缘；和，用于沿其边缘连接所述模件的楔面接头。每个所述模件包括多层。邻接数个模件的类似层在楔面接头处可以是邻接的或搭接的。在一个变化中，所述楔面接头可以是指形接头，某些所述邻接模件之间的接头可以形成小圆齿状图案。
公开内容的实施方式满足了对使用合适大小的、代表较低资金投资的设备制造大型复合结构的方法的需求。公开的实施方式也满足了对高度灵活并允许结构的多个模件并行形成的制造方法的需求。
1.制造复合结构的方法，包括：
形成多个复合模件，每个所述复合模件具有边缘；和
沿其边缘将所述模件连接在一起。
2.根据权利要求1所述的方法，其中连接所述模件包括在所述模件的各自边缘之间形成楔面接头。
3.根据权利要求1所述的方法，其中所述模件包括相对方位轴形成约45度的角的预浸料纤维，并且其中：
将所述模件连接在一起包括形成接头，所述接头沿所述模件的边缘限定了小圆齿状图案。
4.根据权利要求3所述的方法，其中将所述模件连接在一起包括沿所述模件的边缘形成楔面接头。
5.根据权利要求1所述的方法，其中每个所述模件包括至少两个边缘，以及将所述模件连接在一起包括：
分别沿所述至少两个边缘在所述模件之间形成至少两个楔面接头。
6.根据权利要求1所述的方法，其中每个所述模件包括多个层，并且沿其边缘将所述模件连接在一起包括：
沿所述边缘搭接至少某些所述层。
7.根据权利要求1所述的方法，其中每个所述模件包括多个层，并且沿其边缘将所述模件连接在一起包括：
沿所述边缘充分地邻接所述层。
8.根据权利要求1所述的方法，其中将所述模件连接在一起包括沿所述模件的边缘形成至少一个楔面接头。
9.根据权利要求1所述的方法制造的大型航空器结构。
10.制造复合结构的方法，包括：
形成多个多层复合模件；
将所述复合模件组装在一起，包括在至少某些所述复合模件之间形成楔面接头；和，
在形成所述楔面接头之后共固化所述复合模件。
11.根据权利要求10所述的方法，其中形成楔面接头包括邻接连接在一起的至少某些模件的相邻模件的所述层。
12.根据权利要求10所述的方法，其中形成楔面接头包括充分地搭接连接在一起的至少某些模件的相邻模件的所述层。
13.根据权利要求10所述的方法，其中：
形成所述多层复合模件包括铺放纤维增强复合材料层，其纤维方位横过所述模件的边缘延伸，以使所述边缘形成小圆齿状图案，和
组装所述模件包括将连接在一起的所述模件的相邻模件的所述小圆齿状图案装配在一起。
14.根据权利要求13所述的方法，其中组装所述模件包括使模件相对于彼此错开排列以使所述小圆齿状图案相对于彼此偏移(offset)。
15.根据权利要求10所述的方法，其中将所述模件组装在一起包括将至少一个所述模件放置在一个所述楔面接头之上。
16.根据权利要求10所述的方法，其中组装所述模件包括在固化工具上相对于彼此放置所述模件。
17.根据权利要求1所述的方法制造的复合航空器结构。
18.用于航空器的复合结构，包括：
多个复合层压模件，每个所述复合层压模件具有边缘；和
用于沿其边缘连接所述模件的楔面接头。
19.根据权利要求18所述的复合结构，其中：
每个所述模件包括多层，和
所述模件的邻接模件中的类似层在所述楔面接头处彼此邻接。
20.根据权利要求18所述的复合结构，其中：
每个所述模件包括多层，和
模件的邻接模件中的类似层在所述楔面接头处搭接。
21.根据权利要求18所述的复合结构，其中所述楔面接头是指形接头。
22.根据权利要求18所述的复合结构，其中：
具有通过所述楔面接头连接在一起的边缘的至少某些所述模件每个包括至少一个层，所述层包括具有正常方位(commonorientation)的增强纤维，和
所述楔面接头连接所述某些模件形成小圆齿状图案。
23.根据权利要求18所述的复合结构，进一步包括：
复合材料的至少一个层位于至少一个所述楔面接头之上并与其连接。
24.用于航空器的大型复合结构，包括：
多个共固化的复合层压模件，每个所述复合层压模件包括纤维增强树脂的多层，每个所述模件包括横过彼此延伸的第一边缘和第二边缘，
所述模件的相邻模件的层边缘彼此搭接以形成楔面接头，将所述相邻模件连接在一起，和
至少某些所述相邻模件包括具有方位横过所述边缘的纤维增强的层，并且其中所述第一边缘和第二边缘形成小圆齿状图案。
25.制造大型复合航空器结构的方法，包括：
形成多个复合模件，每个所述复合模件包括多个纤维预浸料的层，其中至少某些所述层的产生包括横过所述模件的边缘延伸的纤维方位；
放置所述模件的边缘以形成小圆齿状轮廓；
将所述复合模件组装在一起，包括在所述模件之间形成楔面接头并匹配所述邻接模件的所述小圆齿状轮廓；
将所述模件放置在固化工具上；和
在将所述模件放置在所述固化工具上之后共固化所述模件。
附图说明
图1是适于模件复合机身外壳制造方法的说明性实施方式的实施的制造系统的示意性俯视图。
图2是适于模件复合机身外壳制造方法的说明性实施方式的实施的制造系统的透视图。
图3是SADL(半自动化双定位器)机、取置机(pick and placemachine)和固化工具的端视图。
图4是概述模件复合机身外壳制造方法的说明性实施方式的流程图。
图5是航空器生产和服务方法的流程图。
图6是航空器的框图。
图7是用于制造复合结构的说明性实施方式的流程图。
图8图解说明用于制造复合结构的其它实施方式。
图9是相邻放置的复合模件的横截面图。
图10是图解说明依据所公开的实施方式由多个模件形成的航空器机身外壳的分部的平面图。
图11是由图10中图解说明类型的分部形成的机身部分的透视图。
图12是沿图10中的沿线12-12取的横截面图。
图13是显示图12所示的楔面接头的层的示意图。
图14是图10中沿线14-14取的横截面图。
图15是显示图14的楔面接头的层的示意图。
图16是图10中指示为“A”的区域的放大图。
图17是依据可选实施方式的另一楔面接头的横截面图。
图18是显示图17的楔面接头的层的示意图。
图19是具有小圆齿状边缘的复合模件的透视图。
图20是显示形成另一实施方式的楔面接头的横截面图。
图21是显示图20的楔面接头的层的示意图。
图22是图解说明楔面接头的另一实施方式的横截面图。
图23是显示图22的楔面接头的层的示意图。
图24是图解说明多个模件之间的小圆齿状接头边缘之间的偏移的平面图。
图25是宽泛地图解说明公开的方法实施方式的步骤的流程图。
具体实施方式
首先参考附图的图1-3，适于模件复合制造方法的说明性实施方式的实施的制造系统由参考数字1大体地指出。制造系统1以图1中的俯视图和图2中的透视图示出。模件复合制造方法可以使用简单的大小合适的设备以确保以并行方法而非串联地铺放复合材料作为复合航空器机身的制造部件或其它部件。使用并行工艺方法来自动层压航空器机身外壳模件或其它部件可以大大地减少制造单个部件需要的流程时间。这可以减少制造复合航空器机身外壳或其它部件需要的资本投资、工厂房屋面积和后勤人员。此外，所述方法可以被用于制造水平铺放的(flat-lay-up)复合部件例如且非限制性地如航空器机身外壳，或者依轮廓铺放的(contoured-lay-up)复合部件例如且非限制性地如航空器机翼外壳和稳定器。所述方法可以被用于制造面板、四开断面(四分之一部件，quarter sections)、半机身部件、多半机身部件或全圆筒部件。
如图1和2所示，制造系统1可以包括一个或多个平带状铺放机(flat tape lay-up machines)(FTLM)2以利于制造水平铺放的复合部件例如且非限制性地如航空器机身外壳。另外地或可选地，制造系统1可以包括一个或多个依轮廓型铺放机(contour type lay-up machines，CTLM)(未显示)以利于制造依轮廓铺放的复合部件例如且非限制性地如航空器机翼外壳、机头外壳(nose skin)和/或机尾外壳。FTLM和CTLM可以具有本领域技术人员已知的设计。尽管FTLM2的示例性结构和操作方法将在下文中描述，但是应当认识到并理解，除了FTLM2之外，或者代替FTLM2，对于一个或多个CTLM，也可以使用同样的操作方法。
每个FTLM2可以包括一对大体上细长、平行、隔开的框架道轨(frame track rail)3。托架(carriage)框架4可以横跨框架道轨3并且适于双向穿过框架道轨3。托架框架4可以包括一对大体上细长、平行、隔开的托架框架部件5。托架框架部件5可以被定位成大体上垂直于框架道轨3的关系。
切割托架6可以适于双向穿过托架框架4的托架框架部件5。托架马达(未显示)可以啮合切割托架6以利于切割托架6在托架框架4上移动。切割设备7可以被提供在切割托架6上。在一些实施方式中，切割设备7可以是超声波刀，但是可以使用本领域技术人员已知的且适于本目的的可选切割器具。
中转站台旋转轨道10——其可以是圆形或环形——可以被提供在框架道轨3之间和托架框架4下边。中转站台14可以可拆卸地提供在中转站台旋转轨道10上。中转站台14可以为大体正方形的。根据本领域技术人员的知识例如且非限制性地如通过滚轮(roll)(未显示)，中转站台14的角部分14a可以可滑动地或可旋转地啮合中转站台旋转轨道10。如将在下文描述的，承载板(carrier sheet)16可以被放置在中转站台14上。如本文所用，“模件”和“复合模件”指连接在一起以形成较大结构的复合材料部件，并且可以是但不必须限制为预浸料纤维束或织物形成的单层或多层组件。复合模件18可以被放置在承载板16上。中转站台14可以在中转站台旋转轨道10上旋转，托架框架4可以沿框架道轨3移动，并且切割托架6可以沿托架框架4的托架框架部件5移动以利于通过切割设备7的操作沿所选的一个轴或多个轴切割复合模件18。
如图1-3所示，制造系统1可以进一步包括SADL(半自动化双定位器)机22。SADL机22可以包括轴架23，通过多个轴架轮24可以使轴架23可移动。模件形成台25可以被提供在轴架23上。模件形成台25可以被适于承受并支撑承载板16，在承载板16上放置复合模件18，其目的将在下文描述。
如图1-3进一步所示，制造系统1可以进一步包括取置机30。如图1和2所示，取置机30可以位于大体上临近SADL机22。如图1进一步所示，在一些实施方式中，SADL机可以被提供在或大体上临近取置机30的各个末端。取置机30可以包括门形构架(gantry)31，其具有一对大体上细长、平行、隔开的轨道32。门形构架31的轨道32可以每个都被多个隔开的轨道支架(rail support)33支撑，如图3所示。至少一个铺放头部托架(placement head carriage)36可以横跨并可滑动地啮合门形构架31的轨道32。每个铺放头部托架36可以适于在轨道32上进行双向移动，如图1中双头箭头8所指。托架马达(未显示)可以啮合每个铺放头部托架36以利于铺放头部托架36在轨道32上移动。
如图2和3所示，模件铺放头部(module placement head)40可以由每个铺放头部托架36悬挂。模件铺放头部40可以包括驱动轴(头部轴，head shaft)41和大体上弯曲或弓形的模件啮合部件42。可以使用本领域技术人员已知的任何适合的技术将模件铺放头部40的驱动轴41附连至铺放头部托架36。在一些实施方式中，至少一个头部安装法兰37从铺放头部托架36延伸。至少一个模件附连托架(moduleattachment bracket)44从驱动轴41延伸。模件附连托架44可以经头部紧固部件38连接至至少一个头部安装法兰37。
如图2和3进一步所示，模件铺放头部40的模件啮合部件42可以包括大体上凸起的模件形成表面43。检测扫描系统46的扫描仪49可以适于穿过模件啮合部件42的模件形成表面43。根据本领域技术人员的知识，扫描仪49可以被附连至模件啮合部件42用于所述目的。在一些实施方式中，大体上细长、弯曲的扫描仪槽47可以被提供在模件啮合部件42中，大体上临近并沿模件形成表面43。扫描仪托架48可以穿过扫描仪槽47啮合扫描仪槽47。扫描仪49可以被提供在扫描仪托架48上。扫描仪马达(未显示)可以啮合扫描仪托架48以利于在扫描仪槽47中扫描仪托架48以及扫描仪49沿着或临近模件啮合部件42的模件形成表面43的选择性移动。检测分析和控制系统(未显示)可以连接至扫描仪马达(未显示)和扫描仪49以利于扫描仪49的扫描动作和重新获得和分析从扫描仪49接收的图像。
制造系统1可以进一步包括固化工具、心轴或铸模54。固化工具54可以例如且非限制性地是OML(外铸模线，Outer Mold Line)或IML(内铸模线，Inner Mold Line)固化工具。如图1、2和3所示，固化工具54可以位于大体上接近SADL机22并且在取置机30的轨道32之间。如图3所示，在一些实施方式中，固化工具54可以包括工具底部55和大体上平行、隔开的工具侧面56，其自工具底部55延伸。大体上弯曲的或半环形的模件铺放表面57可以被提供在工具底部55和工具侧面56中并且可以沿着固化工具54的长度延伸。但是，应当认识并理解，固化工具54(例如，如在IML固化工具的情况下)不必须具有如固化工具54的模件铺放表面57所示的完全圆柱形或半圆柱形横截面。在例如且非限制性地期望对四分之一面板(quarter panel)利用该制造方法的情况下，可以使用具有OML和IML配置的固化工具54。此外，固化工具54可以被配置为翼或稳定器铸模、工具、固化工具或根据待被制造的部件的以任何结构配置。
在典型的模件复合制造方法的实施中，该方法可被用于制造使用多个复合模件18的航空器机身外壳60(图1)。根据应用和待被制造的部件，每个模件18可以包括单向碳纤维预浸料、碳纤维预浸料织物、玻璃纤维、
Figure GSB00001110732500091
聚对苯二甲酰对苯二胺或其它材料的任意组合。每个模件18可以具有至少一个层。承载板16——其上可以放置复合模件18——可以最初被放置在中转站台14上。中转站台14可以被放置在FTLM2的环形中转站台旋转轨道10上。可以操作切割托架6上的切割设备7以将复合模件18整理或切割成期望的大小和形状。在整理、切割或调整操作期间，通过沿托架框架4的托架框架部件5运动切割托架6、沿框架道轨3运动托架框架4和/或在中转站台旋转轨道10上旋转中转站台14，复合模件18可以被定位在相对于切割设备7选择的方位处。，每个FTLM2可以促进使用净整理技术(net trim technology)将形成航空器机身外壳60的复合模件18的高速调整。
在整理或切割复合模件18之后，其上放置承载板16和整理或切割的复合模件18的中转站台14可以从中转站台旋转轨道10移出。可以将中转站台14从FTLM2运输至SADL机22的一个。从中转站台旋转轨道10移出中转站台14和/或运输中转站台14可以是自动化的或手动的。在SADL机22，承载板16可以从中转站台14移出并放置在SADL机22的模件形成台25上。承载板16可以被提供有多个加工/转位(index)口(未显示)，其可以被转位至SADL机22以促进承载板16在模件形成台25上的适当定位和铺放。
铺放头部托架36可以接下来被操作以沿取置机30的门形构架31上的轨道32滑动以将模件铺放头部40的模件啮合部件42直接定位在复合模件18上。然后，通过模件压紧方法，SADL机22的模件形成台25可以被抬升紧靠模件啮合部件42的模件形成表面43，以使扁平复合模件18形成或仿形(contour)为模件形成表面43的大体凸起轮廓，如图3的虚线部分所指出。形成或仿形模件18为模件啮合部件42的模件形成表面43可以是自动化的。可以将其它复合模件18从FTLM机2运输至SADL机22的模件形成台25，并根据需要以层压或多层的方式形成模件啮合部件42的模件形成表面43，以获得期望厚度的航空器机身外壳60(图1)。因此，可以将连续的复合模件18放置在彼此之上以形成具有多层的层压的模件18。根据应用，模件铺放头部40可以将连续的纤维层或连续的织物层与复合模件18的编织层联合放置。在一些应用中，相邻模件18可以彼此连接，这将在以下更加详细地讨论。应当认识并理解，复合模件18不需要总是被形成在模件铺放头部40上的模件啮合部件42的模件形成表面43上。在IML固化工具54的情况下，使用SADL机22，模件18可以被直接形成在固化工具54上或其它外壳层上。
在期望数量的复合模件18被筹备在取置机30的模件铺放头部40上之后，出于检测复合模件18的目的，检测扫描系统46的扫描仪49可以被运行穿过模件啮合部件42的模件形成表面43。有缺陷的复合模件18可以从模件铺放头部40移出并用无缺陷的复合模件18替代。检测模件铺放头部40上的模件18可以是自动化方法。
然后，取置机30的铺放头部托架36可以被运行穿过取置机30的门形构架31上的轨道32，并有利于堆叠的、层压的、压缩的和检测的复合模件18精确铺放在固化工具54的模件铺放表面57(图3)上期望的位置中。其它堆叠的、层压的和压缩的模件18可以以类似的方式形成并放置在模件铺放表面57上期望的位置中以形成航空器机身外壳60。相邻模件18的模件边缘19可以有斜面(ramped)并与嵌接(未显示)或斜面铰接(未显示)搭接(交叠)直至航空器机身外壳60被完全铺放。
接下来参考图4中的流程图300，概括了模件复合制造方法的说明性实施方式。所述方法可以用于制造例如且非限制性地具有期望厚度的航空器机身外壳。在框302中，复合模件被铺放。模件可以是航空器机身外壳模件，其可被用于制造结构例如且非限制性地如航空器机身外壳，并且可以使用例如且非限制性地FTLM(平带状铺放机，FlatTape Lay-up Machine)铺放。另外地或可选地，模件可以被用于制造结构例如且非限制性地如航空器机翼外壳、机头外壳和/或机尾外壳，在该情况下可以使用CTLM(依轮廓带状铺放机，contour tape lay-upmachine)铺放模件。在框304中，模件被转移至SADL(半自动化双定位器)机。在框306中，模件可以被形成为航空器机身外壳或其它结构的轮廓。在框308中，可以重复框302、304和306中进行的步骤以形成期望厚度的航空器机身外壳或其它结构。在框310中，模件可以被检测。在框312中，堆叠的或层压的模件可以被堆叠在固化工具上。固化工具可以例如且非限制性地是OML(外铸模线，Outer Mold Line)或IML(内铸模线，InnerMold Line)固化工具。在框314中，可以根据需要重复框302、304、306、308、310和312中进行的步骤以完全铺放航空器机身外壳或其它结构。
接下来参考图5和6，公开内容的实施方式可以在图5所示的航空器制造和服务方法78以及图6所示的航空器94中的情况中进行使用。在生产前期间，示例性方法78可以包括航空器94的说明书和设计80以及材料获得82。在生产期间，进行航空器94的组件和部件制造84和系统整合86。此后，航空器94可以经历发照和交货88以进行使用90。在客户使用的同时，航空器94可以被安排进行日常维护和保养92(其也可以包括改进、重新配置、整修等)。
可以由系统整合者、第三方和/或操作者(例如用户)进行或执行方法78的每个过程。对本说明书的目的，系统整合者可以非限制性地包括诸多航空器制造商和主要系统转包商；第三方可以非限制性地包括诸多销售商、转包商和供应商；以及操作者可以是航空公司、租赁公司、军事实体、服务组织等。
如图6所示，通过示例性方法78生产的航空器94可以包括带有多个系统96的机体98和内部100。高水平的系统96的例子包括一个或多个推进系统102、电力系统104、水压系统106和环境系统108。可以包括许多其它系统。尽管显示了航空实例，但是本发明的原理可以应用于其它工业，如汽车工业。
本文实施的设备可以在生产和服务方法78的任意一个或多个阶段期间使用。例如，相应于生产过程84的组件或部件可以被以类似于使用航空器94时生产的组件或部件的方式进行加工或制造。同样，例如，通过显著加速航空器94的组装或减少航空器94的成本，在生产阶段84和86可以使用一种或多种设备实施方式。类似地，在使用航空器94时，一种或多种设备实施方式可以例如但不限于用于维护和保养92。
如前所述，模件复合制造方法可以利用大小合适的设备以确保以并行方法而不是串联地铺放复合材料作为复合航空器机身的制造部件或其它部件。在这点上，参考图7和图8。根据大量实施方式，制造复合结构的方法700可以包括将多个模件18放置702在工具54上，以使每个模件18邻近于至少另一个模件18，如图9所示，以便邻近的模件18例如在接头704处可连接在一起，形成复合结构。
在一些实施方式中，多于一个模件18可以在基本同一时间被放置在工具54上；在这样的实施方式中，多个中转站台14可以被提供。此外，在形成复合结构中，模件18可以以基本上连续的方式被放置在工具54上，在已经放置在工具18上的模件18的一个之上进行铺放后过程706(如图8中符号n-2所指出)，而随后的模件18被放置在工具54上(如图8中符号n-1所指出)。在许多实施方式中，放置步骤702和铺放后过程步骤706可以在随后的模件18被准备(prep)708进行铺放时进行(如图8中符号n所指出)。
关于进行铺放后过程706，这可以包括检测710已被放置在工具18上(如图8中符号n-2所指出)的模件18中的一个。进行铺放后过程706还可以包括在相邻模件18之间形成的接头704上进行工作。在如图7和图8所示的一些实施方式中，制造方法700可以包括例如几乎同时在不同放置的模件18上进行检测步骤710和铺放后过程步骤706。
在许多实施方式中，在工具54上放置702模件18可以包括在中转站台14上装载712模件18、转位714装载的模件进入合适的位置和/或然后将模件铺放716在工具54上。在所有的模件18被放置在工具54上并且任何随后的铺放后过程706被完成之后，则结构可以被固化。
现在参考图10和图11，之前描述的一般类型的复合模件208可以沿其共有的边缘210被连接在一起以形成大型结构如圆筒形航空器机身部件204的外壳202。如以下更详细描述的，每个模件208可以包括一个或多个用单向或双向纤维增强的复合材料层压层，并且可以包括在形成部件如图11所示的机身外壳202中的门206时使用的切除部分(未显示)和/或增强(未显示)和/或轮廓(未显示)。
现在参考图12-15，模件208中的临近模件可以沿其共有边缘210通过楔面接头被连接在一起，楔面接头的例子由数字213a、213b指出。如本文所用，“楔面接头”指两层材料之间的接头，其通过嵌接或倾斜(bevel)其末端、边缘或侧面而制成，以便当部件被放在一起时，其具有形成一个基本连续部件的搭接(交叠)边缘。如图13所示，通过楔面接头213a连接的两个相邻模件208a、208c可以包括在夹在顶面材(facesheet)216和底面材218之间的单向或双向预浸料纤维的多层212。面材216、218的每个可以包括布或其它片材。通过铺放两个模件208a、208c的层212以使两个模件208a、208c的类似层的外端214彼此交叠来形成楔面接头213a。楔面接头213a表示简单的嵌接，其具有的40∶1的斜面(即，宽高比，run-to-rise ratio)，包括总数12个交叠的层212；根据应用，其它斜面比例是可能的。
特定的外壳分部200(图10)可以包括沿其共有边缘210通过多于一种类型的楔面接头213连接在一起的模件208，并且实际上特定的模件208可以沿其边缘210通过不同类型的楔面接头连接至相邻模件208。例如，图10所示的模件208a的一个边缘210a可以通过图12和13所示的楔面接头213a连接至模件208c，而模件208a的另一边缘210b可以通过图14和15所示的另一形式的楔面接头213b连接至模件208b。如图14和15所示，楔面接头213b是简单的嵌接配置，其包括安排为80∶1斜面的12个层212，其中类似层212的外缘214基本处于相同的平面，并且彼此邻接；根据应用，其它斜面比例是可能的。
现在参考图10和16-18，一些模件208如模件208d和208e可以包括层212，其中增强纤维的方位角延伸穿过边缘210。在图解说明的实例中，纤维的取向方向由图16中的数字215指示并且包括45度。为了在邻接模件208d和208e之间形成楔面接头213c，边缘210被形成为z字形或小圆齿状图案220，其相对于接头轴221对称(图16)。通过在两个正交方向嵌接模件208d、208e的边缘210生成小圆齿状图案220。在图解说明的实例中，最好见图18，楔面接头213c包括以80∶1斜面安排的12个层212，其中类似层邻接而非彼此交叠。根据应用，非80∶1的斜面比例是可能的。图19图解说明具有小圆齿状边缘220的典型的模件208，其中小圆齿状图案层至层(ply-to-ply)偏移。
图20和21图解说明模件组件219，其中楔面接头213d被用于连接每个由多层212形成的两个模件228a、228b，其中类似层在其边缘217交叠。第三模件226包括放置在楔面接头213d上的多层227。图20和21的实施方式图解说明楔面接头213d可以穿过分部200错开排列(图10)，并且分部200的整个厚度可以是不连续的。
注意力现在转向图22和23，其图解说明模件组件229的另一实施方式，模件组件229使用通过多个嵌接221形成的指形接头型楔面接头213e。楔面接头213e延伸通过模件组件229的整个厚度并连接多个相邻模件230-236。在该实例中，模件组件229包括12个层212，其包括顶面材216和底面材218，其中每个嵌接221具有80∶1的斜面；根据应用，其它斜面比例是可能的。同样在该实例中，相邻模件230-236的类似层212邻接而非彼此交叠。
注意力现在转向图24，其图解说明由多个模件208形成的层压结构238，多个模件208沿形成小圆齿状图案240的楔面接头(未显示)连接在一起。在该实例中，小圆齿状图案240被安排为两组240a、240b。小圆齿状图案240相对于彼此错开排列，以便两组240a、240b的相位(phase)偏移距离“x”，使得小圆齿状图案240的相邻小圆齿状图案不彼此对齐。小圆齿状图案240的这种错开排列可以增强层压结构238的结构性能。
注意力现在转向图25，其概括了使用先前描述的模件208制造结构的方法的一般步骤。始于步骤246，形成可包括单层或多层复合材料的模件208。接下来在248，使用以上讨论的各种类型的任何一种楔面接头213组装模件208。组装之后，模件208可以在步骤250被放置在固化工具之上或之中，其可以包括内部铸模线或外部铸模线固化工具。如先前结合图1-3所述，通过连续将模件放置在固化工具上或者通过组装模件208组，然后将该组放在固化工具上，模件208可以被组装。最后，在步骤252，组装的模件208在固化加工中被共固化，使得树脂流动通过楔面接头213，形成固结的、充分均匀的结构。
尽管本公开的实施方式已就某些示例性实施方式进行了描述，但是应当理解，具体实施方式是用于阐述目的并且是非限制性的，本领域技术人员可以想到其它变化。

Claims (7)

1.模件复合制造方法，包括：
提供多个带铺放复合模件(18)；
提供包括模件铺放表面(57)的固化工具(54)，所述模件铺放表面(57)被配置为接收多个模件(18)，以便每个模件(18)与所述模件(18)的至少另一个邻近；
用检测系统(46)检测所述复合模件(18)；
将所述复合模件(18)放置在所述固化工具(54)的所述模件铺放表面(57)上；
将所述多个复合模件(18)的所述邻近复合模件彼此连接，其中连接所述模件包括在所述模件的各自边缘之间形成楔面接头；和
将所述模件(18)固化在所述固化工具(54)上；
所述方法的特征在于其进一步包括相对于模件啮合部件(42)的模件形成表面(43)压紧每个复合模件(18)，以便给所述复合模件(18)的每个赋予选择的轮廓，然后所述检测，之后将每个复合模件(18)放置在所述固化工具(54)的所述模件铺放表面(57)上；
其中所述检测系统(46)是具有扫描仪(49)的检测扫描系统，所述扫描仪(49)附连至模件啮合部件(42)并适合于穿过所述模件形成表面(43)。
2.根据权利要求1所述的方法，进一步包括在给所述复合模件的每个赋予选择的轮廓之前，切割所述复合模件(18)。
3.根据权利要求1所述的方法，其中所述多个复合模件(18)的每个包括至少一层。
4.根据权利要求1所述的方法，进一步包括将所述多个复合模件(18)的连续的复合模件放置在彼此之上以形成多层。
5.根据权利要求1所述的方法，其中所述复合模件(18)包括斜面模件边缘，其相对于彼此以搭接关系放置在所述固化工具(54)上。
6.根据权利要求1所述的方法，其中所述复合模件(18)的每个包括单向碳纤维预浸料、碳纤维织物、玻璃纤维、玻璃纤维织物、聚对苯二甲酰对苯二胺或聚对苯二甲酰对苯二胺织物的任意组合。
7.根据权利要求1所述的方法，其中所述固化工具(54)包括工具底部(55)和从所述工具底部(55)延伸的隔开的工具侧面(56)；和
所述模件铺放表面(57)设置在所述工具侧面(56)和所述工具底部(55)中，并且是大体凹面的。
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