CN102528966A - 制备用于由碳/碳复合材料制造环形部件的三维纤维预成型体的方法 - Google Patents

制备用于由碳/碳复合材料制造环形部件的三维纤维预成型体的方法 Download PDF

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CN102528966A
CN102528966A CN2011103731359A CN201110373135A CN102528966A CN 102528966 A CN102528966 A CN 102528966A CN 2011103731359 A CN2011103731359 A CN 2011103731359A CN 201110373135 A CN201110373135 A CN 201110373135A CN 102528966 A CN102528966 A CN 102528966A
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V·德莱克鲁瓦
K·常
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Safran Landing Systems SAS
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Abstract

本发明提供了一种制备用于由碳/碳复合材料制造环形部件的三维纤维预成型体的方法，所述方法包括堆叠由碳纱或碳丝束组成的纤维片材的层，当所述层重叠时逐一针刺所述层以将它们结合在一起，以及通过增加位于所述纤维预成型体的一半厚度处的纤维片材的层的纤维密度而局部改变所述纤维预成型体的电磁性质。

Description

制备用于由碳/碳复合材料制造环形部件的三维纤维预成型体的方法
技术领域
本发明涉及制备三维纤维预成型体。 
本发明的特定应用领域为制备用于由碳-碳(C-C)复合材料制造环形部件，特别是制造刹车盘的三维纤维预成型体。 
背景技术
由复合材料，特别是具有碳纤维加强件和碳基体的复合材料(碳/碳复合材料)制成的刹车盘是公知的。制造所述刹车盘包括制备环形纤维预成型体以及用基体将所述环形纤维预成型体致密化。 
纤维预成型体通常通过堆叠纤维片材的层或片层，并通过将所述层结合在一起(通常通过针刺)而制得。所述纤维片材可以是线性的，在此情况中，预成型体的环状形状通过从由所述纤维片材的堆叠层组成的所得块切割出盘而获得。或者，所述纤维片材可以是螺旋形的，则预成型体的环状形状直接通过堆叠和针刺纤维片材的层而获得。 
以此方式获得的环形纤维预成型体通常通过化学汽相渗透(CVI)，或通过使用液体技术(用作为基体前体的树脂浸渍，并热解所述树脂)进行致密化。 
本发明更特别适用的另一已知的致密化方法为膜沸腾。其包括将环形纤维预成型体置于反应器中的两个螺旋电感线圈之间，所述反应器填充了在环境温度下为液体的碳前体，使得所述预成型体和电感线圈完全浸入液体中。之后通过电磁耦合加热所述预成型体直至其内部温度达到大约1000℃，由此使前体在预成型体内裂解并随后导致碳基体沉积。 
膜沸腾致密化相比于常规用于制造刹车盘的CVI致密化的优势在于其致密化的高速度(比使用气态技术的致密化快约100倍)。通过在预成型体的中心与其通过沸腾前体冷却的表面之间建立陡峭的温度梯 度而使得这些反应动力学成为可能。因此致密化优选在材料的中心进行，而不在材料的表面进行(如当通过CVI致密化时所发生)，因此有可能使用产生快速反应动力学的条件。 
该特定的致密化方法与预成型体本身的特性密切相关。特别地，纤维加强件的结构、所用的纤维类型、预成型体中的缺陷等，都对在电磁耦合过程中产生的温度分布具有显著的影响，并因此影响致密化预成型体的速度。 
发明内容
本发明的主要目的在于提出一种制备纤维预成型体的方法，所述纤维预成型体能够使其通过膜沸腾的致密化的速率得以改进。 
该目的通过一种制备纤维预成型体的方法而得以实现，根据本发明，在该方法的过程中通过增加纤维片材某些层中的纤维密度而局部改变纤维预成型体的电磁性。 
纤维密度得以局部增加而不改变组成纤维片材的碳纱或碳丝束的性质。该增加用于增强预成型体在其特定区域中所经受的电磁耦合。通过适当选择该区域，有可能加速预成型体通过膜沸腾的致密化。 
有利地，增加位于纤维预成型体的一半厚度处的纤维片材的层的纤维密度。通过增强预成型体的一半厚度处的电磁耦合，这种预成型体的致密化将在预成型体的该区域中开始，因此每个致密化前沿仅需穿过预成型体的一半厚度。这产生更快速的致密化循环。 
在本发明的另一实施方案中，纤维密度增加的纤维片材的层经受参数与其他层所经受的针刺的参数不同的针刺。 
因此，纤维密度增加的纤维片材的层可经受针刺密度大于其他层所经受的针刺的针刺密度的针刺。例如，这些层可经受针刺密度为约每平方厘米60冲程(冲程/平方厘米)的针刺，其他层经受针刺密度为约30冲程/平方厘米的针刺。 
或者，纤维密度增加的纤维片材的层经受针的穿透深度大于其他层所经受的针刺的针的穿透深度的针刺。例如，这些层可经受针的穿透深度在14.5毫米(mm)至15.5毫米范围内的针刺，其他层经受针的穿透深度为约12.5毫米的针刺。 
在本发明的另一实施方案中，纤维密度增加的纤维片材的层显示大于其他层的重量的重量。例如，这些层可显示每平方米1100克(克/平方米)量级的重量，而其他层显示700克/平方米量级的重量。 
具体实施方式
本发明涉及制备特别地但不排他地用于由碳-碳(C-C)复合材料制造刹车盘的三维纤维预成型体。 
由复合材料，特别是由具有碳纤维加强件和碳基体的复合材料(碳/碳复合材料)制造刹车盘包括由纤维片材(每个纤维片材由碳的纱或丝束组成)制备环形纤维预成型体，以及用基体致密化所述环形纤维预成型体。 
当通过膜沸腾进行致密化时，以常规方式将环形纤维预成型体置于反应器中的两个螺旋电感线圈之间。之后用在环境温度下为液体的碳前体填充所述反应器以完全浸没所述预成型体和电感线圈。 
由于预成型体由导电的纱或丝束制成，可以通过电磁耦合直接将其加热直至其内部温度达到大约1000℃，由此导致前体在所述预成型体内裂解，继而导致碳基体沉积。 
为了加速膜沸腾过程，本发明寻求在该操作过程中在纤维预成型体的特定区域内增强电磁耦合。 
为此目的，本发明提供了通过增加形成纤维预成型体的某些层的纤维密度(并因此增加导电性)而局部改变纤维预成型体的电磁性质。 
理想地，由于纤维预成型体具有环状形状，纤维密度的局部增加涉及位于预成型体中间厚度处的片材。 
下文描述了根据本发明制得的纤维预成型体的两种特定实施方案。不论哪种实施方案，都应观察到实现了本发明的纤维预成型体的某些片材的纤维密度的局部增加而无需改变纤维片材中的纱或丝束的性质。 
实施例1：由具有对针刺参数的改变的线性片材制备纤维预成型体 
在该实施例中，纤维预成型体由二维线性片材制得，所述二维线性片材由碳纱或碳丝束(例如氧化的聚丙烯腈(PAN)长丝的丝束)组成。线性片材的层或片层在针刺台上互相堆叠，当所述层或片层重 叠时逐一针刺所述层或片层以形成块。之后从所述块切割出环形纤维预成型体。 
在制备纤维预成型体时所用的针刺台本身是公知的，因此不在本文中作详细描述。简言之，所述针刺台包括放置线性片材的水平工作表面，用于在所述表面上驱动所述片材的装置，和设置为相对于所述表面垂直往复运动的针头。 
针头携带提供有倒钩(barbs)、钩(hooks)或叉的针，所述针用于从预成型体的堆叠层挑出纤维，并在穿透预成型体时拉动纤维穿过层。此外，每次针刺新的层时，通过适宜的驱动装置将针刺台的工作表面垂直移动对应于针刺层的厚度的预定向下位移。 
当使用这种针刺台时，可以改变的针刺参数特别地包括针刺密度，即当层在针头下通过时每平方厘米(cm2)针刺的层所接收的冲程数，以及针进入预成型体的穿透深度。 
在该实施方案中，纤维预成型体由21个的线性片材的层的堆组成，所述线性片材本身由氧化的PAN长丝的丝束组成。 
堆叠线性片材的首先两个层，之后以30冲程/平方厘米的针刺密度和穿透约12.5毫米的针将所述两个层针刺在一起。 
堆叠以下七个层，并使用相同的针刺密度(即30冲程/平方厘米)逐一针刺所述七个层，同时使针刺台的工作表面以确保针的穿透深度保持恒定(即约12.5毫米)的方式向下移动。 
将以下三个层(即第10层、第11层和第12层)叠放在首先九个层上，并以大于针刺首先九个层所用的针刺密度的针刺密度逐一针刺所述三个层，以在这些层中增加纤维密度。 
例如，选择60冲程/平方厘米的针刺密度，并设定针刺台的工作表面向下移动以确保针的穿透深度保持恒定在12.5毫米。 
可易于理解，当位于预成型体的中间厚度处的三个层在针头下自动通过时，增加所述三个层所接收的每平方厘米的冲程数用于增加穿过这些层的针数，并因此增加从下层传递进入这三个特定层的纤维数。这导致了所述三个层的纤维密度的增加。 
最后，将以下九个层堆叠在首先12个层上，并使用与首先九个层所用的相同的针刺密度和相同的针穿透深度而逐一针刺所述九个层。 
在该实施方式的一个变体中，线性片材的所有21个层的针刺密度保持相同，并使位于预成型体的一半厚度处的三个层(即第10层、第11层和第12层)经受具有穿透深度大于应用于其他层的针刺所用的深度的针的针刺。 
例如，对于需要增加纤维密度的这三个层，选择穿透深度在14.5毫米至15.5毫米范围内的针，其他层经受针的穿透深度为约12.5毫米的针刺。 
在该变体中，对于位于预成型体一半厚度处的三个层，当其在针头下通过时，针刺台的针穿透进入预成型体更深。因此大量纤维从下层传递至这三个特定层。这增加了所述三个层的纤维密度。 
作为结果，以此方式形成的位于纤维预成型体的一半厚度处的三个层显示出大于所述预成型体的首先九个层和最后九个层的纤维密度的纤维密度，获得了该纤维密度的增加而不改变组成线性纤维片材的碳丝束的性质。 
之后从以此方式获得的盘切割出环形纤维预成型体，并如上所述将环形纤维预成型体置于膜沸腾反应器中的两个螺旋电感线圈之间。由于每个环形纤维预成型体在一半厚度处具有更大的纤维密度，在膜沸腾操作过程中电磁耦合在该区域中得以增强。作为结果，预成型体的致密化将在该一半厚度区域中开始，并且致密化前沿将仅需要穿过所述预成型体的一半厚度。这导致预成型体的整个致密化的加速。 
实施例2：由具有对片材重量的改变的螺旋片材制备纤维预成型体 
在该实施方案中，第一环形纤维预成型体由二维螺旋片材制得，每个所述二维螺旋片材由碳纱或碳丝束(例如氧化的聚丙烯腈长丝(PAN)的丝束)组成。制备这种螺旋片材本身是公知的，因此不在本文中作详细描述。 
这些螺旋片材的层或片层在环形针刺台上互相堆叠，当所述层或片层重叠时逐渐将它们互相针刺以直接形成环形预成型体。 
在该实施方案所用的环形针刺台就操作而言基本与上文简述的针刺台相同，因此不作详细描述。必要时，可参考描述其实施方案的文献WO 02/088451。 
首先，制备具有不同重量的两类螺旋片材。例如，一个片材重700 克/平方米，另一个重1100克/平方米。可在制造片材的过程中，通过增加在一个方向(例如周向)上延伸的碳丝束的量而获得重1100克/平方米的片材。因此该片材显示密度大于重700克/平方米的片材的密度的纤维。 
首先堆叠700克/平方米的片材的九个层，并以相同的针刺密度将所述九个层互相针刺，同时使针刺台的工作表面向下移动以确保针穿透恒定深度。例如，选择45冲程/平方厘米的针刺密度以及约12毫米的针穿透深度。 
之后用1100克/平方米的片材代替将700克/平方米的片材。之后将该螺旋片材的三个层(即预成型体的第10层、第11层和第12层)叠放在首先九个层上，并以相同的针刺参数(针刺密度45冲程/平方厘米，针穿透深度12毫米)逐一针刺所述三个层以形成预成型体的中心层。 
之后再次将700克/平方米的片材置于针刺台上，将该片材的九个新层叠放在其他层上，并仍以相同的针刺参数逐一针刺所述九个新层。 
作为结果，位于以此方式制得的纤维预成型体的一半厚度处的三个层显示出大于所述预成型体的首先九个层和最后九个层的纤维密度的纤维密度，获得了该纤维密度的增加而不改变组成所述线性片材的丝束的性质。 
之后如上所述将以此方式获得的环形纤维预成型体置于膜沸腾反应器中的两个螺旋电感线圈之间。由于该预成型体在一半厚度处具有更大的纤维密度，在膜沸腾操作过程中电磁耦合在该区域中得以增强。作为结果，预成型体的致密化在一半厚度处的该区域中开始，并且每一致密化前沿仅需要穿过所述预成型体的一半厚度。这导致预成型体的整个致密化的加速。 
或者，相同的700克/平方米的片材可用于制备纤维预成型体的所有21层，之后在第10层、第11层和第12层中针刺的过程中引入相同类型的另外的丝束以增加那些层的重量。 
例如，使用由七条周向丝束(所谓的0°丝束)和十条横向丝束(所谓的60°丝束)组成的片材，该片材具有10厘米(cm)的宽度和700克/平方米的重量，有可能在针刺第10层、第11层和第12层的同时在 0°引入五条另外的丝束。通过使用与形成片材的那些丝束相同类型并具有3.8克/米(g/m)的重量/单位长度的丝束，所得预成型体的第10层、第11层和第12层的重量因此增加了190克/平方米。 
在实践中，当针刺第10层时，首先将引入的0°的另外的丝束固定在片材上(例如通过针刺、粘合剂或吹制固定)。之后用这些另外的丝束针刺第10层、第11层和第12层，之后在针刺第12层之后切割所述另外的丝束。 

Claims (8)

1.一种制备用于由碳-碳复合材料制造环形部件的三维纤维预型件的方法，所述方法包括堆叠由碳纱或碳丝束组成的纤维片材的层，当所述层重叠时逐一针刺所述层以将它们结合在一起，所述方法的特征在于其还包括通过增加位于所述纤维预成型体的一半厚度处的纤维片材的层的纤维密度而局部改变所述纤维预成型体的电磁性质。
2.根据权利要求1所述的方法，其中所述纤维密度增加的纤维片材的层经受参数与其他层所经受的针刺的那些参数不同的针刺。
3.根据权利要求2所述的方法，其中所述纤维密度增加的纤维片材的层经受针刺密度大于其他层所经受的针刺的针刺密度的针刺。
4.根据权利要求3所述的方法，其中所述纤维密度增加的纤维片材的层经受针刺密度为约60冲程/平方厘米的针刺，其他层经受针刺密度为约30冲程/平方厘米的针刺。
5.根据权利要求2所述的方法，其中所述纤维密度增加的纤维片材的层经受针的穿透深度大于其他层所经受的针刺的针的穿透深度的针刺。
6.根据权利要求5所述的方法，其中所述纤维密度增加的纤维片材的层经受针的穿透深度在14.5毫米至15.5毫米范围内的针刺，其他层经受针的穿透深度为约12.5毫米的针刺。
7.根据权利要求1所述的方法，其中所述纤维密度增加的纤维片材的层显示大于其他层的重量的重量。
8.根据权利要求7所述的方法，其中所述纤维密度增加的纤维片材的层显示约1100克/平方米的重量，且其他层显示约700克/平方米的重量。
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