CN102917869A - 制造具有内部通道的复合物件的方法 - Google Patents

制造具有内部通道的复合物件的方法 Download PDF

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CN102917869A
CN102917869A CN2010800667091A CN201080066709A CN102917869A CN 102917869 A CN102917869 A CN 102917869A CN 2010800667091 A CN2010800667091 A CN 2010800667091A CN 201080066709 A CN201080066709 A CN 201080066709A CN 102917869 A CN102917869 A CN 102917869A
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laminated layer
base portion
mandrel
groove
pipe
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CN102917869B (zh
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D·A·埃利奥特
C·J·基尔曼
谢尔曼·S·林
R·梅索姆
W·赖利
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Bell Helicopter Textron Inc
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Abstract

本发明公开了一种制造具有内部通道的纤维增强复合物件的方法。在一个具体实施例中，一种制造具有内部通道的纤维增强复合物件的方法包括提供铺放工具，将基部层合层纤维铺放到铺放工具上，并且在基部层合层中形成凹槽。该方法进一步包括将芯轴放置在凹槽中，纤维铺放一个顶部层合层到基部层合层和芯轴上，固化基部层合层和顶部层合层，并且从基部层合层和顶部层合层中移除芯轴。在另一个具体实施例中，芯轴由不可移动的管代替。

Description

制造具有内部通道的复合物件的方法
技术领域
本申请大致涉及复合物件领域。
背景技术
许多传统的包括内部通道的物件例如被用于将流体从一个位置连通到另一个位置。这种物件的一个例子为传动箱，例如用于旋翼飞机的传动箱。这种传统的物件典型地由金属材料制成并且使用铸造工艺形成。这些金属物件通常由于物件在应用中所需的机械特性而非常重。并且，制造用于形成铸造物的模具所需模型很贵，需要较长的生产周期，并且制造起来比较困难。进而，模型的改变也更贵。
由于纤维增强聚合物复合物件公知的比由金属制成的物件更轻，使得具有内部通道的复合物件的制造更加困难，耗时并且昂贵。
在本领域中公知的有许多中制造具有内部通道的物件的方法；然而，仍然存在改进的空间。
附图说明
被认为是本申请的特性的新颖性特征在所附的权利要求中提出。然而，本申请本身，还有优选的应用模式，以及进一步的目标和优点参照下面的详细描述并结合所附的附图将获得最好的理解，其中参考数字最左边的有效数字表示各个参考数字在其中出现的第一张图，其中：
图1为具有内部通道的典型物件的透视图；
图2为图1的物件的横截面视图；
图3A-7B为描绘用于制造具有内部通道的纤维增强聚合物复合物件的方法的优选实施例的程式化视图；
图8A-11B为描绘用于制造具有内部通道的纤维增强聚合物复合物件的方法的一个替代实施例的程式化视图；并且
图12A-14B为描绘用于制造具有内部通道的纤维增强聚合物复合物件的方法的一个替代实施例的程式化视图。
虽然本申请的系统和方法可以具有各种变形和替代形式，其具体的实施方式通过图中的例子示出并且在这里进行详细的描述。然而，应当理解的是这里对具体实施方式的描述并不是将本申请限定于公开的特定实施方式，而恰恰相反，其目的是为了覆盖落入由所附的权利要求所限定的本申请的工艺的精神和范围之内的全部变形，等同，以及替代的方案。
具体实施方式
本申请的说明性实施例将在下面描述。为了清楚起见，在本说明书中并没有描述实际实施的全部特征。当然可以意识到在任何实际实施方式的发展过程中，需要视具体情况做出各种决定以实现研发者的特定目标，例如服从系统相关和商业相关的系统规定参数，其从一种实施方式变化到另一种。此外，可以意识到的是这种发展努力可能是复杂和耗时的，但是仍然是享有本公开的利益的本领域普通技术人员必须经历的常规过程。
在说明书中，如在附图中描绘的，参考标记用于标示各种组件之间的空间关系以及组件的各种方位的空间指向。然而，如本领域技术人员在完整地阅读了本申请之后能够认识到的，这里描述的装置，元件，设备，等等可以设置成任何期望的指向。因此，诸如“上方”，“下方”，“上部”，“下部”或其它类似的用于描述各种组件之间的空间关系或者用于描述这些组件的方位的空间指向的术语的使用应当理解为描述组件之间的相对关系或这些组件的方位的空间指向，而这里描述的装置可以指向任何期望的方向。
为了本公开的目的，术语“纤维铺放”表示一种通过一种将丝束形式的预浸渍纤维铺设到芯轴或工具上的装置来制作复合形状的工艺，复合形状通常具有复杂的外形和/或切口。术语“丝束”表示一种一束连续的细丝或纤维，例如碳纤维，玻璃纤维，芳纶纤维或其它类似的纤维。应该意识到即使纤维铺放工艺为优选的复合制造工艺，也可以采用其它复合制造工艺。例如，包括使用编织纤维的树脂传递模制工艺，其不需要用树脂浸渍，以所选的模型放置在模具中。进而，树脂被传递到模具内部以使得纤维和树脂结合到一起，然后固化。这种树脂传递模制工艺为复合制造工艺的一个不同于纤维铺放工艺的典型工艺，但是与这里公开的实施例是相容的。
在一个具体实施例中，一种制造具有内部通道的纤维增强复合物件的方法包括提供铺放工具，纤维铺放一个基部层合层到铺放工具上，并且在基部层合层上形成一个凹槽。该方法进一步包括将芯轴放置在凹槽中，纤维铺放一个顶部层合层到基部层合层和芯轴上，固化基部层合层和顶部层合层，并且从基部层合层和顶部层合层中移除芯轴。在另一个具体实施例中，一种至少具有内部通道的纤维增强复合物件的制造方法包括提供铺放工具，纤维铺放一个基部层合层到铺放工具上，并且在基部层合层中形成一个凹槽。该方法进一步包括在凹槽中放置管，纤维铺放顶部层合层到基部层合层和管上，并且固化基部层合层和顶部层合层。
图1描绘了具有内部通道的纤维增强聚合物复合物件的具体实施例的透视图。具体示出的物件为用于旋翼飞机（未示出）的传动箱101。图2为图1的传动箱101沿着线2-2的横截面视图，示出由传动箱101限定出的内部通道201。
图3A-7B描述了制作诸如图1的传动箱101之类的纤维增强聚合物复合物件的程式化图。具体地，图3A,4A,5A,6A,和7A为纤维增强聚合物复合物件的一个部分301的程式化侧面正视图，例如传动箱101（图2所示）的部分203处于各个制造阶段的视图。图3B,4B,5B,6B,和7B为部分301处于分别与图3A,4A,5A,6A,和7A相对应的制造阶段的程式化横截面视图。因此，图xB为图xA中沿xB-xB线的程式化横截面视图，其中“x”为3,4,5,6,或7。例如，图3B为图3A中沿线3B-3B的程式化横截面视图。
参照图3A和3B，部分301的基部层合层303纤维铺放到工具或模具305上。应该注意到部分301的基部层合层303包括多个具有期望方向的未固化纤维增强复合材料层片或层。如图4A和4B所示，在基部层合层303上形成有凹槽401用以容纳芯轴501（最好参见图5B）。优选地，凹槽401通过将一部分材料移除而形成，例如通过切削，机械加工，铣削或类似的工艺。现在参照图5A和5B，芯轴501放置在凹槽401中。芯轴501优选地包括易熔材料，易熔材料为金属复合物，其在相对低的温度下从固态转变成液态。芯轴501也可以由其它材料形成，例如，芯轴501可以是弹性材料，例如硅橡胶；溶水材料，例如盐；或者类似的材料。如图6A和6B所示，顶部层合层601接着纤维铺放在基部层合层303和芯轴501上方。如同基部层合层303，顶部层合层601包括多个具有期望方向的未固化纤维增强复合材料层片或层。基部层合层303和顶部层合层601通过加压和加热而固化并且使芯轴501处于适当的位置。如图7A和7B所示，芯轴501被移除以形成具有内部通道701的部分301，内部通道701与传动箱101的内部通道201相对应。当芯轴501为易熔材料时，芯轴501暴露于一定温度下，易熔材料熔化，使得芯轴501作为流体被移除，由此形成内部通道201。类似地，当芯轴501为水溶材料时，芯轴501暴露于水，由此溶解芯轴501并且形成内部通道201。
图8A-11B为描述用于制造诸如图1的传动箱101的纤维增强聚合物复合物件的方法的一个替代实施例的程式化视图。在该实施例中，由管1001（如图10A-10C所示）形成内部通道1103（如图11A和11B所示），而不是上面图3A-7B示出的第一实施例中由基部层合层303和顶部层合层601限定出内部通道701。具体地，图8A,9A,10A,和11A为描绘类似于传动箱101的部分203（如图2所示）的纤维增强聚合物复合物件的部分801处于各个制造阶段的程式化侧面正视图。图8B,9B,10B，和11B为部分801处于分别与图8A,9A,10A,和11A相对应的制造阶段的程式化横截面视图。因此，图xB为图xA中沿xB-xB线的程式化横截面视图，其中“x”为8,9,10,或11。例如，图8B为图8A中沿线8B-8B的程式化横截面视图。
参照图8A和8B，部分801的基部层合层803纤维铺放在工具或模具805上。应该注意到基部层合层803包括多个具有期望方向的未固化纤维增强复合材料层片或层。如图9A和9B所示，凹槽901形成在基部层合层803中用以容纳管1001（最好参照图10B）。优选地，凹槽901通过将一部分材料移除而形成，例如通过切削，机械加工，铣削或类似的工艺。现在参照图10A和10B，管1001放置在凹槽901中。管1001包括任何适于运送流体的材料，流体诸如为液压流体或类似的流体，但并不限于这些流体。如图10C所示，粘结层1003可以设置在管1001的外表面1005。如图11A和11B所示，顶部层合层1101接着纤维铺放在基部层合层803和管1001上方。与基部层合层803一样，顶部层合层1101包括多个具有期望方向的未固化纤维增强复合材料层片或层。基部层合层803和顶部层合层1101例如通过加压和加热而固化，并且使管1001处于适当的位置以形成具有内部通道1103的部分801，内部通道1103对应于传动箱101的内部通道201。
图12A-14B为描述用于制造诸如图1的传动箱101的纤维增强聚合物复合物件的方法的一个替代实施例的程式化视图。在该实施例中，凹槽1207（最好参照图12B）使用纤维铺放工艺形成，而不是像图3A-7B和图8A-11B中分别描绘的第一和第二实施例那样，凹槽401或901通过金属移除工艺形成。具体地，图12A,13A,和14A为描绘类似于传动箱101的部分203（如图2所示）的纤维增强聚合物复合物件的部分1201处于各个制造阶段的程式化侧面正视图。图12B,13B，和14B为部分1201处于分别与图12A,13A,和14A相对应的制造阶段的程式化横截面视图。因此，图xB为图xA中沿xB-xB线的程式化横截面视图，其中“x”为12,13,或14。例如，图12B为图12A中沿线12B-12B的程式化横截面视图。
参照图12A和12B，部分1201的基部层合层1203纤维铺放在工具或模具1205上。应该注意到基部层合层1203包括多个具有期望方向的未固化纤维增强复合材料层片或层。在纤维铺放过程中，使用纤维铺放工艺在基部层合层1203中形成凹槽1207以容纳管1301（最好参见图13B）。现在参照图13A和13B，管1301设置在凹槽1207中。管1301包括任何适于运送流体的材料，流体例如是液压流体或类似的流体，但并不限于这些流体。优选地，如图10C所示，粘结剂，例如粘结剂1003可以设置在管1301的外表面1303上。如图14A和14B所示，顶部层合层1401接着纤维铺放在基部层合层1203和管1301上方。与基部层合层1203一样，顶部层合层1401包括多个具有期望方向的非固化纤维增强复合材料层片或层。基部层合层1203和顶部层合层1401例如通过加压和加热被固化，使管1301处于适当的位置以形成具有内部通道1403的部分1201，内部通道1403与传动箱101的内部通道201相对应。
应该指出形成凹槽401的工艺（在图4B中最好地示出）也可以采用纤维铺放工艺完成，而不是材料移除工艺。
还应该指出的是纤维铺放工具305，805，以及1205均为低成本，容易制造的工具，与传统铸造工具相比其需要更少的生产周期，并且更容易制造，成本更低，改变耗时更少。
本申请具有显著的优点，包括：（1）提供具有内部通道的物件，其比相应的金属材料制成的物件更轻；（2）提供具有内部通道的传动箱，其比相应的金属材料制成的传动箱更轻；（3）提供一种采用工具制造物件的装置，与传统的铸造工具相比更容易制造，成本更低并且容易改变。
上面公开的具体实施例仅仅是示意性的，本申请可以以对享有这里的教导的利益的本领域技术人员来说现已建的不同但是等效的方式进行修改和实施。进而，除了下面在权利要求中描述的，这里示出的结构或设计的细节并不是限制性的。因此显而易见的是上面描述的具体实施例可以被改变和修改并且全部的修改都被认为位于本申请的范围和精神之内。相应地，这里寻求的保护在下面的权利要求中提出。显而易见的是描述和示出的系统具有显著的优点。尽管本申请的系统以有限数量的形式被示出，其并不限于这些形式，而是可修改的具有各种改变和修改而不会脱离本申请的精神。

Claims (20)

1.一种制造具有内部通道的纤维增强复合物件的方法，包括：
提供铺放工具；
在铺放工具上放置基部层合层，基部层合层包括复合材料；
在基部层合层中形成凹槽；
在凹槽中放置芯轴；
在基本层合层和芯轴上放置顶部层合层，顶部层合层包括复合材料；
固化基部层合层和顶部层合层；并且
从基部层合层和顶部层合层中移除芯轴。
2.根据权利要求1所述的方法，其中在基部层合层中形成凹槽通过材料移除工艺完成。
3.根据权利要求2所述的方法，其中材料移除工艺为切削，机械加工以及铣削中的一种。
4.根据权利要求1所述的方法，其中通过树脂转移模制工艺将基部层合层放置在铺放工具上，并且将顶部层合层放置在基部层合层和芯轴上。
5.根据权利要求1所述的方法，其中通过纤维铺放工艺将基部层合层放置在铺放工具上，并且将顶部层合层放置在基部层合层和芯轴上。
6.根据权利要求1所述的方法，其中在将基部层合层放置在铺放工具上的过程中在基部层合层中形成凹槽。
7.根据权利要求1所述的方法，其中芯轴包括：易熔材料。
8.根据权利要求1所述的方法，其中芯轴包括：水溶材料。
9.根据权利要求8所述的方法，其中水溶材料包括：盐。
10.根据权利要求1所述的方法，其中纤维增强复合物件为旋翼飞机的传动箱。
11.一种制造具有内部通道的纤维增强复合物件的方法，包括：
提供铺放工具；
在铺放工具上设置基本层合层；
在基部层合层中形成凹槽；
在凹槽中放置管；
在基部层合层和管上放置顶部层合层；并且
固化基部层合层和顶部层合层。
12.根据权利要求11所述的方法，其中在基部层合层中形成凹槽通过材料移除工艺完成。
13.根据权利要求12所述的方法，其中材料移除工艺为切削，机械加工以及铣削中的一种。
14.根据权利要求11所述的方法，其中通过树脂转移模制工艺将基部层合层放置在铺放工具上，并且将顶部层合层放置在基部层合层和管上。
15.根据权利要求11所述的方法，其中通过纤维铺放工艺将基部层合层放置在铺放工具上，并且将顶部层合层放置在基部层合层和管上。
16.根据权利要求11所述的方法，其中在将基部层合层放置在铺放工具上的过程中在基部层合层中形成凹槽。
17.根据权利要求11所述的方法，进一步包括在将管放置在凹槽中之前在管的外表面上涂敷粘结剂。
18.根据权利要求11所述的方法，其中纤维增强复合物件为用于旋翼飞机的传动箱。
19.根据权利要求11的方法，其中管配置成运送流体使其从中穿过。
20.根据权利要求19的方法，其中流体为液压流体。
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