CN103038051A - 构造复合材料组件的系统及方法 - Google Patents

构造复合材料组件的系统及方法 Download PDF

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Publication number
CN103038051A
CN103038051A CN2010800632478A CN201080063247A CN103038051A CN 103038051 A CN103038051 A CN 103038051A CN 2010800632478 A CN2010800632478 A CN 2010800632478A CN 201080063247 A CN201080063247 A CN 201080063247A CN 103038051 A CN103038051 A CN 103038051A
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China
Prior art keywords
mould
casting die
removable insert
edge
module
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CN2010800632478A
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CN103038051B (zh
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阿兰·兰翠
杰曼·贝朗热
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LearJet Inc
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LearJet Inc
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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
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5042—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like covering both elements to be joined
    • B29C65/505—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like covering both elements to be joined and placed in a recess formed in the parts to be joined, e.g. in order to obtain a continuous surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C31/00—Handling, e.g. feeding of the material to be shaped, storage of plastics material before moulding; Automation, i.e. automated handling lines in plastics processing plants, e.g. using manipulators or robots
    • 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
    • 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
    • B29C31/00—Handling, e.g. feeding of the material to be shaped, storage of plastics material before moulding; Automation, i.e. automated handling lines in plastics processing plants, e.g. using manipulators or robots
    • 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
    • B29C31/085—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 combined with positioning the preforms according to predetermined patterns, e.g. positioning extruded preforms on conveyors
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    • B29C33/20—Opening, closing or clamping
    • B29C33/26—Opening, closing or clamping by pivotal movement
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/12842—Stepped joint cross-sections comprising at least one butt joint-segment comprising at least two butt joint-segments comprising at least three butt joint-segments
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
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    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
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    • 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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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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Abstract

一种用于构造复合材料组件的系统和方法。该组件的部件源自于多于一个的模具，同时在仅一个步骤中在加热和真空的条件下对不需要高压处理的预浸渍形式的复合材料提供固化或硬化。在将第一模具组装至第二模具之前，将可移除插入件从第二模具移除。在将第一模具和第二模具闭合并且将第一模具装配在第二模具上之后，在该可移除插入件上方延伸的层压件的一部分重叠在相邻的层压件之上。

Description

构造复合材料组件的系统及方法
技术领域
本发明总体上涉及复合材料。更具体地，本发明涉及一种用于构造复合材料组件的系统和方法。
背景技术
通过使用多部件部分制造复合材料组件，并且更具体地制造机身，在对多部件部分进行组装并接合单独的部分或部件之前通常需要预硬化并且固化每个部件。
所述方法具有限制：
-需要最少为两步的固化；
-对于主要的结构部件，在接合接头处需要额外的机械紧固件；
-该方法需要操作设备以及装配夹具(用于拔模操作)；
-长的机身制造时间；
-在接头处过厚造成应力集中；
-增加的组件重量；以及
-在结合之前需要表面处理。
在现有技术中提出了用于组装多部件部分的多种解决方案。
US 7,459,048公开了一种制造飞机机身的单元部分的方法，包括将薄的层叠心轴元件设置在圆筒形内部心轴壳体的外侧壳体表面上从而形成具有层叠表面的心轴的步骤。该方法还包括以下步骤：将纤维铺放在该层叠表面上，同时使该心轴旋转以形成飞机机身的单元预固化部分。
WO 98/32589公开了一种具有利用自动纤维铺放方法形成的连续表层(skin)的复合结构。该多层纤维被放置在纤维铺放工具上，该纤维铺放工具包括被囊袋包围的心轴主体。通过围绕纤维铺放工具将纤维放置成不连续的片段来形成未固化的复合结构，该不连续的片段能够相对于彼此移动或滑动从而能够从内部扩展开。通过在囊袋和模具之间形成真空，该未固化的结构抵着模具的其它表面扩展。
US 7,325,771公开了一种用于连接复合机身部分的结构和方法，该方法通过配合从而利用接合接头来附接在第一复合部件上的第一加强件和在第二复合部件上的第二加强件。之后使用条带将第一复合部件和第二复合部件接合在一起。
US 2006/0251847公开了一种连接复合元件的方法，在该方法中通过纤维复合层压件的厚度来完成该结合，从而使用非互锁和互锁结合降低层间应力。
US 2009/0148647公开了如下构造复合结构的方法：通过使用斜接接头而不是使用前述的纤维铺放机沿着多个复合模块的边缘连接多个复合模块，前述纤维铺放机需要高资金支出和高操作成本。
然而，仍然需要一种构造复合材料组件的系统和方法，该系统和方法在形成结构时便于部件的组装，同时使组装设备成本最小化。
发明内容
本发明的一个目的在于提出一种系统和方法，该系统和方法满足至少一个上文提及的需求。
根据本发明，通过用于构造复合材料组件的系统来实现该目的，该系统包括：
-第一模具，该第一模具用于接纳由复合材料制成的第一模块，该第一模具包括：
-第一复合材料层压件支撑结构，该第一复合材料层压件支撑结构具有相对的第一边缘和第二边缘；以及
-第一附接界面，该第一附接界面用于将第一模具附接至相邻的模具；
以及
-第二模具，该第二模具用于接纳由复合材料制成的第二模块，该第二模具包括：
-第二复合材料层压件支撑结构，该第二复合材料层压件支撑结构具有相对的第一边缘和第二边缘；
-第二附接界面，该第二附接界面用于将第二模具附接至该第一模具；和
-至少一个可移除插入件，该至少一个可移除插入件在第二模具的第一边缘和第二边缘中的至少一个之外延伸，
其中该第一模块包括覆盖第一层压件支撑结构的第一层压件，该第二模块包括第二层压件，该第二层压件覆盖第二层压件支撑结构并在该至少一个可移除插入件上方延伸，并且其中在将第一模具组装至第二模具之前，将该至少一个可移除插入件从该第二模具移除，并且在将第一模具闭合并且组装到第二模具上之后，第二层压件在该至少一个可移除插入件上方延伸的一部分重叠在该第一层压件之上。
根据本发明，还提供了一种构造复合材料组件的方法，该方法包括如下步骤：
a)提供一种组装系统，包括：
-第一模具，该第一模具用于接纳由复合材料制成的第一模块，该第一模具包括：
-第一复合材料层压件支撑结构，该第一复合材料层压件支撑结构具有相对的第一边缘和第二边缘；以及
-第一附接界面，该第一附接界面用于将第一模具附接至相邻的模具；
以及
-第二模具，该第二模具用于接纳由复合材料制成的第二模块，该第二模具包括：
-第二复合材料层压件支撑结构，该第二复合材料层压件支撑结构具有相对的第一边缘和第二边缘；
-第二附接界面，该第二附接界面用于将第二模具附接至该第一模具；和
-至少一个可移除插入件，该至少一个可移除插入件在第二模具的第一边缘和第二边缘中的至少一个之外延伸；
b)将第一模块放置在第一模具上，该第一模块包括覆盖第一层压件支撑结构的第一层压件；
c)将第二模块放置在第二模具上，该第二模块包括第二层压件，该第二层压件覆盖第二层压件支撑结构并在该至少一个可移除插入件上方延伸；
d)从第二模具移除该至少一个可移除插入件；以及
e)将该第一模具组装至该第二模具，同时将第二层压件在该至少一个可移除插入件上方延伸的一部分重叠在该第一层压件之上。
本发明提供制造源自于多于一个模具的一件式复合部件的方法，同时提供一种结构，可以在仅一个步骤中在加热和真空的条件下固化或硬化该结构，优选地该结构具有不需要高压处理的预浸渍形式的复合材料。
现在将参考附图给出本发明的优选实施例的非限制性说明。
附图说明
图1a至图1c是根据本发明的优选实施例的系统的侧截面视图，示出在移除可移除插入件之前，将第一模具上的第一整体层压件组装在第二模具的第二整体层压件上的顺序；
图2a至图2c是根据本发明另一优选实施例的系统的侧截面视图，示出在移除可移除插入件之前，将第一模具上的第一夹层层压件组装在第二模具的第二夹层层压件上以及接下来引入层叠接合的顺序；
图3a至图3e是构建利用根据本发明的另一优选实施例的系统的管状部件的顺序的正视图，每个模具使用一个可移除插入件；
图4a至图4e是构建图3a至图3e示出的管状部件的顺序的透视图；
图5a至图5c是构建利用根据本发明的另一优选实施例的系统的管状部件的顺序的初始步骤的正视图，以及可移除插入件关于模具的替换分布，在第一模具上不具有插入件，第二模具上具有一个(1)插入件并且在第三模具上具有两个(2)插入件；
图6a至图6c是构建图5a至图5c示出的管状部件的顺序的透视图；
图7是构建利用根据本发明的另一优选实施例的系统的机身部件的顺序的透视图，并且示出通过人工来组装复合层叠材料；以及
图8a和图8b分别是阶梯重叠式接头界面和斜接式接头界面的示意图。
具体实施方式
本发明的一个目的在于由两个或更多个纵向部分部件制造一种复合材料组件，诸如但不限于管状轮廓结构。可以在一个步骤中固化整个的组件以形成一件式管状结构，例如机身。因此，在固化发生之前连接将要组成该整个组件的部件，并且之后通过这些部件的共固化来固化该整个组件，从而生产不具有任何过度明显的接缝的最终产品。
参见图1a至图1c，根据本发明的第一优选实施例，公开了一种用于构造复合材料组件的系统10。该系统10包括第一模具12以用于接纳由复合材料制成的第一模块13。该第一模具12具有第一复合材料层压件支撑结构14，该第一复合材料层压件支撑结构14具有相对的第一边缘16和第二边缘18。该第一模具12还具有第一附接界面20以用于将第一模具12附接至邻接的模具22。该系统10还包括第二模具22以用于接纳由复合材料制成的第二模块23。该第二模具22包括第二复合材料层压件支撑结构24，该第二复合材料层压件支撑结构24具有相对的第一边缘26和第二边缘28。该第二模具22还具有第二附接界面30以用于将第二模具22附接至第一模具12。
系统10还包括可移除插入件32，该可移除插入件32在第二模具22的第二边缘28之外延伸。该插入件32被成形为使得如果第一模具12和第二模具22被附接在一起，则该插入件32将与第一模具12相接触，并且如果插入件32存在的话，该插入件32将防止第一模具12和第二模具22之间的附接。
第一模块13包括第一层压件34，该第一层压件34覆盖第一层压件支撑结构14。第二模块23包括第二层压件36，该第二层压件36覆盖第二层压件支撑结构24并在该可移除插入件32上方延伸。如在图1a至图1b的过渡中所更好地示出的，在将第一模具12组装至第二模具22之前，从第二模具22移除该可移除插入件32。如在图1b中更好地示出的，在将第一模具12闭合并且组装在第二模具22上之后，第二层压件36在可移除插入件32上方延伸的部分38重叠在第一层压件34上。在模具12、22初始闭合的时候，层压件34、36并没有固化或硬化，允许所需要的粘着性、柔软性以及挠性以确保在界面处的合适的相互配合和层叠。
优选地，第一层压件34具有第一界面轮廓40，该第一界面轮廓40被成形为配合到第二层压件36在可移除插入件32上方延伸的部分的互补第二界面轮廓42中。由此该第二层压件36可以重叠在该第一层压件34上，并在第一模块13和第二模块23之间形成没有过度明显接缝的连接。优选地，该界面轮廓40、42被选择成形成阶梯重叠式的接头。将层压件34、36初始放置在模具12、22上的过程中，该可移除插入件32提供形成阶梯重叠式接头所需的延伸表面。
优选地，当该复合材料组件为管状部件时，由两个或更多个接头形成最终组件。对于该应用，给定所选择类型的接头必须使任何过厚最小化，从而沿着组件周边的周界获得均匀的结构厚度，优选通过如上所述的阶梯重叠式的界面，使用需要叠加两个半体元件的类型的接头。在本发明的针对机身应用的其它实施例中，如图8A所示的在模块之间的截面界面处的该阶梯重叠式界面可以替换为如图8B所示的斜接类型的层压件，而不影响该机身结构所需要的恒定厚度。
如在图1b中所示的，制造根据本发明的接头需要层压件36的部分38暂时地悬垂并因此在模具32的边缘28之外不被支撑。需要在移除插入件32至闭合模具12、22来形成组件的时间段内持续该悬垂的构造。
为了允许模具12、22的闭合，将要被堆叠的互补的界面轮廓40、42的半体元件中的每一个必须在模具12、22的闭合移动期间避免相互接触，因为在该两个半体元件被准确定位之前，可能具有局部预粘着的风险。该层压件界面的两侧的任何不正确的定位都有可能会导致气穴的形成，并且在接头组装区域中导致结构层压件的异常中断。
为了在模具12、22的最终闭合位置之前避免在接头的两个半体元件之间的预粘着的可能性，该可移除插入件32优选具有以下几何形式：被成形为在插入件32被移除之后，通过截面轮廓42，在另一模具12上的对应的截面轮廓40上方定位层压件36的悬垂部分38，而不导致任何的接触或预粘着。
优选地，插入件32的层压件界面的悬垂部分38所搁置的表面在第二模具22的边缘28处，朝向第二模具22的内侧面，具有相对于第二模具22的第二层压件36的切线方向的至少10°并且优选在10°至15°之间的角位置，该可移除插入件32被定位在该边缘28处。
对于机身的应用，所需要的用于机身的层压件的结构可以是如图1a至图1c中所示的整体构造，或是如图2a至图2c中所示的夹层/芯部结构，或是该两者的组合。优选地，在如图2a至图2c所示的机身夹层/芯部结构的情况下，利用可移除插入件32和模具12、22来制造的初始层压组件是相同的，但是现在这一层压组件可以被命名为“外表层”74a。如在图2b中所示的，该“外表层”74a接纳夹层蜂窝芯部72，该夹层蜂窝芯部72后面是“内表层”74b，该“内表层”74b可以具有不同的结构。该内表层层压件74b在与夹层芯部72的表面完全接触的情况下，其纵向边缘78、79也被阶梯重叠式的几何构造终止。优选地，由“非高压”碳-环氧预浸渍材料制成该层压件并且该夹层/芯部结构包括NomexTM蜂窝芯部，然而，可以使用其它的材料。
优选地，可移除插入件32为结构元件。然而，该可移除插入件可以是可膨胀的结构，或本领域技术人员所已知的任何其它可伸缩模具结构。
优选地，附接界面20、30为铰接式界面。然而，可以使用其它类型的附接界面。此外，该附接界面20、30可以包括凸轮组件以便对层压件36的悬垂部分38提供足够量的空隙，从而避免与界面其它侧无意的接触和预粘着。
优选地，系统10还包括在第一模具12和第二模具22之间的接头界面处的柔性弹性体密封件。该柔性弹性体密封件提供固化步骤中所需要的模具组件的真空完整性。
优选地，在第一模具12和第二模具22上放置第一模块13和第二模块23之前将脱模剂涂覆至第一模具12和第二模具22。该脱模剂优选为三种类型中的一种：(i)液体或糊状，(ii)具有塑料薄膜形式和(iii)具有诸如TeflonTM涂层的永久型涂层，并且本领域技术人员可以根据对脱模剂的具体需求选择合适的脱模剂。另外，可以考虑其它类型的脱模剂。该脱模剂被涂覆在每个模具中以允许在固化步骤之后再次模制其它的模块。
优选地，第一模具12和第二模具22为具有圆筒形结构的部件。由此该系统可以用于形成如图3a至图3e和图4a至图4e中所示的弯曲组件。优选地，该模具具有适应形成管状轮廓结构的几何形状并且包括至少两个180°部分或优选三个120°部分。
参考图3a，当由三部分构成模具时，中间模具12安置在地面上，且相邻地设置其它两个模具22、52。
优选地，当组装模具12、22、52包括三个部分来形成圆筒形结构时，可以以不同的方式定位该可移除插入件。在本发明的某一优选的实施例中，每个模具12、22、52与一个插入件相连，如在图3a至图3e中所示的，因此该构造允许制造三个(3)相同的模具/插入件。然而，可以考虑其它的构造。例如，没有插入件与第一模具12相连，一个插入件与第二模具22相连，两个插入件与第三模具52相连，如在图5a至图5c中所示的。
不同模具12、22、52的闭合顺序不受不同模具间插入件的位置和分布的影响，因为空隙区域已经被设计成模具的形状从而在该空隙区域内放置层压件36的悬垂部分38，以在模具闭合期间避免组装的层压件的界面两侧之间的接触。
优选地，在其它的应用之中，对于组装圆筒形机身部件，提供了三个模具12、22、52。如在图5a至图5c中更好地示出的，用于构造复合材料组件的系统10包括第三模具52以用于接纳由复合材料制成的第三模块。该第三模具52包括第三复合材料层压件支撑结构54，该第三复合材料层压件支撑结构54具有相对的第一边缘56和第二边缘58。该第三模具还具有一对相对的第三附接界面60和第四附接界面62以用于将第三模具52附接至第一模具12和第二模具22。该第三模具52还具有第二可移除插入件64和第三可移除插入件65，该第二可移除插入件64在第三复合材料层压件支撑结构54的第一边缘56之外延伸，该第三可移除插入件65在第三复合材料层压件支撑结构54的第二边缘58之外延伸。第一模具12包括第五附接界面66以用于将第一模具12附接至第三模具52。第二模具22包括第六附接界面68以用于将第二模具22附接至第三模具52。第三层压件70覆盖第三层叠结构54并且在第二可移除插入件64和第三可移除插入件65上方延伸。在组装第一模具12、第二模具22和第三模具52之前，从第二模具22和第三模具52移除第一可移除插入件32、第二可移除插入件64和第三可移除插入件65。在将第三模具52闭合并且组装在第一模具12上之后，第三层压件在第二可移除插入件64上方延伸的一部分71重叠在第一层压件34上。在将第三模具52闭合并且组装在第二模具22上之后，第三层压件在第三可移除插入件65上方延伸的另一部分73重叠在第二层压件36上。如上所述的，图5a至图5c中所示的插入件32、64、65在不同的模具中的分布可以根据选定的组装闭合顺序而改变并且例如对应于图3a至图3e中所示的插入件32、64、65的分布。在图5a至图5e中，插入件的分布使得安置在地面上的第一模具12不具有插入件并且部分71、38重叠在第一层压件上，在特定的组件构造中，其可能是一种更加实际的层压件组装顺序。
根据本发明，还提供了一种构造复合材料组件的方法，该方法包括以下步骤：
a)提供如图1a至图1c中所示的组装系统10，包括：
-第一模具12，该第一模具12用于接纳由复合材料制成的第一模块13，该第一模具12包括：
-第一复合材料层压件支撑结构14，该第一复合材料层压件支撑结构14具有相对的第一边缘16和第二边缘18；和
-第一附接界面20，该第一附接界面20用于将第一模具12附接至相邻的模具22；
以及
-第二模具22，该第二模具22用于接纳由复合材料制成的第二模块23，该第二模具22包括：
-第二复合材料层压件支撑结构24，该第二复合材料层压件支撑结构24具有相对的第一边缘26和第二边缘28；
-第二附接界面30，该第二附接界面30用于将第二模具22附接至第一模具12；以及
-至少一个可移除插入件32，该至少一个可移除插入件32在边缘28之外延伸；
b)在第一模具12上放置第一模块13，该第一模块13包括覆盖第一层压件支撑结构14的第一层压件34；
c)在第二模具22上放置第二模块23，该第二模块23包括第二层压件36，该第二层压件36覆盖第二层压件支撑结构24并且在可移除插入件32上方延伸；
d)从第二模具22移除该可移除插入件32；
e)组装第一模具12和第二模具22，同时将第二层压件36在可移除插入件32上方延伸的部分38重叠在第一层压件34上。
优选地，该方法还包括步骤f)在烘炉中固化组装的第一模块13和第二模块23。当根据本发明的方法被用来制造机身组件时，考虑到机身的整个复合结构已经实现完全未固化的状态并且该复合结构被完全组装为管状轮廓的事实，必须将在闭合模具内的该整个机身组件放置在固化炉中以在真空和加热条件下对其进行硬化。在仅一个“加热和压力周期”内，该预浸渍层压件和粘结剂将固化和硬化从而生成一件式管状部分机身，而不存在过度明显的接缝。然而，根据本发明，本领域技术人员应当理解任何合适的固化工艺都是可以的。
优选地，使用该系统或方法制造的一件式部分机身可以集成或包括地板附接元件、驾驶舱挡风玻璃、座舱机窗以及客舱门包覆结构。所有的这些特征结构都可以在仅一个步骤中固化。根据本发明的系统和方法可被用于飞机的任何部分，该飞机具有需要共固化以降低任何过度明显接缝的管状轮廓，例如飞机的任何舱室。
参考图7，根据本发明的系统和方法可以用于制造一件式机身部分并便于在几乎水平的位置中将复合预浸渍材料层叠在模具12、22、52上，由此当与管状模具或圆筒形模具相比时降低重力的反作用。
尽管在这里已经详细地描述并且在附图中示出了本发明的优选实施例，但是应当理解本发明并不限制在这些特定的实施例中，并且在不脱离本发明的范围或精神的情况下，可以对这些特定的实施例做出各种改变和修改。

Claims (24)

1.一种用于构造复合材料组件的系统，包括：
-第一模具，所述第一模具用于接纳由复合材料制成的第一模块，所述第一模具包括：
-第一复合材料层压件支撑结构，所述第一复合材料层压件支撑结构具有相对的第一边缘和第二边缘；以及
-第一附接界面，所述第一附接界面用于将所述第一模具附接至相邻的模具；
以及
-第二模具，所述第二模具用于接纳由复合材料制成的第二模块，所述第二模具包括：
-第二复合材料层压件支撑结构，所述第二复合材料层压件支撑结构具有相对的第一边缘和第二边缘；
-第二附接界面，所述第二附接界面用于将所述第二模具附接至所述第一模具；和
-至少一个可移除插入件，所述至少一个可移除插入件延伸超过所述第二模具的所述第一边缘和第二边缘中的至少一个边缘，
其中所述第一模块包括第一层压件，所述第一层压件覆盖所述第一层压件支撑结构，所述第二模块包括第二层压件，所述第二层压件覆盖所述第二层压件支撑结构并在所述至少一个可移除插入件上方延伸，并且其中在将所述第一模具组装至所述第二模具之前，将所述至少一个可移除插入件从所述第二模具移除，并且在将所述第一模具和所述第二模具闭合并且将所述第一模具组装到所述第二模具上之后，在所述至少一个可移除插入件上方延伸的所述第二层压件的部分重叠在所述第一层压件上方。
2.根据权利要求1所述的系统，其中所述第一模具和第二模具是圆筒形结构的部分。
3.根据权利要求1或2所述的系统，其中所述第一层压件具有第一界面轮廓，所述第一界面轮廓被成形为配合到在所述至少一个可移除插入件上方延伸的所述第二层压件的并且重叠在所述第一层压件上的所述部分的互补的第二界面轮廓中，用于形成所述第一模块和第二模块之间的接头。
4.根据权利要求1至3中的任一项所述的系统，其中所述至少一个可移除插入件包括层压件悬垂支撑表面，所述层压件悬垂支撑表面被定向为在所述第二模具的所述第一边缘和第二边缘中的所述至少一个边缘处，以相对于所述第二模具的第二层压件的切线方向至少10°的偏斜角朝向所述第二模具的内侧，所述至少一个可移除插入件定位在所述至少一个边缘处。
5.根据权利要求4所述的系统，其中所述偏斜角在10°至15°之间。
6.根据权利要求1至5中的任一项所述的系统，还包括在所述第一模具和第二模具之间的接头界面处的柔性的弹性体密封件。
7.根据权利要求1至6中的任一项所述的系统，其中在将所述第一模块和第二模块放置在所述第一模具和第二模具上之前，将脱模剂涂覆至所述第一模具和第二模具。
8.根据权利要求1至7中的任一项所述的系统，其中所述第一模块和第二模块在组装期间处于未固化的状态。
9.根据权利要求1至8中的任一项所述的系统，还包括：
-第三模具，所述第三模具用于接纳由复合材料制成的第三模块，所述第三模具包括：
-第三复合材料层压件支撑结构，所述第三复合材料层压件支撑结构具有相对的第一边缘和第二边缘；
-一对相对的第三附接界面和第四附接界面，所述一对相对的第三附接界面和第四附接界面用于将所述第三模具附接至所述第一模具和第二模具；和
-第二可移除插入件和第三可移除插入件，所述第二可移除插入件和第三可移除插入件分别延伸超过所述第三模具的第一边缘和第二边缘，
其中所述第一模具包括第五附接界面以用于将所述第一模具附接至所述第三模具，所述第二模具包括第六附接界面以用于将所述第二模具附接至所述第三模具，所述第三模块包括第三层压件，所述第三层压件覆盖所述第三层压件支撑结构并在所述第二可移除插入件和第三可移除插入件上方延伸，并且其中在组装所述第一模具、第二模具和第三模具之前，将所述第一可移除插入件、第二可移除插入件和第三可移除插入件从所述第二模具和第三模具移除，在将所述第三模具和所述第一模具闭合并且将所述第三模具组装到所述第一模具上之后，在所述第二可移除插入件上方延伸的所述第三层压件的第一部分重叠在所述第一层压件上方，在将所述第二模具和所述第三模具闭合并且将所述第二模具组装到所述第三模具上之后，在所述第三可移除插入件上方延伸的所述第三层压件的第二部分重叠在所述第二层压件上方，并且其中所述第一模具、第二模具和第三模具形成闭合的圆筒形结构。
10.根据权利要求1至9中的任一项所述的系统，其中所述第一层压件和第二层压件是外模具线表层。
11.根据权利要求10所述的系统，还包括内模具线表层以及芯部，所述内模具线表层被放置在所述外模具线表层上方，所述芯部介于所述内模具线表层与外模具线表层之间。
12.一种用于构造复合材料组件的方法，包括如下步骤：
步骤a)提供一种组装系统，包括：
-第一模具，所述第一模具用于接纳由复合材料制成的第一模块，所述第一模具包括：
-第一复合材料层压件支撑结构，所述第一复合材料层压件支撑结构具有相对的第一边缘和第二边缘；以及
-第一附接界面，所述第一附接界面用于将所述第一模具附接至相邻的模具；
以及
-第二模具，所述第二模具用于接纳由复合材料制成的第二模块，所述第二模具包括：
-第二复合材料层压件支撑结构，所述第二复合材料层压件支撑结构具有相对的第一边缘和第二边缘；
-第二附接界面，所述第二附接界面用于将所述第二模具附接至所述第一模具；和
-至少一个可移除插入件，所述至少一个可移除插入件延伸超过所述第二模具的所述第一边缘和第二边缘中的至少一个边缘；
步骤b)将所述第一模块放置在所述第一模具上，所述第一模块包括第一层压件，所述第一层压件覆盖所述第一层压件支撑结构；
步骤c)将所述第二模块放置在所述第二模具上，所述第二模块包括第二层压件，所述第二层压件覆盖所述第二层压件支撑结构并且在所述至少一个可移除插入件上方延伸；
步骤d)将所述至少一个可移除插入件从所述第二模具移除；和
步骤e)将所述第一模具与所述第二模具组装在一起，同时将在所述至少一个可移除插入件上方延伸的所述第二层压件的一部分重叠在所述第一层压件上方。
13.根据权利要求12所述的方法，其中所述第一模具和第二模具是圆筒形结构的部分。
14.根据权利要求12或13所述的方法，其中所述第一层压件具有第一界面轮廓，所述第一界面轮廓被成形为配合到在所述至少一个可移除插入件上方延伸的所述第二层压件的并且重叠在所述第一层压件上方的所述部分的互补的第二界面轮廓，用于形成所述第一模块和第二模块之间的接头。
15.根据权利要求12至14中的任一项所述的方法，其中所述至少一个可移除插入件包括层压件悬垂支撑表面，所述层压件悬垂支撑表面被定向为在所述第二模具的所述第一边缘和第二边缘中的所述至少一个边缘处，以相对于所述第二模具的第二层压件的切线方向至少10°的偏斜角朝向所述第二模具的内侧，所述至少一个可移除插入件定位在所述至少一个边缘处。
16.根据权利要求15所述的方法，其中所述偏斜角在10°至15°之间。
17.根据权利要求12至16中的任一项所述的方法，其中所述组装系统还包括在所述第一模具和第二模具之间的接头界面处的柔性的弹性体密封件。
18.根据权利要求12至17中的任一项所述的方法，还包括如下步骤：在步骤b)之前，在将所述第一模块和第二模块放置在所述第一模具和第二模具上之前将脱模剂涂覆至所述第一模具和第二模具。
19.根据权利要求12至18中的任一项所述的方法，还包括步骤f)：固化所组装的第一模块和第二模块。
20.一种飞机机身，包括根据权利要求12至19中的任一项构造的复合材料组件。
21.根据权利要求20所述的飞机机身，其中所述机身是实心层压件。
22.根据权利要求20所述的飞机机身，其中所述机身是夹层结构。
23.根据权利要求20所述的飞机机身，其中所述机身是一些位置中的实心层压件和其它位置中的夹层结构的组合体。
24.根据权利要求20至23中的任一项所述的飞机机身，包括选自以下组中的至少一个部件，所述组包括：地板附接件、驾驶舱挡风玻璃、座舱机窗以及客舱门包覆结构。
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