CN103038052A - 用于宇航飞行器的复合材料加劲肋 - Google Patents

用于宇航飞行器的复合材料加劲肋 Download PDF

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Publication number
CN103038052A
CN103038052A CN2011800371824A CN201180037182A CN103038052A CN 103038052 A CN103038052 A CN 103038052A CN 2011800371824 A CN2011800371824 A CN 2011800371824A CN 201180037182 A CN201180037182 A CN 201180037182A CN 103038052 A CN103038052 A CN 103038052A
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China
Prior art keywords
degree
laminate
orientation
fiber
ribbed stiffener
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CN2011800371824A
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English (en)
Inventor
M·U·金斯马顿
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Boeing Co
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Boeing Co
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Publication of CN103038052A publication Critical patent/CN103038052A/zh
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Abstract

宇航飞行器（100）包括多个复合材料加劲肋（220）。多个加劲肋中的每一个均具有增强纤维层的堆垛。为了在不增加重量的情况下增加劲度，在堆垛中的至少一些层板具有相对于主载荷轴线以±α被定向的增强纤维，其中α是在2和12度之间。在堆垛中的至少一些层板具有相对于主载荷轴线以±β被定向的增强纤维，其中β是在50和85度之间。

Description

用于宇航飞行器的复合材料加劲肋
背景技术
在飞机中，桁条执行若干功能。这些功能包括传递蒙皮面板中的弯曲载荷，以及加劲蒙皮面板，所以在加载情况下面板不会屈曲。
桁条和蒙皮面板可以由纤维复合材料制成，例如碳纤维增强的塑料（CFRP）。CFRP是用来替代金属的，特别是在需要相对较低重量和高机械强度的应用中。在比强度和刚度/劲度（stiffness）上，CFRP提供了优于传统金属合金的显著改进。更好的比强度和劲度转化为重量节省，其转化为燃料的节省和较低的操作成本。
复合材料桁条是由多个增强纤维制造的。为了制造使用四个传统轴线（0/+40/-45/90度）来指定单个层板取向的复合材料铺层，存在设计规定的标准，其中0度通常与主载荷方向对齐。该标准也结合到测试件，以及最终复合材料铺层强度可用性及工业强度优化分析方法。
一些层板具有相对于主要加载的桁条轴线以0度取向的增强纤维。这些纤维传递了单轴载荷。其他层板具有以±45度和90度取向的增强纤维，从而传递剪切、横向和支承载荷。每一个层板均增加了重量到桁条上。也已经知道，在单个主载荷方向上高百分比的总层板能够削弱在非主载荷方向上的桁条，这样的削弱导致例如在桁条主载荷方向上的早期断裂或者分裂。这种影响限制了在没有添加层板的情况下增加桁条劲度的能力。
需要增加复合材料桁条的比强度和劲度。
发明内容
根据这里的实施例，宇航飞行器包括多个复合材料加劲肋。多个加劲肋中的每一个均具有增强纤维层板的堆垛。在堆垛中至少一些层板具有相对于主加载轴线以非传统取向±α被定向的增强纤维，其中α是在2和12度之间。在堆垛中至少一些层板具有相对于主加载轴线以非传统取向±β被定向的增强纤维，其中β是在50和85度之间。
根据这里的另一个实施例，物体包括宇航飞行器加劲肋。加劲肋包括基板（base）和腹板（web）。基板和腹板中的至少一个包括增强纤维层板的堆垛，其中至少50%相对于主载荷轴线以±α被定向，其中α是在2和12度之间。
根据这里的另一个实施例，物体包括宇航飞行器加劲肋。加劲肋包括基板和腹板。腹板包括增强纤维层板，以用于沿着主加载轴线提供在拉伸和压缩上的强度。腹板也包括增强纤维层板，其相对于主加载轴线以±β度被定向，其中β是在50和85度之间。以±β度被定向的纤维被偏置朝向腹板的外表面，从而增加在屈曲和横向加载上的劲度。
附图说明
图1是商用飞机的图解。
图2是包括桁条的主要飞机装配件的图解。
图3是蒙皮面板和桁条的图解。
图4是不同类型的飞机桁条几何构造的图解。
图5a是以±α度和±β度被定向的增强纤维层板的堆垛的图解。
图5b是仅以±α度被定向的增强纤维层板的堆垛的图解。
图6是具有被偏置朝向腹板的外表面的β-纤维的桁条腹板的图解。
图7a是增强纤维的图解，其相对于在中间钻有洞的桁条的主加载轴线以0度定向。
图7b是增强纤维的图解，其相对于在中间钻有洞的桁条的主加载轴线以±α度定向。
具体实施方式
参考图1和图2，其说明了商用飞机100。飞机100的主要装配件包括机身110、机翼装配件120和尾翼130。一个或更多个推进单元140耦合到机翼装配件120或者机身110或者飞机100的其他部分。
主要飞机装配件110、120和130包括蒙皮面板210和加劲肋。加劲肋起到防止主要装配件110、120和130屈曲的作用，包括传递在蒙皮面板210内的弯曲载荷，以及加劲蒙皮面板210，以便面板210在加载情况下不会屈曲。加劲肋不限制于图2中说明的主要飞机装配件110、120和130。加劲肋可以用在需要加劲的任何飞机结构中。
如这里所描述，桁条220是加劲肋的一种类型。
机身110中的桁条220主要经受单轴拉伸和压缩以及平面外屈曲（out-of-plane buckling）。机身桁条220也经受次要载荷，包括剪切和支承载荷/轴承载荷（bearing load）。
每一个机翼装配件120均包括上部桁条和下部桁条220。上部桁条220主要经受单轴压缩，而下部桁条220主要经受单轴拉伸（有时主加载是相反的）。上部和下部桁条220也经受次要载荷，包括剪切、轴承和横向载荷。
尾翼130包括水平稳定器和竖直稳定器。稳定器中的桁条220经受与机翼装配件120相同的主要载荷和次要载荷。
在压缩下，桁条220会趋向于扭曲、损坏（cripple）和屈曲。桁条220提供了抵抗压缩和拉伸的强度以及抵抗扭曲、损坏和屈曲的稳定性。
现在参考图3，其说明了被紧固到蒙皮面板210的桁条220的实施例。图3的桁条220具有工字梁（I-beam）几何构型。这样的桁条220包括在第一凸缘16和第二凸缘18之间的腹板14。腹板14具有深度为D，其提供对施加的加载的理想抗性。
第一凸缘16和第二凸缘18是大体平面构件。将被称为帽状物16的第一凸缘16具有宽度W1。将被称为基板18的第二凸缘18具有宽度W2。
腹板14、帽状物16和基板18沿着X-轴线在X-方向上延伸（其正交于图纸）。X-轴线是主加载轴线。腹板、帽状物16和基板18沿着X-方向具有恒定宽度，或者其可以沿着X-方向连续地变化或者甚至不连续地变化。
图3也显示了针对腹板14（X-Yw-Zw）、帽状物16（X-Yc-Zc）和基板18（X-Yb-Zb）中每一个的坐标系。这些坐标系可以对应于由背对背C型通道（back-to-back C-channel）形成的工字梁。如下面所讨论，所有增强纤维的取向均是相对于X-方向测量的。
这里的桁条220不限制于图3中所说明的工字梁几何构型。其他可用的几何构型包括但不限制于Z字梁、刀片状（blade）、C型通道和帽型梁（hat beam）。具有这些几何构型的桁条都包括至少一个腹板和基板。图4中说明了帽型、Z字梁和C型通道几何构型410、420和430。
厚度为T1的蒙皮面板210耦合到基板18上。在一些实施例中，基板18可以粘附地结合到蒙皮面板210。在其他的实施例中，基板18可以与蒙皮面板210共同固化。
在图3显示的实施例中，基板18通过紧固件22被夹持到蒙皮面板210。紧固件22穿过蒙皮面板210和基板18中的孔延伸。紧固件22由螺母24接合从而给予蒙皮面板210和基板18预定的压缩力。可以使用紧固件22替代或补充粘结。
用于使桁条220夹持到蒙皮面板210的紧固件不限制于螺栓22和螺母24。其他紧固件包括但不限制于，订书钉、Z字钉、铆钉、型铁紧固件和倒钩。不过，例如螺栓22的紧固件完全延伸穿过桁条基板和蒙皮面板210，而例如订书钉、Z字钉和倒钩的紧固件可以部分延伸到蒙皮面板中。例如订书钉、Z字钉和倒钩的紧固件可以与桁条基板形成一体。
紧固件的其他示例是缝线/缝合（stitching）。纤维层板可以被缝合在一起。缝线可以被穿过干燥复合材料层板铺层内的孔。然后在结构中灌注树脂，并固化结构。
蒙皮面板210包括嵌入基质中的增强纤维的层板的堆垛。不同的层板可以具有以0、+45、-45和90度定向的纤维。一些实施例可以具有近似各向同性的铺层，由此使用了等量和相等百分比的0、+45、-45和90度层板。在其他的实施例中，不同层板能够包括以10、-55、+100和-35度或一些其他角度定向或者组合的增强纤维。在蒙皮面板210中的增强纤维可以是具有40MSI的中间模数的碳纤维。蒙皮面板210的层板劲度（即，碳纤维加树脂的劲度）可以具有22-25MSI的模数。沿着0度的堆垛劲度可以是10-12MSI。
桁条220包括多个嵌入基质/基体中的增强纤维的层板。增强纤维和基质不限制于任何具体的组合物。纤维的示例包括但不限制于，碳纤维、玻璃纤维、芳纶纤维、硼纤维和钛纤维。基质的示例包括但不限制于，塑料和金属。作为第一个示例，碳纤维被嵌入到塑料基质中。作为第二个示例，碳纤维被嵌入到钛基质中。在一些实施例中，碳纤维可以具有40MSI的中间模数，并且层板劲度可以是22-25MSI。
现在参考图5a，其说明桁条220的腹板14、基板16或帽状物的层板500a-500d的堆垛500。在图5a中说明的堆垛500包括第一层板500a和第二层板500b，其具有相对于X-轴线以+α度和-α度定向的纤维。以±α定向的这些纤维提供沿X-轴线在拉伸和压缩上的强度。
层板设置进一步包括第三层板500c和第四层板500d，其具有以+β度和-β度定向的纤维，其中β是在50和85度之间（例如，±50、±60、±70、±80）。在一些实施例中，β的范围会更窄，在50和75度之间。以±β度定向的纤维增加了剪切、横向和支承强度。例如，能够添加以±β度定向的纤维，从而增加使用紧固件以形成紧固接头或修复接头的区域内的支承强度。因为越少地需要±β层板来实现相同的横向强度和支承（也就是说，相对于以90度、+45度和-45度定向的纤维），所以最终结构更有用、更适合、更有效且更轻。
选择的纤维取向允许调整六个特征中的任何一个：剪切强度、剪切劲度、横向强度、横向劲度、支承强度和支承劲度。如果需要更大的剪切强度，则选择接近50度的β。如果需要更大的横向强度，则选择接近85度的β。如果需要更大的支承强度，则选择接近65-70度的β。
在以±α和±β定向的全部纤维中，仅仅需要处于±β的全部纤维中的20-30%来达到与传统的0/+45/-45/90度硬层压板类似的支承强度水平，在硬层压板中，0度层板的百分比是在40和100%之间。
在一些实施例中，以±β定向的纤维层板可以与以±α定向的纤维层板交叉。考虑交叉的单向层板的示例。层板可以具有下列顺序：+α/-α/+β/+α/-α/-β/+α/-α/……。交叉的层板可以使用在腹板14、帽状物16和18中。然而，在其他的实施例中，在腹板14中的β纤维层板偏置朝向腹板的外表面。
参考图6，其说明具有β纤维层板的腹板14，该β纤维偏置背离中平面14a并且偏置朝向外表面14b。也就是说，在Zw方向上，β纤维层板的密度朝向外表面14b增大。例如，α纤维层板形成腹板14的核芯，并且β纤维层板形成腹板14的外表面14b。朝向外表面14b偏置β纤维层板增加了抵抗屈曲和横向弯曲的劲度。
虽然图5a仅仅说明了增强纤维的四个层板500a-500d，但是桁条220不限于此。可以提供以±α定向的增强纤维的附加层板，从而沿着轴线L增加在拉伸和压缩上的强度。可以提供以其他角度（下面称为±β）定向的增强纤维的附加层板，从而增加剪切、横向和支承强度和/或劲度中的至少一者。
不同的设置可以组合在一起。例如，桁条可以包括多个纤维组（fibergroup）。在每个组中的层板对应于处于不同取向的纤维设置。可以以任何需要的组合来应用所述组，并且可以以任意所需程度重复所述组。
优选地，在堆叠中至少50%层板具有以±α度定向的纤维。然而，在桁条的一些实施例中，100%的纤维以±α度被定向。
图5b说明具有相对于X-轴线仅以±α定向的纤维层板的桁条的实施例。在图5b中，说明了具有四个层板550a-550d的堆叠550。
在堆叠500和550中，以±α度定向的增强纤维沿着X-轴线提供在拉伸和压缩上的强度。相对于X-轴线以0度定向的增强纤维将提供沿X-轴线的最大强度。相对于X-轴线以在2和12度之间的角度α定向的增强纤维将不提供最大强度，但是当桁条220沿着X-轴线被单轴加载时（例如，当桁条被置于单轴压缩情况下时），其将抑制或者延迟层板分裂。
紧固件孔可以垂直于层板，并且延伸穿过构成基板18的层板。以在2和12度之间的α定向的纤维能够抑制或者延迟可能由于延伸穿过基板18的这些孔所引起的层板分裂。相对于具有大部分纤维以α＝0度定向的层压件而言，层板的分裂将被抑制或者延迟10到100倍。使得抗分裂性增加1到3个数量级可以使这样的层压件更为实用。
现在参考图7a和图7b，其说明如何抑制或者延迟层板分裂。图7a说明单个层板710，其具有嵌入基质720中的六个纤维712到717。纤维712到717相对于x-轴线被定向成0度。通过钻出洞730而切割纤维714和715。当沿着X-轴线施加拉伸载荷T时，未切割的纤维712、713、716和717承载该载荷并且拉伸/绷紧（stretch）。切割的纤维714和715不承载该载荷，不拉伸，并且切变离开基质720。这反过来削弱了切割的纤维/短切纤维（cut fiber）714和未切割的纤维/毛边的纤维（uncut fiber）713之间的树脂。在切割的纤维714和未切割的纤维713之间的基质720内形成微小的裂缝740（由虚线所表示）。该裂缝740能够沿着层板710的整个长度传播。裂缝740能够产生，而无论结构具有仅一个层板、五个层板、十个层板还是更多个层板。裂缝740严重地降低了桁条的强度。
图7b说明相对于X-轴线以-α度定向的纤维752a到756a以及相对于X-轴线以+α度定向的纤维752b到756b的层750，其中α是在2和12度之间。层750可以包括具有纤维752a到756a和752b到752b的单个层板，或者两个单向层板（一个单向层板具有纤维752a到756a，另一个单向层板具有纤维752b到756b）。如果纤维754a、756a、754b和756b均被洞770所切割，则在层750中将形成小裂缝780。然而，裂缝780将不会以未受控方式生长。实际上，裂缝780的生长将是缓慢的并且迅速地停止，由此桁条的强度被保持。此外，由于纤维取向α在2和12度之间，所以将需要一直增加的载荷来使得裂缝780传播（成角度纤维被示出以便在裂缝尖端处扩散能量）。因而，抑制或者延迟了层板分裂。
在2到8度范围内的角度α提供了强度和分裂抑制的良好结合。对于小于2度的角度，层板分裂会快速增加。对于超过8度的角度α，轴向强度会很快地降低。然而，对于一些应用而言，高达12度的角度将提供可接受的强度。
在一些实施例中，在3到5度范围内的角度α提供了强度和分裂抑制/延迟的更好结合，并且其也提供了抵抗强度下降的误差容限，而这种强度下降会发生在小于α=2度以及高于α=8度时（如果在制造期间，纤维控制不充分，则一些纤维的取向可以为小于2度或者大于8度的角度）。已经发现，3度的角度α可以提供甚至更好的结合，这是因为其提供了1-2%的更大的压缩强度。
纤维可以是均衡的或者稍微不均衡的。作为均衡纤维的示例，桁条具有交叉有N个-α纤维层板的N个+α纤维层板。作为稍微不均衡纤维的示例，桁条具有交叉有N-1个-α度纤维层板的N个+α纤维层板。
在一些实施例中，所有的层板可以具有相同的+α值和相同的-α值。在另一些实施例中，层板可以具有不同的α值。例如，可以铺设具有α=3度和α=5度取向的增强纤维的层板。
在一些实施例中，一个层板可以具有不同角度的纤维。例如，一个层板可以包括以-3度、+7度、-7度和+2度的角度定向的纤维。在一些实施例中，一个层板可以具有以角度+α和-α度二者定向的纤维。
α的最优值通常是若干因素的作用。这些因素包括但不限制于，纤维、基质、纤维和基质之间的界面结合强度、纤维密度、纤维长度等。这些因素也包括控制纤维取向的能力。
传统上，将主载荷方向内单轴层板的最大百分比限制成通常为50-60%来防止层板分裂，从而实现这种优化。
使用偏离零度的层板取向的这种新方法在最大劲度的减小较小但没有进一步将剪切限制成轴向强度等级的情况下提供了固有的层板分裂抑制。这允许将减少的剪切层板达到有用的100%单轴铺层。需要测试从而限定施加到任何具体优化分析的特有的许用限制。
上面结合飞机描述了复合材料加劲肋。然而，这里的复合材料加劲肋不受限于此。这里的复合材料加劲肋可以为直升飞机、宇宙飞船和其他宇航飞行器的结构提供劲度。这里的复合材料加劲肋甚至不限于宇航飞行器。其能够使用在需要加劲的任何轻量结构中。
使用描述的方法能够限定的其他实施例包括而不受限制，
其中用于提供在拉伸和压缩上的强度的增强纤维相对于主加载轴线以±α被定向，其中α是在2和12度之间，或者是在2和8度之间，或者是在3和5度之间。

Claims (12)

1.一种包括多个复合材料加劲肋的宇航飞行器，所述多个中的每一个加劲肋均具有增强纤维层板的堆垛；在所述堆垛中的所述层板的至少一些层板具有相对于主加载轴线以±α定向的增强纤维，其中α是在2和12度之间；所述层板中的至少一些层板具有相对于所述主加载轴线以±β定向的增强纤维，其中β是在50和85度之间。
2.根据权利要求1所述的飞行器，进一步包括由所述加劲肋加劲的多个蒙皮面板，其中所述加劲肋包括通过紧固件紧固到所述蒙皮面板的基板，其中以±α定向的纤维抑制或者延迟在所述基板中的层板分裂。
3.根据权利要求1所述的飞行器，其中α是在2和8度之间。
4.根据权利要求1所述的飞行器，其中α是在3和5度之间。
5.根据权利要求1所述的飞行器，其中在每个加劲肋中以±α定向的增强纤维构成纤维总数的至少50%。
6.根据权利要求1所述的飞行器，其中所述加劲肋包括腹板，并且其中以±β定向的纤维偏置朝向所述腹板的外表面从而增加在屈曲和横向弯曲中的劲度。
7.根据权利要求1所述的飞行器，其中所述蒙皮面板和所述加劲肋包括在聚合物基质中的碳纤维。
8.根据权利要求1所述的飞行器，其中所述飞行器包括机身、机翼装配件和尾翼；并且其中所述多个加劲肋被包括在所述机身、所述机翼装配件和所述尾翼中的至少一者中。
9.根据权利要求1所述的飞行器，其中在所述堆垛中的所有纤维均由以±α和±β定向的纤维组成；并且其中总纤维的20-30%以±β被定向，从而达到与传统的0/+45/-45/90度硬层压板相类似的支承强度水平。
10.一种包括宇航飞行器加劲肋的物体，所述加劲肋包括基板和腹板，所述基板和腹板中的至少一者包括增强纤维层板的堆垛，所述增强纤维中的至少50%相对于主加载轴线以±α被定向，其中α是在2和12度之间。
11.根据权利要求10所述的物体，其中以±α定向的增强纤维构成所述堆垛中的纤维总数的100%。
12.一种包括宇航飞行器加劲肋的物体，所述加劲肋包括基板和腹板，所述腹板包括增强纤维层板以用于沿着主加载轴线提供在拉伸和压缩上的强度，所述腹板也包括相对于所述主加载轴线以±β度定向的增强纤维的层板，其中β是在50和85度之间，其中以±β度定向的纤维偏置朝向所述腹板的外表面，从而增加在屈曲和横向加载上的劲度。
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