CN103465528A - 形成复合接合部的方法 - Google Patents

形成复合接合部的方法 Download PDF

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CN103465528A
CN103465528A CN201310285532XA CN201310285532A CN103465528A CN 103465528 A CN103465528 A CN 103465528A CN 201310285532X A CN201310285532X A CN 201310285532XA CN 201310285532 A CN201310285532 A CN 201310285532A CN 103465528 A CN103465528 A CN 103465528A
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恩佐·科森蒂诺
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Abstract

本发明涉及一种形成复合接合部的方法。该方法包括：组装第一叠置件，该第一叠置件包括多层复合材料和至少一层自修复材料，所述自修复材料层包括多个容纳部，每个所述容纳部均容纳可固化修复液；组装第二叠置件，该第二叠置件包括多层复合材料；以及在组装所述第一叠置件和第二叠置件之后将二者在结合线处结合在一起。

Description

形成复合接合部的方法
本发明是申请号为200980113311.6（PCT/GB2009/050330）、申请日为2009年4月2日、发明名称为“具有自修复层的复合层压件”的中国发明专利申请的分案申请。
技术领域
本发明涉及一种复合层压结构，以及一种在一对复合结构之间形成接合部的方法。
背景技术
图1a示出了第一结构40和第二结构41之间的结合接合部。由于疲劳负载，裂纹将传播并且沿不能被预先确定的路径传播。可以识别三种不同的情况。
·裂纹43b穿过第二结构41传播，并与结合线42平行（图1b）。这将使得第二结构41完全失效，该第二结构41将停止其与第一结构40的协作。通常该情况不是致命的。如果利用自动防故障装置的设计原理，则第二结构41的失效将不会产生结构完全失效，该结构仍能够承受外部负载。
·裂纹43c朝第二结构41的外表面传播并消失（图1c）。该情况可致使第二结构41完全失效或者部分降低其性能。在这两种情况下，由于第一结构40保持不变，因此这不会使整个结构完全致命地失效。
·裂纹43d朝第二结构41的内表面传播，然后穿过第一结构40（图1d）。该情况不能被接受，因为其导致第一结构40致命地失效，因此必须被避免。
将裂纹限制在确定范围内的能力将简化认证活动，提高信用水平，改进备用系数和最终整体重量，并且最终提高安全性。
在J.R.Soc.Interface（2007）4,363-371(doi:10.1098/rsif.2006.0194)的R.S.Trask、G.J.Williams、I.P.Bond的“使用中空玻璃纤维的先进复合结构的仿生自修复”中描述了多种自修复结构。描述了一种16层的玻璃纤维层压件，其中，自修复丝被引到四个损坏的关键层界面。还描述了一种16层的碳纤维层压件，其中修复玻璃纤维（HGF）位于层内的两个界面处，在层压之前直接卷绕在未固化的碳纤维增强塑料（CFRP）层上。根据Trask等人的研究，作为离散层的HGF的结合被视为不适用于CFRP层压件，因为其实际上产生混合的玻璃碳层压件，并且导致它们的优良机械性能大为降低。
发明内容
本发明的第一方面提供一种复合结构，该复合结构包括：第一叠置件，该第一叠置件包括多层复合材料和至少一层自修复材料，所述自修复材料层包括多个容纳部，该多个容纳部均容纳可固化修复液；以及第二叠置件，该第二叠置件包括多层复合材料，所述第一叠置件和第二叠置件在结合线处接合在一起。
本发明的另一方面提供一种形成复合接合部的方法，该方法包括：组装第一叠置件，该第一叠置件包括多层复合材料和至少一层自修复材料，所述自修复材料层包括多个容纳部，该多个容纳部均容纳可固化修复液；组装第二叠置件，该第二叠置件包括多层复合材料；以及在组装所述第一叠置件和第二叠置件之后将二者在结合线处结合在一起。
本发明的再一方面提供一种使本发明的第一方面中所述的复合结构中的裂纹偏转的方法，所述裂纹产生于所述结合线或第二叠置件中，该方法包括使所述自修复层中的所述容纳部中的至少一些断裂，使得所述可固化修复液从所述断裂的容纳部流出并固化，由此使所述裂纹偏转。
通过将自修复材料层放置在叠置件的其中一个（优选较靠近于结合线）中，所述自修复材料层可以阻止裂纹在第一叠置件与第二叠置件之间传播。优选地，第一叠置件的整体强度大于第二叠置件的整体强度。
典型地，所述第一叠置件包括按一定叠置顺序布置的N个层，所述N个层包括：第一层，该第一层位于所述叠置顺序的与所述结合线相邻的一端处；以及第N层，该第N层位于所述叠置顺序的远离所述结合线的另一端处，其中，所述自修复材料层较靠近所述结合线定位，使得其在所述叠置顺序中的位置小于N/2。
典型地，所述自修复材料层是所述叠置顺序中的第一层、第二层、第三层或第四层。优选地，所述自修复材料层不是所述叠置顺序中的第一层。
可以通过粘合剂层将所述叠置件结合在一起。在该情况下，所述结合线的厚度等于所述粘合剂层的厚度。可选地，所述叠置件可以通过将它们共同固化而结合在一起。在该情况下，所述结合线的厚度为零。
本发明的又一方面提供一种复合层压结构，该复合层压结构包括：多层复合材料的叠置件，每层复合材料均包括嵌入在基体内的多个增强纤维；以及一层或更多层自修复材料，该自修复材料嵌入在所述多层复合材料的叠置件内，每层自修复材料均包括多个容纳部，每个容纳部均容纳可固化修复液，其中，所述叠置件的总厚度为T2，所述自修复材料层的总厚度为T1，其中，比例T1/T2小于0.1。
通过使比例T1/T2变得较低，则可以阻止裂纹传播，而不对所述结构的弯曲性能存在明显有害的影响。
下面对本发明的所有方面进行说明。
所述容纳部可以由玻璃材料或任何其它合适的材料形成。
所述容纳部和所述增强纤维可以由不同的材料形成。与Trask等人的教导相反，已发现，由不同的材料形成容纳部不会导致层压件的机械性能明显降低，特别是如果比例T1/T2足够低时尤为如此。
所述自修复材料层可以包括“预浸渍物”层，也就是在“预浸渍物”层被组装至叠置件中之前所述多个容纳部被灌注基体的层。可选地，如Trask等人所述，所述容纳部可以是在层压之前直接卷绕在未固化的复合材料层上的纤维，而不是作为离散的“预浸渍物”层被组装至叠置件中。
在以下描述的实施方式中，所述自修复材料层具有容纳部，而无增强纤维。然而，在可选实施方式中，所述自修复材料层可以包括与多个增强纤维混合的多个容纳部。
所述容纳部可以包括纤维、泡囊或者任何其它合适的中空结构。
所述自修复材料层中的所述容纳部可以容纳可固化修复液的单组分系统（one-part system）。可选地，所述自修复材料层还可以包括多个容纳部，每个容纳部均容纳硬化剂液，该硬化剂液在与所述可固化修复液接触时使该可固化修复液固化。在另一个可选例中，催化剂或硬化剂可以被包含在所述基体内。
附图说明
现在将参考附图描述本发明的实施方式，附图中：
图1a、图1b、图1c和图1d示出了传统的结合接合部；
图2示出了根据本发明的第一实施方式的结合接合部；
图3示出了单层的CFRP；
图4示出了铺设的第一结构；
图5示出了单层的自修复材料；
图6详细地示出了两个HGF；
图7示出了在共同固化之前被放置在一起的两个叠置件；
图8示出了偏转的裂纹；
图9示出了根据本发明的第二实施方式的结合接合部；
图10示出了通过桁条与面板之间的粘结接合部的纵剖视图；
图11示出了通过面板的横剖视图，该面板示出了多个桁条；以及
图12是示出了改变裂纹偏转部的数量如何能影响结构的机械性能的曲线图。
具体实施方式
图2中所示的复合层压结构包括在结合线14处接合的第一结构1和第二结构2。每个结构1、2均通过组装多层复合材料的叠置件而形成。每层复合材料均包括嵌入在基体内的多个增强纤维。图3中示出了示例层3。在该情况下，层3是具有单层的单向碳纤维4的所谓“预浸渍物”，该单层碳纤维4灌注有部分固化的环氧树脂基5。为了易于说明，图中的纤维4均示出为指向页面内或指出页面外。然而，实际上，纤维的方向可以在所述叠置件中变化，以使所述叠置件具有期望的机械特性。
图4示出了如何形成第一结构1。N层复合材料的叠置件以一定的叠置顺序被放置在台50上，该叠置顺序包括使第一层（i=1）位于叠置顺序的底部并且使第N层（i=N）位于顶部。
第四层6是一层自修复材料（以下被称作“裂纹偏转部”）。裂纹偏转部6在图5和6中被详细地示出，并且包括具有多个中空纤维8、9的“预浸渍物”层，在将“预浸渍物”层组装在所述叠置件中之前多个中空纤维8、9灌注有部分固化的环氧树脂基15。如图6所示，每个纤维8均包括含有液体粘合剂11（诸如
Figure BDA00003482363200041
2021/A树脂）的中空玻璃纤维10，并且每个纤维9均包括含有液体催化剂13（诸如
Figure BDA00003482363200042
2021/B硬化剂）的中空玻璃纤维12。由于粘合剂和催化剂被包含在不同的中空纤维内，因此，这确保保存期限更长。
为了易于说明，图中的纤维8、9均示出为沿与纤维4相同的方向指向页面内或指出页面外。然而，实际上，纤维8、9可以沿任何方向取向。
在图4中所示的叠置件被组装之后，在高压釜中对其部分固化。以类似的方式组装并部分固化第二结构2。接下来，如图7所示将部分固化的结构1、2放在一起，并且放置在高压釜中，它们在高压釜中被完全固化。在该共同固化处理期间，结构1、2在结合线14处被粘接在一起。
注意，第一结构1的叠置次序可以与图4中的相反，也就是说使裂纹偏转部6作为顺序中的第三层，并且使顶层（第N层）与图2中的结合线14相邻。在这两种情况下，裂纹偏转部6较靠近于结合线定位。
第二结构2的整体强度小于第一结构1的整体强度。因此，如果在接合部的循环加载期间开始形成裂纹，则该裂纹最可能位于第二结构2内的某处。
当裂纹偏转部6被撞击并且/或者经受疲劳循环时，玻璃纤维10、12断裂并且使液体粘合剂10和催化剂13流出，而渗透由裂纹形成的空隙。这带来两种效果（该两种效果相互促进，以减轻或阻止裂纹传播）：
·因液相倾翻而吸收冲击波传播的能量
·凝固，这将用固体粘合剂组分取代因裂纹传播而破碎的材料，因此保证材料的连续性和较平滑的负载路径，并且减轻裂纹尖端处的应力集中。
图8示出了当结合线14或者第二结构2中出现的裂纹前部遇到裂纹偏转部6时局部发生的物理现象。
一旦裂纹16使裂纹偏转部6中的纤维断裂，则液体粘合剂将开始渗透所述空隙并且凝固而形成固化粘合剂20的区域，由此使裂纹偏转。显然，由于疲劳加载，裂纹前部将继续传播，并且使新的纤维断裂，使得新的粘合剂流出并且渗透所述空隙。
粘合剂/催化剂自复原系统可以被“调整”，使得每单位时间的固化体积量可以与单位时间内通过裂纹传播形成的空隙的体积相当。图8示出了存在微空隙21，在裂纹如图8所示被偏转后，该微空隙将保留。这是因为液体系统的粘性不允许裂纹路径全部渗透。期望微空隙21的尺寸最小化，并且可以通过适当地选择修复系统的固化速度和粘性来确保该尺寸的最小化。由于所使用的制造过程，因此微空隙的尺寸应优选与裂缝偏转部6内统计学上存在的最大微空隙相当。
图9示出了可选接合部，其中，第一结构1a通过粘合剂层16（在该情况下，其限定结构的结合线）被粘接到第二结构2a，而不是共同固化。在该情况下，结构1a、2a在它们结合在一起之前被完全固化。注意，在该实施例中，第二结构2a中的第四层也包含裂纹偏转部6。
图10示出了位于复合层压面板34上的桁条突出部（stringer run-out）中的一对嵌入自修复层30、31。面板34承载了许多沿该面板的长度延伸的加强元件（已知为“桁条”）。如图11所示，桁条为T形，并且具有结合到面板34的脚部以及垂直于面板34延伸的刀形件35。如图10所示，各桁条的脚部延伸到刀形件之外，而形成所谓的桁条突出部33。
上自修复层30被嵌入在形成桁条突出部33的“预浸渍物”复合层的叠置件内。桁条突出部33通过粘合剂层35结合到复合面板34。复合面板34包含下自修复层31。这两个层30、31一起形成在它们之间限制裂纹32的“裂纹通道”。
注意，在以上所举实施例中，在每个构件1、2中仅需要单个的裂纹偏转部6。然而应注意，如果需要，可以在叠置件中一体形成其它裂纹偏转部。图12是示出了改变裂纹偏转部的数量能能影响结构的机械特性的曲线图。
图12中的X轴表示T1与T2之间的比，其中，T1是裂纹偏转部的总厚度，T2是结构的总厚度。例如在图4中示出了T1和T2。当在结构中存在超过一个裂纹偏转部时，则T1是所有裂纹偏转部的厚度的总和。
曲线51表示弯曲容许曲线。也就是说，曲线51表示第一构件1将响应于与叠置件中的层平行地施加的压缩负载而弯曲所在的负载。可以看出，该弯曲负载51在不存在裂纹偏转部时处于最大值，并且随着T1/T2的增大而逐渐降低。
曲线52是断裂力学容许曲线。也就是说，曲线52表示用于裂纹形成并随后传播到第一结构中的容许负载。可以看出，该负载52在不存在裂纹偏转部时处于最小值，并且随着T1/T2的增大而逐渐增大。曲线52以这样的方式增大是因为裂纹传播到第一结构中的机会变小。
曲线交叉点限定阈值比53，在该点之上增加其它裂纹偏转部将整体降低结构的机械性能。阈值53将基于结构的几何形状、层的厚度、各层中纤维的方向以及各层所使用的材料而变化。然而，通常上，预想在大多数情况下该阈值不大于0.3，最可能在0.2以下。
本发明人已明白，通过使比例T1/T2明显小于阈值53，可以阻止裂纹传播，而不对结构的弯曲性能存在明显有害的影响。如果我们考虑图4中所示的N层叠置件，则仅层的1/N是裂纹偏转部，其中N通常介于20至40之间。如果我们设想裂纹偏转部6的厚度与预浸渍物层的其中一层的厚度相同，则这将比例T1/T2变成小于或等于0.05。
注意在以上所举实施例中，裂纹偏转部不是叠置顺序中的与结合线紧邻的第一层。这优选是下列原因。为了使裂纹偏转部的效率最大，优选的是，使裂纹开始于裂纹偏转部自身的外侧。因此，如果裂纹开始于结合线（其是裂纹可能开始的区域）处，则通过在结合线与裂纹偏转部之间放置几层预浸渍物3，确保裂纹必须穿过裂纹偏转部的整个厚度以传播到第一结构中。
尽管已经参考一个或多个优选实施方式来描述本发明，但应该认识到在不脱离如所附的权利要求限定的本发明的范围的情况下，可以进行多种变化与修改。

Claims (8)

1.一种形成复合接合部的方法，该方法包括：组装第一叠置件，该第一叠置件包括多层复合材料和至少一层自修复材料，所述自修复材料层包括多个容纳部，每个所述容纳部均容纳可固化修复液；组装第二叠置件，该第二叠置件包括多层复合材料；以及在组装所述第一叠置件和第二叠置件之后将二者在结合线处结合在一起。
2.如权利要求1所述的方法，其中，所述第一叠置件包括按一叠置顺序布置的N个层，所述N个层包括：第一层，该第一层位于所述叠置顺序的与所述结合线相邻的一端处；以及第N层，该第N层位于所述叠置顺序的远离所述结合线的另一端处，其中，所述自修复材料层较靠近所述结合线定位，使得所述自修复材料层在所述叠置顺序中的位置小于N/2。
3.如权利要求2所述的方法，其中，所述自修复材料层是所述叠置顺序中的第一层、第二层、第三层或第四层。
4.如权利要求2或3所述的方法，其中，所述自修复材料层不是所述叠置顺序中的第一层。
5.如权利要求1或2所述的方法，其中，所述结合线包括粘合剂层。
6.如权利要求1或2所述的方法，其中，所述第一叠置件和第二叠置件在所述结合线处共同固化。
7.如权利要求1或2所述的方法，其中，所述第一叠置件形成第一结构，所述第二叠置件形成第二结构，并且所述第二结构的整体强度小于所述第一结构的整体强度。
8.如权利要求1或2所述的方法，其中，在所述第一叠置件中的每层复合材料均包括嵌入在基体内的多个增强纤维，并且在所述第二叠置件中的每层复合材料均包括嵌入在基体内的多个增强纤维。
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US8361609B2 (en) 2013-01-29
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EP2285563A1 (en) 2011-02-23
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CN102006998A (zh) 2011-04-06
JP2011518056A (ja) 2011-06-23
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CA2719192A1 (en) 2009-10-22
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US20130209764A1 (en) 2013-08-15

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