CN103492172A - 可模制的飞离工具结构系统 - Google Patents

可模制的飞离工具结构系统 Download PDF

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CN103492172A
CN103492172A CN201180052594.5A CN201180052594A CN103492172A CN 103492172 A CN103492172 A CN 103492172A CN 201180052594 A CN201180052594 A CN 201180052594A CN 103492172 A CN103492172 A CN 103492172A
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surface layer
foam unit
mould
composite construction
foam
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CN103492172B (zh
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S·米什拉
J·R·麦卡洛
M·克里斯
S·B·沃奇辛
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Bell Helicopter Textron Inc
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Bell Helicopter Textron Inc
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    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/04—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities
    • B29C44/0415—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities by regulating the pressure of the material during or after filling of the mould, e.g. by local venting
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    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
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  • Composite Materials (AREA)
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  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)
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Abstract

一种复合结构包括第一面层、第二面层、以及位于第一面层和第二面层之间的发泡部件。发泡部件具有模制的外形，模制外形被配置成在复合结构固化之前为第一面层和第二面层中的至少一个提供加工表面。一种制造发泡部件的方法包括生成具有内表面的模制工具，其内表面与发泡部件期望的外部形状相似。混合物被灌注到模制工具的灌注口中。混合物可以随着泡沫在模制工具内膨胀和散布而聚合成泡沫。模制工具的通气口选择性地定制以控制发泡部件的密度。发泡部件在模制工具中固化。

Description

可模制的飞离工具结构系统
技术领域
本申请的系统涉及复合结构。尤其，本申请的系统涉及一种在复合结构中产生刚度的有效方法。
背景技术
复合结构通常应用在航空航天领域中，这部分归因于其具有较高的强度重量比以及期望的疲劳质量。复合结构的结构特性，例如刚度和面积惯性矩，能够通过多种方法进行定制。一种常用的方法就是在上下面层之间使用多孔状芯材，例如蜂窝芯。另一种常用的方法是将两个分别固化了的复合部件粘结到一起，由此形成一个复合结构组件。
参照图1，示出一种复合结构101。复合结构101包括上部面层103、下部面层105和粘结在两者之间的蜂窝芯元件107。蜂窝芯元件107典型地包括多个形成重复的几何图样或网格的单元。蜂窝芯元件107有时在与上部面层103和下部面层105组装到一起之前被切割成期望的形状。上部面层103和下部面层105典型地为经过加热和/或加压固化的复合材料，其与蜂窝芯元件107组装到一起以形成复合结构101。使用蜂窝芯，例如蜂窝芯元件107通常是为了定制复合结构的刚性。然而，蜂窝芯的局限使其在某些特定情况下达不到期望。例如，芯的高度尺寸就是一个局限，因为在固化周期内经受固化压力时高且窄的芯容易向边缘发生倒塌。进而，将芯成型为复杂形状需要大量的工作并且可能使蜂窝芯在组装和固化过程中产生不稳定。进而，很难准确地控制上部面层103和下部面层105的表面公差。再进一步，上部面层103和下部面层105有时在固化过程中下陷进入蜂窝芯元件107的单元中，由此在上部面层103和下部面层105中产生凹陷。
参照图2，示出复合机构201。复合结构201包括粘结到面层203的帽形加强件205，帽形加强件205用于为复合结构201提供期望的硬度。典型地，面层203通过在加工表面上复合堆叠层片形成。复合层片接着至少部分固化。帽形加强件205在加工表面上分立堆叠并且接着同样至少部分固化。接着在另一个固化周期中对帽形加强件205和面层203进行组装并且采用粘结剂粘结到一起。依此，制造复合结构201典型地需要单独的独特手工堆叠过程、多个工具、以及三个独立的固化周期。制造复合结构201的复杂性和工作量导致复合结构201的成本不可取。
尽管复合结构的发展已经取得了显著的进步，但是仍然存在相当多的缺点。
附图说明
被认为是本申请的系统特有的新颖性特征在所附的权利要求中阐明。然而，系统本身以及优选的应用模式，还有其进一步的目标和优点将参照后面的详细描述并结合附图获得最好的理解，其中附图标记最左边的有效数字表示该附图标记第一次出现在哪幅图中，其中：
图1为现有技术的结构系统的剖视图；
图2为现有技术的另一个结构系统的剖视图；
图3为根据本申请的优选实施例的结构系统的透视图；
图4为图3所示的根据本申请的优选实施例的结构系统沿着剖面线IV-IV的剖视图；
图5为图3所示的根据本申请的优选实施例的结构系统沿着剖面线V-V的剖视图；
图6为图3所示的根据本申请的优选实施例的结构系统沿着剖面线VI-VI的剖视图；
图7A-7F示出根据本申请的优选实施例，制造模制发泡部件的过程的立体图；
图8为根据本申请的优选实施例，用于制造模制发泡部件的发泡系统各成分的示意图；
图9为根据本申请的优选实施例，用于混合发泡系统的混合器的立体图；
图10为根据本申请的优选实施例，用于制造模制发泡部件的发泡系统的混合物的示意图；
图11为根据本申请的优选实施例，结构系统未固化的预成型件的剖视图；以及
图12为根据本申请的另一个实施例的结构系统的剖视图。
尽管本申请的系统允许具有各种改变和替代形式，但是其具体实施例通过附图中的例子而被示出并且在文中对其进行了详细描述。然而，应该理解的是，这里对具体实施例的描述并不是要将该方法限定于公开的特定形式，恰恰相反，本发明旨在覆盖落入由所附的权利要求所限定的本申请的精神和范围之内的全部的修改、等同方案以及替代方案。
具体实施方式
本申请系统的示意性实施例将在下面描述。为了清楚起见，在该说明书中并没有描述实际产品的全部特征。当然还应该意识到的是在任何实际的具体产品的开发中，必须视情况而做出各种具体的决定以实现开发者的具体目标，例如符合系统相关以及商业相关的规定，从一种产品变换到另一种产品。此外，可以意识到这种开发的工作可能是复杂并且耗时的，不过却是得益于本公开内容的本领域普通技术人员的常规任务。
在该说明书中，如在附图中描绘的装置所示，附图标记可以用于标示各种组件之间的空间关系以及组件的各种朝向的空间指向。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朝向的空间方位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朝向的空间指向，而这里描述的装置可以指向任何期望的方向。
参照图3-6，示出根据本申请的优选实施例的复合结构301。复合结构301包括第一面层303、第二面层305、以及模制发泡部件307。模制发泡部件307为复合结构301提供结构硬度。第一面层303和第二面层305优选地包括置于聚合物基体内的多个增强纤维。如这里进一步的公开，第一面层303和第二面层305优选地被组装成多个未固化的复合层片，并且接着进行固化以形成刚性的复合层压板。在另一个实施例中，第一面层303和第二面层305中的一个或全部在与模制发泡部件307组装之前固化。应该意识到第一面层303和第二面层305可以由各种纤维和树脂系统形成。还应该意识到可以根据具体实施情况而采用特定的复合材料。例如，在一种应用中可能要用碳纤维，而在另一种应用中可能要用玻璃纤维。在该优选的实施例中，如图4所示，第一面层303和第二面层305完全包覆模制发泡部件307。然而，复合结构301的另一个实施例可以配置成发泡部件307部分暴露在外。
简略地参照图12，示出另一种实施形式的复合结构1201。除了第一面层1201没有完全包覆发泡部件1207之外，复合结构1201与复合结构301其他都相似。发泡部件1207与发泡部件307基本相似。在一种实施方式中，发泡部件1207被模制成定位在第二面层305上的带条。发泡部件1207的侧部1205被留在外面。与复合结构301相反，复合结构1201尤其适用于预定负载不需要第一面层1203和第二面层305之间结构性接合的实施情形。
如同文中进一步描述的，模制发泡部件307优选地通过模具中的可灌注且可膨胀的结构泡沫形成。在与第一面层303和第二面层305组装之前，模制发泡部件307优选地经被固化。模制发泡部件307被配置成在很多种几何形状和外形的情况都向复合结构301提供结构完整性。模制发泡部件307对于在需要狭窄而细长的加强筋几何形状的复合结构301各部分中提供结构刚度特别有用。复合结构301的固化需要压力，例如热压器的固化压力，用于恰当地固化第一面层303和第二面层305。依此，模制发泡部件307被配置成提供对抗压力的结构抗力以保持模制的发泡部件307周围期望的几何形状。相比之下，当经受热压器的压力和温度时蜂窝芯的高且窄的部分非常容易倒塌。例如，假设蜂窝芯部分具有发泡部件307的高度H1和宽度W1，当其经受热压器的压力和温度时，有可能沿着方向A1、A2和A3向里破碎。然而，与蜂窝芯不同，发泡部件307配置成各向同性。依此，发泡部件307各向同性的特性使其在很多种几何形状和外形的情况都能保持结构的完整性。
仍然参照图3-6，复合结构301可选地还可以包括蜂窝芯元件309，其用于在几何形状和外形相对简单的区域中提供结构硬度。例如，图5描绘了具有用于提供硬度的蜂窝芯元件309的复合结构301的一部分。进而，图6描绘了复合结构301的一节，在该部分模制发泡部件309和蜂窝芯元件309相邻接。期望的是在几何形状相对简单的位置使用蜂窝芯以增强结构硬度，而在几何形状不允许使用蜂窝芯的地方使用模制发泡。然而，应该完全地意识到模制发泡部件307可以用于替代蜂窝芯元件309从而不需要蜂窝芯材料。
现在参照图7A-7F，示出制造模制发泡部件309的过程。如图7A所描绘的，标准工具701被制成具有发泡部件307所期望的几何形状。标准工具701可以由各种材料和技术制作而成。例如，标准工具701可以通过选择性的激光烧结工艺而形成。参照图7B，模制工具703来自于标准工具701。优选地，模制工具703的基部部件705通过在标准工具701上组装和固化复合层片制造而成。应该还可以意识到模制工具703的基部部件705不需要标准工具701就可以制造而成；例如，发泡部件307的几何形状和外形使其能够用机器直接加工到基部部件705中。模制工具703还包括配置成可释放地连接到基部部件703的盖部件707（在图7C、7D和7E中示出），由此形成一个空腔，发泡部件307在空腔中模制成型。
参照图7C和7D，发泡混合物807（在图10中示出）被灌注到灌注口711中。灌注口711优选地位于中心位置以使得发泡混合物807均匀地膨胀并流到该部分的末端。在另一个实施例中，发泡混合物807被散布到基部元件705的沉降区域中。接着，在灌注操作完成之后不久盖部件707通过一个或多个紧固构件709连接到基部部件705。一个或多个通气口，例如通气口713a和713b优选地设置成邻近该部分的末端以允许各种易挥发物质在聚合阶段排放出去，并且还便于进行完全均匀的模具填充。聚合阶段就是发泡混合物807发生化学反应从而膨胀。释放剂优选地被施加到模制工具703内部以促进发泡部件307从模制工具703中释放和移除。
简略地参照图8-10，用来生成发泡部件307的发泡系统优选地为聚氨酯发泡系统，其膨胀以填充模制工具703。固化时，发泡材料优选地为刚柔并济，同时具有相对低的密度。优选的发泡系统为聚异氰脲酯灌注发泡系统，由Stepan化学公司生产以名称Stepan发泡（Stepanfoam）BX450A进行销售。应该完全地意识到其它发泡系统也可以用在模制发泡部件307的模制过程中。Stepan发泡（Stepanfoam）BX450A包括两种独立的树脂成分，即树脂T（重量比70%）805和树脂R（重量比30%）803。称量出期望重量的树脂T805和树脂R803并且将其灌注到容器801中。树脂T805和树脂R803经过机械搅拌形成均匀的混合物807。混合器901进行旋转以混合树脂T805和树脂R803形成混合物807。混合器901包括轴903，轴903配置成由钻孔电机或者类似的电机驱动。混合器901还包括设置在第一桨叶盘905和第二桨叶盘907上的多个桨叶。在该优选的实施例中，当混合树脂T805和树脂R803形成混合物807时，混合器901以3500转每分钟的转速旋转10-15秒。一旦混合完成，优选的是混合物807被尽快地灌注到模制工具703中。下文进一步描述混合物807的灌注。
混合物807的总重量至少部分地取决于发泡部件307所期望的密度和体积。例如，因为密度定义为单位体积的质量，所以发泡部件307期望的密度至少部分地决定了混合物807的重量大小。然而，混合物807的一小部分可以通过开口711、713a和713b逸出，这将影响发泡部件307的最终密度。
在该优选的实施例中，“受控过程”（captive process）使用开口711、713a和713b来使易挥发物质得以在混合物807的聚合过程中逸出，同时还在模制工具703内产生期望的压力。在聚合过程中，模制工具703内的压力抑制了发泡混合物807的膨胀，由此加大了发泡部件307的密度。依此，开口711、713a和713b的尺寸和数量被配置成选择性地定制发泡部件807的密度。例如，模制工具703中的开口711、713a和713b生成的发泡部件307的密度近似为12-16磅/立方英尺（pounds/ft3）。然而，可以增加开口711、713a和713b的尺寸和数量以生成具有较低密度的发泡部件307。
在另一个实施例中，模制工具703可以没有盖部件707以使发泡混合物807可以在基部部件705内“自由发起”。在该“自由发起”的实施例中，可以取得近似8.0磅/立方英尺或更小的密度。发泡部件307的这种“自由发起”的实施例在发泡部件307的几何形状和外形相对地简单的情形中尤其是所期望的。这是因为暴露在外的表面需要进行切割或切削操作以将发泡部件307暴露在外的表面修整成期望的外形。
发泡部件307的密度优选地根据发泡部件307在复合结构301中的具体情形而定制。例如，一种类型的复合结构301与另一种类型的复合结构301相比需要更高的固化压力；因此，用在需要更高的固化压力的复合结构中的发泡部件307被制造成具有高密度以承受复合结构101更高的固化压力。在一个实施例中，复合结构301被配置成使得发泡部件307在固化周期之前和固化周期过程中最低程度地执行对第一面层303和第二面层305的物理支撑功能。在这个实施例中，发泡部件307作为一种“飞离工具”而起作用，使得其在复合结构301的组装和固化过程中作为一种工具，但是在飞机运行期间仍然属于复合结构301。应该意识到复合结构301还可以用在汽车以及除了飞机之外的其它结构中。进而，当发泡部件307简单地作为“飞离工具”时，在复合结构301的组装过程中可以施加释放部件以防止在第一面层303、第二面层305和发泡部件307之间产生粘结接触。
所期望的复合结构101的工作载荷是另一个可能影响发泡部件307密度定制的因素。发泡部件307的密度可以根据所期望的发泡部件307的结构强度进行定制。例如，在复合结构101的一个实施例中，发泡部件307可以被配置成在第一面层303和第二面层305之间提供结构载荷路径。在这个实施例中，第一面层303和第二面层305优选地均与发泡部件307粘结接触。粘结接触可以通过来自第一面层303和第二面层305的树脂而产生。粘结接触还可以通过在第一面层303、第二面层305以及发泡部件307的每两个之间设置的粘结层而产生或补充。粘结接触有利于结构载荷在第一面层303、第二面层305以及发泡部件307之间的各种载荷路径方向上转移。
参照图7E，发泡部件307被示出位于模制工具703的基部部件705中。为了清楚起见，盖部件707被移除。优选地，在发泡部件307从模制工具703的基部部件705中移除之前对发泡部件进行完全固化。完全固化通过下面的步骤实现，首先在发泡混合物807在模制工具703内膨胀之后使发泡部件307可以在模制工具703内保留至少24小时。此后，发泡部件307仍然保留在模制工具703中，将模制工具703在350°F到375°F的温度范围内固化2个小时。应该意识到与此不同的发泡系统具有不同的固化要求。
参照图7F，发泡部件307被示出从模制工具703中分离出来。优选的是发泡部件307和模制工具703在脱模之前被冷却到150°F或者更低的温度。发泡部件307的脱模需要柔韧的工具以便将发泡部件307从模制工具703中脱离开。一旦发泡部件307从模制工具703移除，接着发泡部件307就可以在复合制造过程中与第一面层303和第二面层305组装到一起以形成复合结构301。因为在模制工具703中模制成型，所以发泡部件307的几何形状和外形准确成型以具有高的耐受性。
参照图11，示出复合结构301未固化的预成型件1107。应该意识到复合制造工艺可以采用很多种制造工艺，部分因为第一面层303和第二面层305可以由多种复合纤维/树脂系统形成。例如，在一个示例性实施例中，复合制造工艺包括如下步骤，首先在工具1101的表面上铺设多个预浸渍纤维分布图案以形成第一未固化层1101。接着，发泡部件307放置在层1103的期望位置。然后，多个预浸渍纤维分布图案铺设在层1103和发泡部件307上以形成层1105。发泡部件307作为工具确定层1105的几何形状。因为发泡部件307在模制工具中形成，所以其几何形状和外形准确度很高。依此，发泡部件307在层1105的支撑中起到了高耐受的作用。接着，预成型件1107可以真空袋装并且采用多种传统复合固化工艺中的一种进行固化。在最终固化之后，预成型件1107变成复合结构301。
本申请的系统具有显著的优点，包括：（1）提供一种在复合结构中产生刚性的发泡部件，其能够以各种几何形状和外形模制而成；（2）提供一种在复合结构中产生刚性的发泡部件，其能够经受住热压器的固化压力；（3）提供一种在复合结构中产生刚性的发泡部件，发泡部件的密度可以选择性地定制；（4）提供一种在复合结构中产生刚性的发泡部件，其为上部面层提供连续的支撑以便发泡部件能够防止上部面层发生凹陷；以及（5）提供一种在复合结构中产生刚性的发泡部件，其为上部面层提供连续的支撑以便发泡部件能够防止上部面层发生凹陷。
上面公开的具体实施例仅仅是示例性的，本申请可以以不同但是等效的方式修改并且实施，这对于受益于本申请的教导的本领域技术人员来说是显而易见的。进而，下面权利要求中描述的内容之外，不对这里示出的结构或设计的细节进行限制。因此，显而易见的是上面公开的具体实施例可以改变或修改并且所有的这些变形都被认为在本申请的精神和范围之内。因而，本申请在这里寻求的保护范围如下面的权利要求所述。很明显，上面已经描述和示出了具有显著优点的系统。虽然本申请的系统以有限数量的形式被示出，但是其并不是仅限于这些形式，而是可修改地具有多种变形和改变而不会脱离本申请的精神。

Claims (20)

1.一种复合结构，包括：
第一面层；
第二面层；
设置在第一面层和第二面层之间的发泡部件，发泡部件具有模制的外形，模制的外形被配置成在对复合结构进行固化之前为第一面层和第二面层中的至少一个提供加工表面。
2.根据权利要求1的复合结构，其中第一面层和第二面层中的至少一个为复合材料。
3.根据权利要求1的复合结构，其中发泡部件具有留在外面的侧部以使第一面层和第二面层不会完全地包覆发泡部件。
4.根据权利要求1的复合结构，其中发泡部件粘性地粘结到第一面层和第二面层中的至少一个上，以使发泡部件能够在第一面层和第二面层之间承载剪切载荷。
5.根据权利要求1的复合结构，其中释放剂用于防止发泡部件与第一面层和第二面层发生粘结接触，从而基本上防止第一面层和第二面层之间的剪切载荷通过发泡部件传送。
6.根据权利要求1的复合结构，其中发泡部件的密度被定制以使发泡部件能够经受住将要在复合结构的固化周期中受到的预定压力载荷。
7.根据权利要求1的复合结构，其中发泡部件的密度被定制以使发泡部件能够经受住将要在复合结构的使用寿命期间受到的预定载荷。
8.根据权利要求1的复合结构，进一步包括：
位于第一面层和第二面层之间的蜂窝芯部件，蜂窝芯部件被配置成在复合结构中提供结构硬度。
9.一种制造用于复合结构的发泡部件的方法，包括：
生成具有内表面的模制工具，该内表面与发泡部件期望的外部形状相似；
将液体混合物灌注到模制工具的灌注口中；
使得液体混合物聚合成泡沫以在模制工具内膨胀并散布；
选择性地在模制工具中配置一个或多个通气口以选择性地确定发泡部件的密度；并且
在模制工具中固化发泡部件。
10.根据权利要求9的方法，其中一个或多个通气口设置在接近于模制工具的末端的位置。
11.根据权利要求9的方法，其中一个或多个通气口设置在模制工具的盖部件中。
12.根据权利要求9的方法，进一步包括：
在将液体混合物灌注到灌注口中之前在模制工具中施加释放剂。
13.根据权利要求9的方法，其中选择性地配置一个或多个通气口，使易挥发物质得以在液体混合物膨胀成泡沫的过程中逸出。
14.根据权利要求9的方法，其中选择性地配置一个或多个通气口包括选择性地确定通气口直径的大小。
15.根据权利要求9的方法，其中选择性地配置一个或多个通气口包括选择性地生成大量的一个或多个通气口。
16.一种制造复合结构的方法，包括：
提供未固化的复合下部面层；
提供未固化的复合上部面层；
提供至少部分固化了的发泡部件；
将未固化的复合下部面层铺放到一个表面上；
将发泡部件放置在下部面层上所期望的位置；
将未固化的复合上部面层铺放到下部面层以及发泡部件上以便发泡部件将上部面层的一部分支撑处于期望的几何形状；以及
在发泡部件支撑上部面层该部分的同时固化复合下部面层和复合上部面层。
17.根据权利要求16的方法，其中提供至少部分固化了的发泡部件的步骤包括：
生成具有内表面的模制工具，内表面与发泡部件所期望的外部形状相似；
将混合物灌注到模制工具的灌注口中；
使混合物随着泡沫在模制工具内膨胀和散布而聚合成泡沫；
选择性地配置模制工具中的一个或多个通气口以选择性地控制发泡部件的密度；以及
固化模制工具中的发泡部件。
18.根据权利要求16的方法，进一步包括：
选择性地定制混合物的体积以与发泡部件的密度相符。
19.根据权利要求16的方法，进一步包括：
在下部面层和发泡部件之间，以及上部面层和发泡部件之间施加粘结剂。
20.根据权利要求16的方法，其中在模制工具中选择性地配置一个或多个通气口包括将一个或多个通气口设置在接近模制工具的末端的位置。
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