CN104448877B - 包括分散的纤维丝的复合织物 - Google Patents

包括分散的纤维丝的复合织物 Download PDF

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CN104448877B
CN104448877B CN201410423099.6A CN201410423099A CN104448877B CN 104448877 B CN104448877 B CN 104448877B CN 201410423099 A CN201410423099 A CN 201410423099A CN 104448877 B CN104448877 B CN 104448877B
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boundary
filament
fabric
reinforcing fiber
fiber bundles
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CN104448877A (zh
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K·H·格里斯
J·J·埃斯波西托
G·E·乔治森
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Boeing Co
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3076—Aircrafts
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
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Abstract

一种包括多方向织物的制品，该多方向织物由在第一方向延伸的第一增强纤维束和在第二方向延伸的第二增强纤维束构成。第一纤维束的纤维丝延伸经过织物的边界并分散。纤维束嵌入树脂中。

Description

包括分散的纤维丝的复合织物
背景技术
纤维加强塑料(FRP)复合材料对于航空航天结构应用而言是具有吸引力的。它们具有比金属好的比强度和硬度，这意味着重量的节省、燃料的节约以及更低的操作成本。
诸如蒙皮、加强件、框架和翼梁的FRP结构元件可以接合在一起构成主要部件，如机翼、机身以及尾翼。这些FRP元件的脱粘是不希望发生的。
发明内容
根据本文的实施例，一种包含由第一加强纤维束和第二加强纤维束构成的多方向织物的制品，其中第一加强纤维束在第一方向延伸，而第二加强纤维束在第二方向延伸。第一纤维束的纤维丝延伸经过织物的边界并分散。纤维束被嵌入树脂中。
根据本文另一实施例，一种包括接合在一起的第一和第二部件的结构。第一部件包括多层加强纤维。外边的一层包括由纤维束构成的多维织物，纤维束具有分散的纤维丝，其中分散的纤维丝接合到第二部件的表面。
根据本文另一实施例，一种包含匹配第一和第二部件的制造复合结构的方法。第一部件包括外层，该外层具有由在第一方向延伸的第一纤维束和在第二方向延伸的第二纤维束构成的纺织物。该方法还包括将纤维束的末端分散成独立的纤维丝，并将分散的纤维丝接合到第二部件的表面。
这些特征和功能可以在各种实施例中独立实现，或者可以结合在其他实施例中实现。参照下面的说明和附图能够看到实施例的更详细内容。
此外，本公开包括根据下列条款的实施例：
条款1：一种结构，其包括接合在一起的第一和第二部件，第一部件包括多层加强纤维，外边的一层包括由具有分散的纤维丝的纤维束加强的多维织物，其中分散的纤维丝被接合到第二部件的表面。
条款2：根据条款1的结构，其中所述第一和第二部件为分离的部件。
条款3：根据条款2的结构，其中所述分离的部件为飞机结构元件。
条款4：根据条款1的结构，其中所述第一部件为所述第二部件的补片。
条款5：根据条款4的结构，其中所述第二部件位于飞机的易于被冲击破坏的区域。
条款6：根据条款1的结构，其中所述纤维丝的末端是波浪状的。
附图说明
图1A和图1B为具有分散的纤维丝的多方向复合织物的图示说明。
图2A和图2B为被分散前和被分散后的纤维束丝的图示说明。
图3为具有被分散的纤维丝的相邻纤维束的图示说明。
图4为包括具有分散的纤维丝的纤维束的复合织物的铺层堆叠的图示说明。
图5为包括图4的铺层堆叠的部件的图示说明，该部件接合到另一部件。
图6为用于碳纤维增强塑料面板的补片的图示说明。
图7和图8为具有分散的纤维丝的复合织物的图示说明。
图9为具有波浪状末端的纤维丝的图示说明。
图10为使用具有分散的纤维丝的复合织物的一般方法的图示说明。
图11为飞机的图示说明。
具体实施方式
参考图1A，其示出了包含由第一增强纤维束和第二增强纤维束构成的多方向复合织物110的制品100，其中第一增强纤维束在第一方向延伸，而第二增强纤维束在第二方向延伸。在一些实施例中，多方向织物110可以为由在x方向延伸的纤维束和在y方向延伸的纤维束构成的纺织物。在图1A中所示的实施例中，x和y方向是正交的。多方向织物110具有边界112。在织物110的边界112内，纤维束提供沿x和y方向的结构强度。
标准的纤维束可包括数千(例如，1千、3千、12千、24千)条纤维。每个纤维束的单独的纤维或纤维丝可以被捆扎成若干(N)纤维束。在纤维束中的捆扎的纤维丝通常通过交叉纤维被保持在一起(即，支撑)。交叉纤维通常正交于纤维丝120。
纤维束的纤维丝120延伸经过边界112。这些纤维丝120仅在其延伸方向提供结构强度。纤维丝120在正交方向没有支撑是松弛的。支撑可以被松弛，例如，通过仅使用小百分比(例如，10％至30％)的交叉纤维，该交叉纤维在纤维束中正常使用。在图1A的示例中，认为纤维束在x方向延伸，而其纤维丝120延伸经过边界112。纤维丝120在x方向提供结构强度。没有交叉纤维用于支撑这些纤维丝120。类似地，在y方向延伸经过边界112的纤维丝120仅在y方向提供强度。没有交叉纤维用于支撑这些纤维丝120。
在正交方向上这样的松弛的结构支撑或者缺乏结构支撑使纤维丝120能够被“分散(spread)”。当被压缩时，纤维丝120重新分布使得纤维束的数目(N)减少。在图1A的织物110中，延伸经过边界112的纤维丝120被分散。
图2A和图2B示出了在其纤维丝220被分散之前和之后的织物中的纤维束210。图2A示出了在纤维丝220被分散之前的具有N＝5行纤维丝220的纤维束210。当压缩力(F)在z方向被施加于纤维束210的无支撑的或松散支撑的部分时，压缩力引起纤维丝220在正交(y)方向分散。图2B示出了已被分散后的纤维丝220。在图2B的示例中，分散的纤维丝220的行数从五被减少到二。分散的纤维丝220的宽度可以比纤维束210中的被完全支撑的纤维丝的宽度大。
再次参照图1A，交叉纤维的减少或消除也使延伸经过边界112的纤维丝120的轴向硬度减小。即，织物110在边界112外侧比在边界112内柔软。
边界112外侧的纤维丝120的硬度可以通过使一些或全部的纤维丝末端122呈波浪状而进一步减小。图1A示出了具有以波浪状末端122终止的直线部分的纤维丝120。波浪状末端122处于x-y平面中。由于纤维丝120也处于同一平面，所述波浪被称为“在平面中”。
因此，织物110具有变化的硬度。在边界112内硬度最高，其在边界112的外侧减小，并且可在波浪状末端122处进一步减小。与在边界112内的纤维丝相比，在其末端聚集载荷的纤维丝120将承受较小的应变力。
对于图1A中所示的织物110，边界112的外侧的纤维丝的直线部分将传递负载。纤维丝的波浪状末端122将不传递负载。
现在参照图1B，图1B示出了制品150的另一示例，制品150包括纤维束构成的复合织物160。纤维丝170延伸超过纤维束的边界162。负载转移可通过改变纤维丝170的长度被调整(tailor)，使得纤维丝在不同位置聚集负载。负载转移还可以通过使纤维丝170的一些末端172呈波浪状而一些末端174呈直线被进一步适当定制。
图1A和图1B的制品100和150还包括树脂(未示出)。织物110和160被嵌入树脂中。作为第一示例，刚好在固化之前纤维束和分散的纤维丝以树脂基质浸渍。作为第二示例，在铺层之前纤维束以树脂基质预浸。作为第三示例，纤维束以部分交叉结合的树脂粘合在一起以便于最终处理前的储存和运输。
参照图3，图3示出了以距离d分散的第一和第二纤维束310和320的示例。当纤维丝312在第一纤维束310中被分散时，分散的纤维的宽度可以超过第一纤维束310的宽度。对于第二纤维束320的纤维丝322也是同样的。因此，从第一纤维束310延伸的一些纤维丝312可以与从第二纤维束320延伸的一些纤维丝322混合(图3仅示出了两个混合的纤维丝312和322以图示说明这个方面)。
现在参照图4，图4示出了铺层堆叠410。铺层堆叠410包括多个层420。铺层堆叠410的一个或更多个最外层420可包括本文的多维织物(图4仅在一个外层示出了本文的织物)。剩余的层410可包括传统的纤维束。
铺层堆叠410不限于任何特定部件或结构。现将提供两个示例。
现在参照图5，图5示出了第一示例，其中第一部件510被接合到第二部件520。但是作为一个示例，第一部件510可以是横梁而第二部件520可以是面板。第一部件510包括铺层堆叠410。从铺层堆叠410的外层延伸的纤维丝412设置在第二部件520的表面上。部件510和520可以通过粘接、共粘接或共固化接合。共固化是指当部件510和520均为生的(即，未固化)时接合部件510和520。共粘接是指当部件中的一个是生的而另一个已经被固化或者成形时接合部件510和520。粘接是指在两个部件510和520已经被固化后接合这两个部件510和520。
纤维丝412改善两个部件510和520的接合。使数千条纤维丝412单独地接合到第二部件520大大减小了脱粘的可能性。由于每条纤维丝412独立于其他纤维丝，要产生任何显著性脱粘需要有数百或数千条纤维丝的脱粘发生。
纤维丝末端的在平面中的波浪形提供了增加的益处。波浪形几乎不聚集负载。
参照图6，图6示出了第二示例：修补包括嵌入塑料基质中的多层碳增强纤维的面板610。在每一层中，碳纤维以特定角度(例如，0度、+45度、-45度和90度)单向延伸。
面板610的损坏区域被挖掉(scarf out)。在图6的例子中，被挖的区域612为七层深并挖成一定角度。
用于面板610的补片620包括铺层堆叠。堆叠的铺层与被移除的面板610的层相对应。因此，补片620的每一铺层被定尺寸和定形状以替换被移除的面板层。另外，每一个铺层可以具有与被移除的面板层相同的纤维取向。顶铺层的边界大致与面板610的上层中的开口一致。
在图6的补片620中，顶铺层包括由纤维束构成的多方向纺织物。分散的纤维丝(未示出)延伸超过纺织物的边界。例如，分散的纤维丝延伸穿过四个边缘。纤维丝的末端可具有在平面中的波浪形。补片620的剩余铺层可包括传统纺织物或单向纤维束。
一层胶合剂630可被置于面板610的被挖区域612上。补片620被置于被挖区域612中。延伸超过纺织物的边界的纤维丝被设置在面板610的上表面上并接合于面板610的上表面。
数千条分散的纤维丝从补片620延伸穿过在补片620和面板610之间形成的接缝，并延伸到面板610上。分散的纤维丝产生到面板610的数千独立粘接，以防止补片620从面板610的剥落。纤维丝的波浪状末端可以聚集负载，但其不向补片的其余部分传递负载，这样进一步防止补片620从面板610的剥落。
本文的织物不限于第一复合部件与第二复合部件的接合。第二部件可以由金属或者其他非复合材料制成。延伸经过两个部件之间的接缝的分散的纤维丝可以胶接地粘接到金属部件。
本文的织物甚至不限于一个复合部件与非复合部件的接合。考虑图6的示例，但是面板和补片二者均由金属制成而不是纤维增强塑料。金属补片可被粘接在金属面板的损坏的区域内，并且本文的织物可覆盖金属补片，其分散的纤维丝延伸经过接缝并延伸到金属面板的表面上。除了将金属补片保持在面板中，织物可以提供屏障以防止湿气进入。
本文的织物不限于图1A和图1B中所示的样式。本文的织物不限于在正交的第一和第二方向上延伸的纤维丝。
图7示出了包括在三个方向(w、x和y)上延伸的三轴编织的纤维束的织物710。织物710的中心部分720由在所有三个方向上延伸的重叠纤维束构成。织物710的外围部分730由以三个方向中的两个方向延伸的纤维束构成。例如，织物710的右下外围部分730由以w和y方向延伸的纤维束构成。延伸经过织物710的边界的纤维丝被分散。
图8示出了具有圆形边界830的织物810和延伸经过圆形边界830的纤维丝820。该织物810可以通过将多维纺织物切割成圆形，拉出边界处的独立的纤维丝，并将那些独立的纤维丝设置为正交于边界830而形成。
本文的多方向织物不限于纺织物或编织物。在其他实施例中，多方向织物110包括多层纤维束构成的压层，其中每层的纤维束为单向的。例如，第一层包括以x方向延伸的纤维束，而第二层包括以y方向延伸的纤维束。这些层的重叠部分在x和y方向上提供强度。
本文的织物不限于延伸经过边界的所有纤维丝。在一些实施例中，仅一些纤维丝可延伸经过边界，而其他纤维丝以相同方向延伸并在边界处终止。在边界处终止一些纤维丝的优势是这更容易将延伸通过边界的纤维分散。
在本文的织物中，所有纤维丝可具有相同的模量和相同的热膨胀系数。然而，本文的织物不受此限制。
在本文的织物中，所有纤维丝可具有相同组分。例如，本文的织物可仅具有碳纤维丝。然而，本文的织物不受此限制，并且一些实施例可具有不同组分的纤维丝。例如，本文的织物可具有玻璃纤维丝和碳纤维丝的结合。玻璃纤维丝的使用可导致在负载处的更高应变。考虑图1B的示例，具有波浪状末端的碳纤维丝可以被具有直线末端的玻璃纤维丝代替。
本文的织物不限于任何特定宽度的纤维束，或任何特定数目的纤维丝。纤维束可包括数千条纤维丝。
在本文的织物中，纤维丝不限于具有正弦曲线形的波浪状末端。在一些实施例中，织物910的纤维丝920可具有弯曲成与织物的边界912平行的波浪状末端922，如图9所示。
现在参照图10，图10示出了使用本文的织物的一般方法。在方框1010处，匹配第一和第二部件。第一部件包括外层，该外层具有由以第一方向延伸的第一纤维束和以第二方向延伸的第二纤维束构成的纺织物。第一纤维束的末端部分延伸至第二部件的表面上。胶合剂可被置于第一和第二部件的接合表面。
在方框1020处，纤维束的末端部分被分散成独立的纤维丝。可向末端部分施加(例如，利用辊子)压力以造成纤维丝分散。可梳理纤维丝以进一步确保纤维丝被分散。胶合剂也可置于分散的纤维丝上。
在方框1030处，通过将部件的接合表面接合在一起，第一部件被接合到第二部件，并且分散的纤维丝被接合到第二部件的表面。取决于部件的成分和固化程度，接合可通过共固化、共粘接或粘接来实现。可通过蒸压器来施加在固化或粘接期间的热和压力。如果第一部件为补片，可通过热毯来施加热和压力。
参照图11，图11示出了包括机身1110、机翼组件1120和尾翼1130的飞机1100。包括一个或更多个推进单元的推进系统1140被联接至机身1110、机翼组件1120或飞机1100的其他部分。诸如蒙皮、加强件、框架和翼梁的FRP结构元件可被接合在一起以形成机身1110、机翼组件1120和尾翼1130。本文的织物可用于这些FRP结构元件中。考虑具有粘接和/或紧固于蒙皮面板的FRP凸缘的横梁的示例。横梁可被用于加强蒙皮面板。本文的织物用于凸缘的外层。从织物延伸出的独立的纤维丝被接合至蒙皮面板。纤维丝可从凸缘纵向地延伸和/或从凸缘横向地延伸。
本文的织物也可用于修补机身1110、机翼组件1120和尾翼的损坏部分。飞机1100的某些区域可能易于腐蚀损坏和/或冲击损坏。本文的织物可以用于修补如上所述的损坏。织物的独立的纤维丝防止补片剥落，纤维丝的波浪状末端进一步防止补片剥落。
补片还降低冲击后的损坏。如果修补的区域再次受到碎片冲击，那么纤维丝的波浪状末端聚集冲击负载，但不向补片的其他部分传递冲击负载。

Claims (14)

1.一种飞机结构元件，其包括多方向织物，其中所述多方向织物由在所述多方向织物的边界内沿第一方向延伸的第一增强纤维束和沿第二方向延伸的第二增强纤维束构成，所述多方向织物中的所述第一增强纤维束和所述第二增强纤维束中的每个束在经过所述边界后包括以若干行布置的一捆拆开的纤维丝，所述第一增强纤维束的所述纤维丝延伸经过所述多方向织物的所述边界并且通过压缩所述一捆拆开的纤维丝而分散使得经过所述边界的纤维丝的行的数量减少，所述第一增强纤维束和所述第二增强纤维束被嵌入树脂中，延伸经过所述边界的分散的纤维丝中的至少一些是笔直的且在蜿蜒波浪状末端处终止，所述蜿蜒波浪状末端在x-y平面中呈现波浪形而在z平面中不具有变化。
2.根据权利要求1所述的飞机结构元件，其中所述第二增强纤维束中的纤维丝也延伸经过所述多方向织物的所述边界并分散。
3.根据前述权利要求中任一项所述的飞机结构元件，其中所述多方向织物的所述边界内的纤维丝沿所述第一方向和所述第二方向提供结构强度，并且其中延伸经过所述边界的那些纤维丝仅在所述第一方向提供结构强度。
4.根据权利要求1或2所述的飞机结构元件，其中延伸经过所述边界的所述分散的纤维丝被各自地接合到第二部件的表面。
5.根据权利要求1或2所述的飞机结构元件，其中所述多方向织物包括由所述第一增强纤维束和所述第二增强纤维束构成的纺织物。
6.根据权利要求5所述的飞机结构元件，其中延伸经过所述边界的所述纤维丝稀疏而没有交叉纤维支撑。
7.根据权利要求1或2所述的飞机结构元件，其中所述多方向织物包括由沿第一方向、第二方向和第三方向延伸的束构成的编织物。
8.根据权利要求1或2所述的飞机结构元件，其中所述多方向织物具有圆形边界并且其中延伸经过所述边界的所述纤维丝正交于所述边界。
9.根据权利要求1或2所述的飞机结构元件，其中所述多方向织物的所述第一增强纤维束和所述第二增强纤维束在所述x-y平面中延伸，并且其中所述分散的纤维丝的所述蜿蜒波浪状末端与所述多方向织物在同一x-y平面中呈现波浪形。
10.根据权利要求1或2所述的飞机结构元件，其中延伸经过所述边界的所述纤维丝以不同长度终止。
11.一种铺层，其包含多层增强纤维以及包括任一前述权利要求所述的飞机结构元件的外层。
12.一种制造用于飞机的复合结构的方法，其包括：
匹配第一部件和第二部件，其中所述第一部件包括外层，所述外层具有由沿第一方向延伸的第一增强纤维束和沿第二方向延伸的第二增强纤维束构成的多方向织物，所述第一增强纤维束和所述第二增强纤维束位于所述多方向织物的边界内，所述第一增强纤维束和所述第二增强纤维束中的每一个在经过所述边界后均包括以若干行布置的一捆拆开的纤维丝，所述第一增强纤维束和所述第二增强纤维束被嵌入树脂中；
通过压缩所述一捆拆开的纤维丝使纤维丝经过所述多方向织物的边界分散，使得在每个束中的经过所述边界的纤维丝的行的数量减少，延伸经过所述边界的分散的纤维丝中的至少一些是笔直的且在蜿蜒波浪状末端处终止，所述蜿蜒波浪状末端在x-y平面中呈现波浪形而在z平面中不具有变化；并且
将所述分散的纤维丝接合到所述第二部件的表面。
13.根据权利要求12所述的方法，其中所述第一部件和所述第二部件是飞机结构元件。
14.根据权利要求12所述的方法，其中所述第一部件是用于所述第二部件的补片，所述第二部件是飞机结构元件。
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RU2619647C2 (ru) 2017-05-17
US10035323B2 (en) 2018-07-31
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CA2851497C (en) 2016-08-30
BR102014021942B1 (pt) 2020-09-08
US20150086745A1 (en) 2015-03-26
RU2619647C9 (ru) 2017-09-18
AU2014202672A1 (en) 2015-04-09
JP2015071300A (ja) 2015-04-16
CA2851497A1 (en) 2015-03-23
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