CN104755252A - 用于形成厚热塑性复合结构的方法和设备 - Google Patents
用于形成厚热塑性复合结构的方法和设备 Download PDFInfo
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Abstract
使用方法和设备预固结并压实热塑性复合层片堆叠(16),之后完全固化并且成形成最终部件形状。预固结和压实是通过将层片堆叠(16)加热至低于热塑性复合层片的熔点的温度以软化层片(18)并且接着压制层片堆叠(16)来实现的。
Description
技术领域
公开的实施方式大体地涉及制造复合层合物,更特别地,涉及用于形成厚热塑性复合结构的方法和设备。
背景技术
可通过组装预浸渍层片的叠堆并且将层片叠堆固结成成品部件来制造纤维增强型热塑性层合物。通过将层片加热至它们的熔融温度并且使用传统压制模制、连续压制模制或其它技术将层片堆叠模制成所需的部件形状来实现固结。在模制期间,层片能彼此相对滑动允许层片堆叠变化形状并且适形于模制工具的几何形状。可使用连续压制模制而没有困难地制造包括相对较少预浸渍层片的薄热塑性层合物,部分地因为熔融热塑性物所需的热相对快速地贯穿层合物的整个厚度。
然而,当制造较厚的热塑性复合层合物(尤其是具有复杂几何形状的层合物)时,会出现问题。当在固结和成形期间热塑性树脂熔融时,固结所需的过量材料移动允许增强纤维既在面内又在面外移动和扭曲。
厚热塑性复合层合物成形中的另一个问题是由于因在层片堆叠中需要大量层片而导致的过大的材料体积造成的。特别厚的层片堆叠会难以或不可能固结和模制成形。可通过在模具加工中进行调节来部分地容纳材料体积,但尽管如此仍难以在成形期间完全固结层片堆叠。由于过大的材料体积导致不能完全固结厚层片堆叠会造成成品部件中有孔隙和内部空隙。
因此,需要用于制造厚热塑性复合层合物的方法和设备,该方法和设备在模制之前压实和部分固结热塑性层片堆叠,以减少成品部件中的褶皱、孔隙和内部空隙。还需要如上所述的方法和设备,该方法和设备当正将层片堆叠成形为最终形状时减少或消除纤维变性。
发明内容
公开的实施方式提供了形成热塑性复合层合部件的方法和设备,这些部件相对厚和/或具有复杂几何形状。未组装的层片堆叠中的材料块体在完全固结和成形之前大大减小,从而减少在用于将部件固结和成形的工具中的材料块体的需要。该方法采用在升高温度下执行的材料压实技术,该温度足以软化热塑性树脂但低于其熔点。该压实导致层片堆叠部分固结,其中层片基本上在它们整个表面区域内面对面接触地彼此粘附,之后被加热至熔融温度以准备进行完全固结和成形。由于该材料压实和部分固结,因此由于材料移动造成的纤维变形大大减小,减少或消除了褶皱以及孔隙和内部空隙,所有这些都导致部件质量提高。另外,该方法和设备可允许制造比迄今为止可能的更厚的热塑性复合层合物。该设备包括连续压制模制(CCM)机,其包含预固结区,该预固结区用于在将层片堆叠固结和成形成最终部件形状之前压实和预固结层片堆叠。
根据一个公开的实施方式,提供了一种制造厚热塑性复合部件的方法。该方法包括:组装包括多个热塑性复合层片的层片堆叠;预固结所述层片堆叠,包括通过将所述层片堆叠中的层片加热至低于所述热塑性复合层片的熔融温度的温度并且压制所述层片堆叠来软化所述层片。该方法还包括固结预固结后的层片堆叠,包括将所述层片堆叠加热至至少所述热塑性复合层片的熔融温度。压制软化后的层片的层片堆叠包括向所述层片施加压力,以足以压实所述层片堆叠,并且还可包括将所述层片堆叠放置在两个工具之间,将所述工具推到一起。压制软化后的层片的层片堆叠是在连续压制模制机中执行的。固结预固结后的层片堆叠是通过压实所述层片堆叠来执行的。该方法还可包括:当所述层片堆叠正在固结时,将所述层片堆叠成形为所需形状。将所述层片堆叠成形为所需形状也可以是在连续压制模制机中执行的。
根据另一个公开的实施方式,提供了一种形成厚热塑性复合部件的方法。该方法包括:通过彼此上下叠置地铺设多个热塑性复合层片来组装层片堆叠,使用第一组参数预固结所述层片堆叠,所述第一组参数包括预选的第一温度、预选的第一压力和预选的第一持续时间。该方法还包括使用第二组参数来固结预固结后的层片堆叠,所述第二组参数包括预选的第二温度、预选的第二压力和预选的第二持续时间。组装所述层片堆叠是通过将多个热塑性复合层片连续供给到连续压制模制机中执行的。所述预选的第一温度是足以软化所述层片但低于所述热塑性复合层片的熔融温度的温度。所述预选的第一压力足以压实所述层片堆叠。所述预选的第一持续时间足以允许所述层片堆叠中的层片在所述预选的第一温度下软化,并且允许在所述预选的第一压力下压实所述层片堆叠。所述预选的第二温度高得足以导致所述层片堆叠中的所述热塑性层片熔融,所述预选的第二压力高得足以完全固结所述层片堆叠。
根据另一个公开的实施方式,提供了一种连续压制模制热塑性复合部件的方法。该方法包括:组装包括多个热塑性预浸渍层片的层片堆叠;通过将层片加热至低于其熔点的温度并且压制所述层片堆叠来压实所述层片堆叠。该方法还包括将压实后的层片堆叠模制成所需的部件形状,包括将层片加热至至少其熔点并且进一步压制所述层片堆叠以完全固结层片。压制所述层片堆叠是通过将所述层片堆叠布置在一对工具之间并且使用所述工具向所述层片堆叠施加压实压力来执行的。压实所述层片堆叠并且模制所述层片堆叠可以是在连续压制模制机中执行的。
根据又一个公开的实施方式,提供一种压制模制厚热塑性复合部件的设备。该设备包括预固结区和固结区。预固结区接收热塑性层片的层片堆叠,并且包括用于加热所述层片堆叠的加热器和用于压制所述层片堆叠的预固结工具。固结区包括用于将预固结后的层片堆叠固结并且成形成所述部件的形状的固结工具。该设备还可包括预成形区,所述预成形区用于在所述层片堆叠已预固结之后将所述层片堆叠预成形。该设备还可包括脉动驱动机构,所述脉动驱动机构用于以连续渐进步骤移动所述层片堆叠通过所述预固结区并且通过所述固结区。
附图说明
在随附的权利要求书中阐述了例证性实施方式的据信是新颖特征的特性。然而,通过参照以下结合附图进行阅读的对本公开的例证性实施方式的详细描述,将最佳地理解例证性实施方式及其优选使用模式、其它目的及其优点,其中:
图1是根据公开的方法和设备制造的厚热塑性复合部件的立体图的图示。
图2是大体上示出用于制造厚热塑性复合层合部件的方法中的步骤的流程图的图示。
图3是已铺设在工具上的热塑性复合层片的堆叠的剖视图的图示。
图4是与图3类似但示出已被放置在层片堆叠上以准备进行预固结循环的工具的图示。
图5是与图4类似但示出在正被加热至软化层片的温度时在工具中对层片堆叠施压以部分固结层片堆叠的图示。
图6是用于执行公开方法的连续压制模制设备的图解的图示。
图7是示出采用预固结和材料压实来进行连续压制模制的方法的步骤的流程图的图示。
图8是飞行器制造和维修方法的流程图的图示。
图9是飞行器的框图的图示。
具体实施方式
首先,参照图1,公开的实施方式涉及形成相对厚的热塑性复合(TCP)部件10的方法。在图示示例中,TCP部件10是具有大体U形横截面12的基本上笔直的细长结构构件,带有形成总体上敞口内部16的内弯凸缘14。然而,可采用公开的方法形成具有各种其它横截面形状以及沿着它们长度的曲率或轮廓和/或变化厚度的TCP结构构件。TCP部件10可包括由预浸渍层片(未示出)堆叠形成的层合物,该预浸渍层片包括合适的热塑性聚合物树脂基质,诸如(而不限于)聚醚醚酮(“PEEK”)、聚醚酮酮(“PEKK”)、聚苯砜(“PPS”)、聚醚亚酰胺(“PEI”),可用诸如玻璃(s型或e型或碳纤维(未示出))的纤维成分加强基质。各层片内的加强纤维可根据特定应用取向成单向或非均匀的布置。聚合物基质内的纤维的相对类型、厚度、量以及各层片中利用的聚合物基质的类型可基于众多因素而有很大的不同,这些因素包括部件10的成本和最终期望的物理和机械性质。复合部件10具有厚度“t”,厚度“t”需要可能难以形成为单个层片堆叠的相对大量层片的铺设。
现在,参照图2至图5,可通过图2中示出的步骤17开始的方法制造图1中示出的TCP部件10,其中,图3中示出的TCP层片堆叠16被组装在合适工具24的其它表面上。层片堆叠16包括多个热塑性预浸渍层片18,可用手或者使用自动化材料布置设备(未示出)将多个热塑性预浸渍层片18彼此上下叠置地铺设。如图3中所示,由于层片18在它们预浸渍状态下的波动或其它不规则,导致层片堆叠16中的层片18可能不处于完全彼此平坦紧贴的状态,从而导致至少一些层片18之间存在褶皱和/或空隙或间隙22。
在将层片堆叠16铺设在工具20上后,执行图2中示出的方法的下一个步骤19,该步骤通过使层片堆叠16经受热和压力达预选的时间长度来预固结层片堆叠16,从而导致压实层片堆叠16。参照图4,在准备进行预固结步骤19中,可将第二工具24放置在层片堆叠16上并且被推动26抵靠层片堆叠16。图4中示出的工具20、24可包括安装在传统冲压式机床(未示出)中的传统平压状工具。工具20、24可被具体构造成执行层片堆叠16的预固结,但另选地,工具20、24可包括随后被用于将层片堆叠16成形为待成形的特定部件10的最终形状的工具。例如,工具20、24可包括具有将层片堆叠16成形为部件10的最终形状所需的曲率、轮廓和其它表面特征的匹配模具。
图5示出上部工具24,上部工具24被推动26抵靠下部工具20,以使用预选量的压力或力26向层片堆叠16施压。当向层片堆叠16施加压力时,层片堆叠16被加热30至预选温度。可通过使用被加热的工具20、24进行接触加热,或者通过在烤炉内执行预固结循环来执行加热。可在预固结循环期间使用其它处理向层片堆叠16施加必要压力,诸如(而不限于)真空袋和/或压热器处理。在导致压实层片堆叠16的预固结循环期间,层片堆叠16被加热至“预固结温度”,在该温度下,层片18软化并且变成易弯,但该温度低于使层片18中的热塑性树脂开始熔融并流动的温度。当达到预固结温度时层片18的软化允许层片18在压力26下变平坦,从而基本上消除了层片18之间导致空隙22的任何间隙(图3)并且部分固结层片18使得它们紧靠地堆积成在基本上它们整个区域上方彼此面对面接触。
压力26、预固结温度和保持时间(层片堆叠16经受固结温度持续的时间段)是预选的并且将随着包括部件厚度、部件几何形状、所使用的热塑性材料的类型以及加强纤维的类型和尺寸的应用而变化。在组装包括60个熔融温度为350℃的碳纤维预浸渍热塑性层片的层片堆叠16的一个典型应用中,使用330℃的预固结温度、5巴的压力和大致80秒的保持时间来实现令人满意的预固化和材料压实。通常,保持时间必须足以允许热穿透层片堆叠16中的所有层片18并且将层片18升至预固结温度。这个示例中的部件是在375℃的温度下形成的。这里,应该注意的是,以上示例只是例证性的,不应该被解释为是限制。
在上述的预固结循环之后,层片堆叠16保持预固结,直到它随后被成形并且完全固结,如图2中的步骤21中所示。层片堆叠16保持预固结,因为在预固结循环期间施加的热和压力的组合造成层片18彼此粘附并且保持它们的形状。此外,层片18的彼此粘附减少了后续固结和成形处理期间的过大材料体积的移动,从而基本上消除了因过量的层片材料移动造成的面内和面外纤维扭曲。
上述公开的方法可被作为使用图6中示出的CCM机32进行连续压制模制(CCM)处理的部件来执行。CCM机32可大体上包括预固结区42、预成形区44和固结工位48。复合材料的多个层片34、36是由连续辊(未示出)供应的或者是以预切制TPC坯料(诸如,之前描述的层片堆叠16)的轧制堆叠(未示出)的形式供应的。TPC材料的层片34、36连同片材构件成形心轴(mandrels)38一起被供给到预固结区42。可使用引导件40或其它加工元件预对准层片34、36并且引导层片34、36进入预固结区42中。
预固结区42可包括合适工具45,工具45可与之前描述的工具20、24类似,用于在预固结循环期间将层片34、36压制到一起,从而实现层片34、36的预固结和压实。预固结区42还可包括加热器47,加热器47用于将层片34、36加热达到预固结温度。加热器47可包括其中容纳有预固结工具45的烤炉,或者可以是加热工具45以在层片34、36正被工具45施压的同时提供层片34、36的接触加热的装置。在一些实施方式中,可以将预固结区42与预成形区44组合,在这种情况下,用于将层片34、36预成形的工具还用于将这些层片预固结,之后在固结工位48将它们加热至熔融温度。
引导件40还可用于预对准预固结后的层片堆叠连同心轴38以及可选的填料材料(未示出)并且将它们引导进入预成形区44中。预成形层片34、36和心轴38可穿过烤炉(未示出)以升高层片材料的温度,这是为了有助于在预成形区44进行预成形操作。例如,可使用由辊40或其它成形工具向层片34、36施加的压力,在预成形区44中将诸如部分凸缘14(图1)的各种特征预成形。
具有最终部件的大体形状的预成形部件46离开预成形区44并移动进入固结操作48。固结操作48包括大体用55指示的多个标准化工具模具,这些工具模具单独与工具构件(未示出)配合,工具构件具有由标准化模具接合的平滑外表面和具有经加工特征的内表面。在固结加工期间,向预成形部件46赋予这些经加工特征。标准化模具55和工具构件的外表面之间的表面的共性省去了对于部分特定匹配模具的需要。
固结操作48包括脉动驱动机构60,脉动驱动机构60将预成形部件46在固结操作48内向前移动并且以连续渐进的步骤离开预成形区44。随着预成形部件46向前移动,预成形部件46首先进入加热区52,加热区52将预成形部件46加热至允许层片34、36中的基质树脂的聚合物成分自由流动的温度。
接下来,预成形部件46向前移动,进入施压区或操作54,在施压区或操作54中,在足以将各个层片34、36压制并且固结(即,允许基质树脂自由流动)成所需形状和厚度的预定压力下,使标准化模具55一起或单独地向下。当打开模具55时,预成形部件46在固结操作48内逐渐前进,之后,再关闭模具55,从而造成部件46的连续片段在不同温度区内被压制,由此在承压区段中固结层合层片。当部件46逐渐前进通过固结操作48时,针对模具55的各温度区重复这个处理。
完全成形和压制(固结)后的部件46接着进入与施压区54分开的冷却区56,在冷却区56中,使温度低于层片34、36中的基质树脂的自由流动温度,从而造成熔融或固结的部件46变硬,成为其最终压制的形状。固结和冷却后的部件58接着退出固结操作48,在固结操作48中,心轴38装载在辊62上。在CCM机32的端部,取下最终形成的部件64。
图7大体上示出使用上述的CCM机32形成TPC层合部件10的步骤,这些步骤包括预固结和压实层片堆叠16,之后将层片堆叠16完全固结和成形。先开始步骤66,如之前描述的,通过预堆叠层片并且将它们作为堆叠供给到CCM机32中,或者通过将层片单独地供给到CCM机32中来组装TPC层片堆叠16。在步骤68中,将层片堆叠16中的层片18加热至使它们软化的温度,但低于热塑性树脂的熔点。层片18的软化是在预固结区42(图6)中执行的。
在步骤70中,在预固结区42中压制层片堆叠16,从而导致层片堆叠16的预固结和层片材料的压实。在步骤72中,在预成形区44中将软化后的层片堆叠16预成形,之后,将预成形后的层片堆叠16加热至树脂的熔融温度,如步骤74中示出的。在步骤76中,在固结工位48,使加热后的层片堆叠16固结并且成形为所需的部件形状。如以上提到的,可通过使加热后的层片堆叠穿过匹配模具来执行这个固结和成形处理,匹配模具压制并且顺序地将层片堆叠16成形为所需部件形状。在步骤78中,成形和固结后的部件被冷却。该部件逐渐前进,如步骤80中所示地,使得它在脉动驱动机构60(图6)的拉动下以渐进方式逐步移动通过预固结区42、预成形区44和固结工位48。
这里应该注意的是,尽管以上出于例证目的已描述了CCM处理,但应该注意,可以将公开的预固结和压实方法结合在其它类型的模制过程中,诸如(而不限于);拉挤成型和辊轧成型。
本公开的实施方式可用于各种潜在的应用,特别是运输行业,包括(例如)航空航天、海运、汽车应用和可使用复合部件的压热器固化的其它应用。因此,现在参照图8和图9,可在如图8中所示的飞行器制造和维修方法82和如图9中所示的飞行器84的背景下使用本公开的实施方式。公开的实施方式的飞行器应用可包括例如(而不限于)形成加强杆构件,诸如(而不限于)梁、翼梁和纵梁,这只是举几个例子。在预制造期间,示例性方法82可包括之前飞行器的规格和设计86和材料采购88。在制造期间,发生飞行器84的组件和子组件制造90和系统整合92。此后,飞行器84可经过认证和交付94,以入役96。当顾客进行入役时,安排对飞行器84进行常规维护和维修98,还可包括改装、重构、翻新等。
可由系统整合商、第三方和/或运营商(例如,顾客)执行或进行方法82的各处理。出于进行此描述的目的,系统整合商可包括(而不限于)任何数量的飞行器制造商和主系统分包商;第三方可包括(而不限于)任何数量的供应商、分包商和供货商;运营商可以是航空公司、租赁公司、军事单位、服务组织等。
如图9中所示,通过示例性方法82制造的飞行器84可包括带有多个系统102和内部104的机身100。高级系统102的示例包括推进系统106、电气系统108、液压系统110和环境系统112中的一个或多个。可包括任何数量的其它系统。尽管示出了飞行器示例,但本公开的原理可应用于其它行业(诸如,海运行业和汽车行业)。
可在制造和维修方法82的任何一个或多个阶段期间采用本文中实施的系统和方法。例如,可以按飞行器84在入役时制造的组件或子组件类似的方式,构造或制造与制造工序90对应的组件或子组件。另外,例如,通过相当大程度地迅速组装飞行器84或降低飞行器84的成本,可在制造阶段90和92期间利用一个或多个设备实施方式、方法实施方式或其组合。类似地,在飞行器84入役时可将一个或多个设备实施方式、方法实施方式或者其组合用于例如但不限制于维护和维修98。
已经出于例证和描述的目的展示了对不同例证性实施方式的描述,该展示不旨在是排他性的或者限于公开形式的实施方式。对于本领域的普通技术人员而言,许多修改形式和变形形式将是显而易见的。另外,不同例证性实施方式可提供相比于其它例证性实施方式不同的优点。所选择的一个或多个实施方式被选择和描述,以最佳地说明这些实施方式的原理、实际应用并且能够使本领域的其它普通技术人员理解本公开的各种实施方式以及适于料想到的特定使用的各种变形。
Claims (20)
1.一种制造厚热塑性复合部件的方法,该方法包括:
组装包括多个热塑性复合层片的层片堆叠;
预固结所述层片堆叠,包括通过将所述层片堆叠中的层片加热至低于所述热塑性复合层片的熔融温度的温度来软化所述层片并且压制所述层片堆叠;以及
固结预固结后的层片堆叠,包括将所述层片堆叠加热至至少所述热塑性复合层片的熔融温度。
2.根据权利要求1所述的方法,其中,压制软化后的层片的所述层片堆叠的步骤包括向所述层片施加足以压实所述层片堆叠的压力。
3.根据权利要求2所述的方法,其中,压制软化后的层片的所述层片堆叠的步骤是通过以下步骤执行的:
将所述层片堆叠放置在两个工具之间,以及
迫使所述工具合在一起。
4.根据任一前述权利要求所述的方法,其中,压制软化后的层片的所述层片堆叠的步骤是在连续压制模制机中执行的。
5.根据任一前述权利要求所述的方法,其中,执行固结预固结后的层片堆叠的步骤从而压实所述层片堆叠,所述方法还包括:
在所述层片堆叠被固结时将所述层片堆叠成形为所需形状。
6.根据权利要求5所述的方法,其中,将所述层片堆叠成形为所需形状的步骤是在连续压制模制机中执行的。
7.一种形成厚热塑性复合部件的方法,该方法包括:
通过彼此上下叠置地铺设多个热塑性复合层片来组装层片堆叠;
使用第一组参数来预固结所述层片堆叠,所述第一组参数包括预选的第一温度、预选的第一压力和预选的第一持续时间;以及
使用第二组参数来固结预固结后的层片堆叠,所述第二组参数包括预选的第二温度、预选的第二压力和预选的第二持续时间。
8.根据权利要求7所述的方法,其中,组装所述层片堆叠的步骤是通过将多个热塑性复合层片连续供给到连续压制模制机中执行的。
9.根据权利要求7或8所述的方法,其中:
所述预选的第一温度是足以软化所述层片但低于所述热塑性复合层片的熔融温度的温度。
10.根据权利要求7-9中任一项所述的方法,其中,所述预选的第一压力足以压实所述层片堆叠。
11.根据权利要求7-10中任一项所述的方法,其中,所述预选的第一持续时间足以允许所述层片堆叠中的层片在所述预选的第一温度下软化,并且允许在所述预选的第一压力下压实所述层片堆叠。
12.根据权利要求7-11中任一项所述的方法,其中:
所述预选的第二温度高得足以导致所述层片堆叠中的所述热塑性复合层片熔融,并且
所述预选的第二压力高得足以完全固结所述层片堆叠。
13.一种连续压制模制热塑性复合部件的方法,该方法包括:
组装包括多个热塑性预浸渍层片的层片堆叠;
通过将所述层片加热至低于其熔点的温度并且压制所述层片堆叠来压实所述层片堆叠;以及
将压实后的层片堆叠模制成所需的部件形状,包括将所述层片加热至至少其熔点并且进一步压制所述层片堆叠以完全固结所述层片。
14.根据权利要求13所述的方法,其中,压制所述层片堆叠的步骤是通过以下步骤执行的:
将所述层片堆叠放置在一对工具之间,以及
使用所述工具向所述层片堆叠施加压实压力。
15.根据权利要求14所述的方法,其中,压实所述层片堆叠并且模制所述层片堆叠的步骤是在连续压制模制机中执行的。
16.根据权利要求13-15中任一项所述的方法,其中,压实所述层片堆叠和模制压实后的层片堆叠的步骤基本上是连续执行的。
17.一种连续压制模制厚热塑性复合部件的设备,该设备包括:
预固结区,热塑性层片的层片堆叠可被供给到该预固结区中,所述预固结区包括用于加热所述层片堆叠的加热器和用于压制所述层片堆叠的预固结工具;以及
固结区,所述固结区包括用于将预固结后的层片堆叠固结并且成形成所述部件的形状的固结工具。
18.根据权利要求17所述的设备,所述设备还包括:
预成形区,该预成形区用于在所述层片堆叠已被预固结之后将所述层片堆叠预成形。
19.根据权利要求17或18所述的设备,所述设备还包括:
脉动驱动机构,该脉动驱动机构用于以连续渐进的步调移动所述层片堆叠通过所述预固结区并且通过所述固结区。
20.根据权利要求17-19中任一项所述的设备,其中,所述预固结工具包括用于将所述层片堆叠预成形的特征。
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