CN104822511A - 使用低温热塑性薄膜融合连接复合部件 - Google Patents
使用低温热塑性薄膜融合连接复合部件 Download PDFInfo
- Publication number
- CN104822511A CN104822511A CN201380062049.3A CN201380062049A CN104822511A CN 104822511 A CN104822511 A CN 104822511A CN 201380062049 A CN201380062049 A CN 201380062049A CN 104822511 A CN104822511 A CN 104822511A
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- Prior art keywords
- thermoplastic
- lamination
- amorphous
- thermoplastic film
- composite
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- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 229920001169 thermoplastic Polymers 0.000 title claims abstract description 270
- 239000004416 thermosoftening plastic Substances 0.000 title claims abstract description 264
- 239000002131 composite material Substances 0.000 title claims abstract description 176
- 230000004927 fusion Effects 0.000 title claims description 35
- 229920001187 thermosetting polymer Polymers 0.000 claims abstract description 119
- 238000000034 method Methods 0.000 claims description 114
- 239000000463 material Substances 0.000 claims description 82
- 238000003475 lamination Methods 0.000 claims description 81
- 238000007596 consolidation process Methods 0.000 claims description 62
- 238000010276 construction Methods 0.000 claims description 33
- 238000007711 solidification Methods 0.000 claims description 23
- 230000008023 solidification Effects 0.000 claims description 23
- 229920000642 polymer Polymers 0.000 claims description 20
- 238000001723 curing Methods 0.000 claims description 18
- 230000009477 glass transition Effects 0.000 claims description 14
- 150000001875 compounds Chemical class 0.000 claims description 12
- 238000005266 casting Methods 0.000 claims description 11
- 229920006135 semi-crystalline thermoplastic polymer Polymers 0.000 claims description 10
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- 239000002184 metal Substances 0.000 claims description 5
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- 238000007906 compression Methods 0.000 claims description 3
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- 229920001652 poly(etherketoneketone) Polymers 0.000 claims description 3
- 229920006260 polyaryletherketone Polymers 0.000 claims description 3
- 229920002530 polyetherether ketone Polymers 0.000 claims description 3
- JUPQTSLXMOCDHR-UHFFFAOYSA-N benzene-1,4-diol;bis(4-fluorophenyl)methanone Chemical compound OC1=CC=C(O)C=C1.C1=CC(F)=CC=C1C(=O)C1=CC=C(F)C=C1 JUPQTSLXMOCDHR-UHFFFAOYSA-N 0.000 claims description 2
- 239000003822 epoxy resin Substances 0.000 claims description 2
- 229920000647 polyepoxide Polymers 0.000 claims description 2
- 238000013007 heat curing Methods 0.000 claims 1
- 229920000069 polyphenylene sulfide Polymers 0.000 claims 1
- 238000004519 manufacturing process Methods 0.000 description 23
- 229920005989 resin Polymers 0.000 description 22
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- 239000000853 adhesive Substances 0.000 description 13
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- 238000005516 engineering process Methods 0.000 description 5
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- 230000002787 reinforcement Effects 0.000 description 4
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- 229920000049 Carbon (fiber) Polymers 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 239000011230 binding agent Substances 0.000 description 3
- 239000004917 carbon fiber Substances 0.000 description 3
- 238000003754 machining Methods 0.000 description 3
- 238000012423 maintenance Methods 0.000 description 3
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 3
- 239000004634 thermosetting polymer Substances 0.000 description 3
- NUOYJPPISCCYDH-BYPYZUCNSA-N (2s)-1-(2,2,2-trifluoroacetyl)pyrrolidine-2-carbonyl chloride Chemical compound FC(F)(F)C(=O)N1CCC[C@H]1C(Cl)=O NUOYJPPISCCYDH-BYPYZUCNSA-N 0.000 description 2
- -1 but not limited to Substances 0.000 description 2
- 239000000835 fiber Substances 0.000 description 2
- 238000007499 fusion processing Methods 0.000 description 2
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- 229920006393 polyether sulfone Polymers 0.000 description 2
- 230000035939 shock Effects 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- RZVHIXYEVGDQDX-UHFFFAOYSA-N 9,10-anthraquinone Chemical group C1=CC=C2C(=O)C3=CC=CC=C3C(=O)C2=C1 RZVHIXYEVGDQDX-UHFFFAOYSA-N 0.000 description 1
- 229920001871 amorphous plastic Polymers 0.000 description 1
- 229920006125 amorphous polymer Polymers 0.000 description 1
- 230000008859 change Effects 0.000 description 1
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- 239000012260 resinous material Substances 0.000 description 1
- 229920006014 semi-crystalline thermoplastic resin Polymers 0.000 description 1
- 229910000679 solder Inorganic materials 0.000 description 1
- 238000010561 standard procedure Methods 0.000 description 1
- 239000012815 thermoplastic material Substances 0.000 description 1
- 230000000699 topical effect Effects 0.000 description 1
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Classifications
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
- B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
- B29C65/481—Non-reactive adhesives, e.g. physically hardening adhesives
- B29C65/4815—Hot melt adhesives, e.g. thermoplastic adhesives
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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- B29C65/44—Joining a heated non plastics element to a plastics element
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
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- B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
- B29C65/5057—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like positioned between the surfaces to be joined
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
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- B29C66/112—Single lapped joints
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
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- B29C66/1122—Single lap to lap joints, i.e. overlap joints
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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- B29C66/01—General aspects dealing with the joint area or with the area to be joined
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- B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
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- B29C66/474—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially non-flat
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/49—Internally supporting the, e.g. tubular, article during joining
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
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- B29C66/524—Joining profiled elements
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
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- B29C66/63—Internally supporting the article during joining
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- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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- B29C66/712—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined the composition of one of the parts to be joined being different from the composition of the other part
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/721—Fibre-reinforced materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
- B29C66/721—Fibre-reinforced materials
- B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
- B29C66/7375—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured
- B29C66/73751—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured the to-be-joined area of at least one of the parts to be joined being uncured, i.e. non cross-linked, non vulcanized
- B29C66/73752—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured the to-be-joined area of at least one of the parts to be joined being uncured, i.e. non cross-linked, non vulcanized the to-be-joined areas of both parts to be joined being uncured
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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- B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
- B29C66/7377—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline
- B29C66/73771—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline the to-be-joined area of at least one of the parts to be joined being amorphous
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
- B29C66/7377—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline
- B29C66/73771—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline the to-be-joined area of at least one of the parts to be joined being amorphous
- B29C66/73772—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline the to-be-joined area of at least one of the parts to be joined being amorphous the to-be-joined areas of both parts to be joined being amorphous
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
- B29C66/7377—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline
- B29C66/73773—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline the to-be-joined area of at least one of the parts to be joined being semi-crystalline
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
- B29C66/7377—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline
- B29C66/73773—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline the to-be-joined area of at least one of the parts to be joined being semi-crystalline
- B29C66/73774—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined amorphous, semi-crystalline or crystalline the to-be-joined area of at least one of the parts to be joined being semi-crystalline the to-be-joined areas of both parts to be joined being semi-crystalline
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
- B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/7394—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/7394—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset
- B29C66/73941—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset characterised by the materials of both parts being thermosets
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
- B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
- B29C66/8145—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
- B29C66/81463—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps comprising a plurality of single pressing elements, e.g. a plurality of sonotrodes, or comprising a plurality of single counter-pressing elements, e.g. a plurality of anvils, said plurality of said single elements being suitable for making a single joint
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- B29C66/82—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps
- B29C66/824—Actuating mechanisms
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- B29C66/90—Measuring or controlling the joining process
- B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
- B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C66/90—Measuring or controlling the joining process
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- B29C66/9192—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams
- B29C66/91921—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature
- B29C66/91931—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature in explicit relation to the fusion temperature or melting point of the material of one of the parts to be joined
- B29C66/91935—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature in explicit relation to the fusion temperature or melting point of the material of one of the parts to be joined lower than said fusion temperature
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- B29C70/02—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers
- B29C70/026—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers and with one or more layers of pure plastics material, e.g. foam layers
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- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/04—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the partial melting of at least one layer
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Abstract
两个部件(32、34),其可以是热塑性复合部件,且通过在部件(32、34)之间形成热塑性接合部(31)的热塑性薄膜(36)连接在一起。热塑性薄膜(36)优选地是非晶状的且其优选地在接合部(31)的形成期间融合。
Description
技术领域
本公开大体涉及用于制造复合结构的过程,并且更具体地涉及使用低温热塑性树脂薄膜融合连接复合部件的方法。
背景技术
用于连接复合层压部件(诸如但不限于,在航空航天和其它应用中使用的子结构和加强筋)的各种技术是熟知的。例如,热固性树脂层压件能够通过共固化、粘合剂粘结或机械紧固连接在一起,而热塑性树脂层压件能够通过各种形式的焊接、熔化融合、粘合剂粘结和机械紧固连接在一起。使用机械紧固件的连接方法在一些应用中可能是不期望的,因为它们增加重量以及材料和安装成本。
不用机械紧固件的连接热塑性树脂层压件特别具有挑战性。通过使用耗时、先进的工艺(诸如等离子刻蚀或劳动密集型打磨),热塑性材料的粘合剂粘结可以需要粘结表面的广泛的表面加工。焊接技术需要专业装备、定制装配夹具以维持部件形状,并且必需在粘结线处以相对高的温度(通常超过700°F)执行,这可以导致预固结部件的再熔化。部件的再熔化可以导致部件的形状和/或材料性质的不期望的变化。
连接两个热塑性层压部件的、被称为双树脂粘合的熟知过程由熔化PEI(聚醚酰亚胺)薄膜的层组成,该薄膜已经与有待连接的部件的粘合表面预固结。然而,该过程的应用受到限制,因为PEI薄膜的熔化需要将薄膜加热到大于475°F的温度。将预固结的热塑性层压部件加热到这些温度可以引起部件的不期望的软化、变形和/或熔化。
因此,需要一种连接复合部件(包括热塑性材料和热固性材料)的方法,该方法减小或消除对广泛的表面加工的需要,并且可以以相对低的温度执行,其中周期时间短于典型的热固性粘结粘合剂。还需要一种上述类型的方法,该方法允许热塑性复合层压件被连接到不同材料(诸如热固性树脂层压件、金属、陶瓷和其它材料)的部件。
发明内容
所公开的实施例提供一种使用低温热塑性薄膜融合将复合部件连接到集成的结构的方法。预固结的热塑性复合(TCP)部件可以以最小表面加工并且以低于TCP部件的熔化温度的相对低的加工温度连接在一起。因此,避免预固结的TCP部件的不期望的软化或预熔化,从而允许部件的初始形状和质量被维持。该连接方法可以减小周期时间、材料和人工成本,同时消除粘结粘合剂、剥离层片、广泛的表面加工和检测、专业工艺装备和/或昂贵的粘合夹具的需要。该连接方法可以在低于500°F的温度且相对低的压力下使用用于处理热固性复合材料的标准技术在烤炉或高压锅中执行。因此,所公开的方法允许TPC部件在固化热固性部件所要求的加工温度下被连接到热固性复合部件。在飞行器工业中,例如但不限于,预固结的热塑性子结构和加强筋能够在较低的温度下与热塑性和/或热固性蒙皮连接,而不需要预熔化热塑性部件,从而允许热塑性部件的初始形状和质量被维持。该方法还可以允许TPC部件连接到混合层压件、金属、陶瓷和其它材料。可以通过使用所公开的非晶状热塑性薄膜连接热固性复合部件改善热固性复合结构的抗冲击性,该薄膜表现为可以吸收由撞击、冲击和/或振动引起的能量的融合的热塑性接合部的形式。
根据一个公开的实施例,提供一种连接两个热塑性部件的方法。该方法包含通过将第一非晶状热塑性薄膜放置在热塑性预浸材料的第一叠层上并且共固结第一非晶状热塑性薄膜和热塑性预浸材料的第一叠层产生第一热塑性复合部件,以及通过将第二非晶状热塑性薄膜放置在热塑性预浸材料的第二叠层上并且共固结第二非晶状热塑性薄膜和热塑性预浸材料的第二叠层产生第二热塑性复合部件。该方法进一步包含装配第一和第二热塑性复合部件,包括将第一和第二非晶状热塑性薄膜彼此紧贴放置,并且通过将压力施加到第一和第二热塑性复合部件而彼此紧贴按压第一和第二非晶状热塑性薄膜,第一和第二非晶状热塑性薄膜在低于大约475°F的温度下融合在一起。
根据另一公开的实施例,提供一种连接热塑性复合部件与热固性复合部件的方法,该方法包含通过共固结非晶状热塑性薄膜与半晶状热塑性预浸材料的叠层形成第一复合部件,以及形成包含热固性预浸材料的叠层的第二复合部件。该方法还包括装配第一部件和第二部件,包括紧贴热固性预浸材料的叠层放置非晶状热塑性薄膜,以及固化热固性预浸材料的叠层。
根据另一公开的实施例,提供一种将热塑性复合部件粘附至非热塑性部件的方法。该方法包含共固结非晶状热塑性薄膜与半晶状热塑性预浸材料的叠层,以及通过装配共固结的非晶状热塑性薄膜和具有非热塑性部件的热塑性预浸材料的叠层(包括紧贴非热塑性部件放置非晶状热塑性薄膜)形成组件。该方法进一步包括将压力施加到该组件以迫使非晶状热塑性薄膜紧贴非热塑性部件,以及将非晶状热塑性薄膜注入到非热塑性部件。
根据进一步的实施例,提供一种连接两个热固性复合部件的方法,该方法包含形成热固性预浸材料的第一叠层,以及形成热固性预浸材料的第二叠层。该方法进一步包括将热塑性薄膜放置在热固性预浸材料的第一叠层和第二叠层之间,以及共固结在一起且热共固化热固性预浸材料的第一叠层和第二叠层与热塑性薄膜。
根据另一实施例,提供一种复合结构,该复合结构包含第一和第二共固化的热固性复合层压件,以及共固化的热固性复合层压件之间的一层热塑性材料。
根据进一步公开的实施例,复合结构包含热塑性复合层压件、热固性复合层压件和连接热塑性复合层压件与热固性复合层压件的非晶状热塑性薄膜层。
根据又一实施例,提供一种使第一热塑性复合部件连接到第二热塑性复合部件的方法。该方法包含在超过大约650°F的第一温度以及在等于或大于大约100psi的第一压力下共固结第一非晶状热塑性薄膜和第一纤维增强的半晶状热塑性聚合物基复合结构,以形成包括第一非晶状热塑性富聚合物表面的第一热塑性复合部件。该方法还包含在超过大约650°F的第二温度且以及在等于或大约100psi的第二压力下共固结第二非晶状热塑性薄膜和第二纤维增强的半晶状热塑性聚合物基复合结构,以形成包括第二非晶状热塑性富聚合物表面的第二热塑性复合部件。该方法包括使第一热塑性复合部件的第一非晶状热塑性富聚合物表面和第二热塑性复合部件的第二非晶状热塑性富聚合物表面配合,以及在大约450°F和500°F之间的温度下加热第一热塑性复合部件和第二热塑性复合部件并且在大约14.7和150psi之间的压力下将第一热塑性复合部件和第二热塑性复合部件压缩在一起一段时间,直至充分粘合第一非晶状热塑性富聚合物表面和第二非晶状热塑性富聚合物表面,而不损害第一热塑性复合部件和第二热塑性复合部件。
根据又一实施例,提供一种使热塑性复合部件连接到未固化的热固性复合部件的方法。该方法包含在超过大约500°F的温度下且在等于或大于大约100psi的压力下共固结非晶状热塑性薄膜和纤维增强的半晶状热塑性聚合物基复合结构,以形成包括非晶状热塑性富聚合物表面的热塑性复合部件。该方法进一步包括使热塑性复合部件的非晶状热塑性富聚合物表面与未固化的热固性复合部件配合。该方法还包括在大约350°F的温度下加热第一热塑性复合部件和未固化的热固性复合部件并且在等于或小于大约100psi的压力下使第一热塑性复合部件和未固化的热固性复合部件相互偏置一段时间,直至充分固化未固化的热固性复合部件且粘合到第一非晶状热塑性富聚合物表面,而不损害第一热塑性复合部件。
特征、功能和优点能够在本公开的各种实施例中独立地实现或可以结合其它实施例被实现,其中参考具体实施方式和附图能够了解实施例的进一步的细节。
附图说明
在随附的权利要求中阐明说明性实施例的特性具有的新颖性特征。然而,当结合附图阅读时,通过参考本公开的说明性实施例的以下具体实施方式,说明性实施例以及其优选的使用模式、进一步目标和优点将被更好的理解。其中:
图1是集成的复合结构的图解视图的图示说明,该集成的复合结构具有通过非晶状热塑性薄膜连接在一起的热塑性复合部件。
图2是示出形成图1中示出的集成的复合结构的一部分的热塑性复合部件和非晶状热塑性薄膜中的一者之间的横截面界面的显微照片的图形。
图3是示出集成的复合结构的热塑性复合部件之间的融合的横截面界面的显微照片的图形。
图4-7是示出制造图1中示出的集成的复合结构的方法的步骤的横截面图解视图的图示说明。
图8是制造图1中示出的集成的复合结构的方法的流程图的图示说明。
图9是放置在预固结的热塑性复合蒙皮上的预固结的热塑性复合帽纵梁的横截面视图的图示说明。
图10是类似于图9的图示说明,但其示出已经放置在蒙皮上的帽纵梁和被安装用于将热塑性薄膜压缩在一起的工具。
图11是以两个预固结的热塑性复合蒙皮装配的预固结的热塑性复合I-横梁的横截面视图的图示说明。
图12是类似于图11的图示说明,但其示出已经装配的I-横梁和蒙皮,以及已经安装的工具。
图13是复合结构的图解视图的图示说明,该复合结构具有通过非晶状热塑性薄膜连接在一起的热塑性和热固性复合部件。
图14是制造图13中示出的复合结构的方法的流程图的图示说明。
图15是放置在预固结的热塑性复合蒙皮上的未固化的热固性复合帽纵梁的横截面视图的图示说明。
图16是类似于图15的图示说明,但其示出已经放置在蒙皮上的帽纵梁和被安装的工具。
图17是连接到热固性复合蒙皮的热塑性复合帽纵梁的横截面视图的图示说明,其还示出在固化期间用于维持蒙皮的形状的工具。
图18是连接到两个未固化的热固性复合蒙皮的预固结的热塑性复合I-横梁的横截面视图的图示说明。
图19是复合结构的图解视图的图示说明,该复合结构具有通过非晶状热塑性薄膜连接在一起的热塑性复合部件和非热塑性部件。
图20是制造图19中示出的复合结构的方法的流程图的图示说明。
图21是复合结构的图解视图的图示说明,该复合结构具有通过非晶状热塑性薄膜连接在一起的两个热固性复合部件。
图22是制造图21中示出的复合结构的方法的流程图的图示说明。
图23是飞行器生产和使用方法的流程图的图示说明。
图24是飞行器的框图的图示说明。
具体实施方式
所公开的实施例提供一种使用薄膜融合过程将热塑性复合(TPC)部件连接到另一部件的方法,该薄膜融合过程可以在相对低的加工温度下以最小表面加工执行。例如,参考图1-3,根据一个实施例,集成的TPC结构30包含通过融合的热塑性接合部31分别连接在一起的第一和第二TPC部件32、34。热塑性接合部31由非晶状热塑性薄膜36形成,该薄膜36在低于TPC部件32、34两者之一的熔点的加工温度下使第一和第二TPC部件32、34有效地融合在一起。如图3最优示出的,第一和第二TPC部件32、34中的每一者包含固结的热塑性复合层压件,其中纤维增强件48的层保持在热塑性树脂基39(图2)中。纤维增强件48可以包含单向或双向纤维,诸如但不限于,根据预限定的层片安排(未示出)以期望的纤维取向布置的玻璃纤维或碳纤维。如将在下面更详细讨论的,TPC部件32、34中的每一者可以由与非晶状热塑性薄膜36的层共固结的合适的热塑性预浸材料的叠层形成。
热塑性聚合物可以是非晶状的或半晶状的。非晶状热塑性聚合物在分子层次上大体缺乏位置顺序,而半晶状热塑性聚合物可以包含晶状区域和非晶状区域两者。热塑性聚合物的结晶度受结构、温度、分子量、立体化学和加工条件的影响。半晶状热塑性聚合物具有熔化温度Tm,在该温度下分子的有序区域破裂且变得无序。相比之下,在非晶状热塑性聚合物中,分子的非晶状区域在低于熔化温度Tm(被称为玻璃转化温度Tg)的相对宽的温度范围内软化。完全非晶状的热塑性聚合物不熔化,并且因此不具有熔化温度Tm。然而,所有热塑性聚合物均表现出玻璃转化温度Tg。根据所公开的实施例,树脂基39(图2)可以是半晶状热塑性聚合物,诸如但不限于聚芳醚酮(PAEK)一类的聚合物,仅举几个例子,包括但不限于聚醚醚酮(“PEEK”)和聚醚酮酮(“PEKK”)。包括上面刚提到的半晶状热塑性聚合物的树脂基39可以具有高于大约500°F(通常超过650°F)的熔化温度Tm。
非晶状热塑性薄膜36是可以具有高于大约140℃且低于大约500°F的玻璃转化温度Tg和适于应用的其它机械、热和物理性质的非晶状聚合物。所选定用作非晶状热塑性薄膜36的特定聚合物应当与半晶状热塑性聚合物树脂基39相容,并且应当在通常用于加工热塑性零件的温度下稳定,该温度例如但不限于从大约650°F到大约800°F。在一个实施例中,可以采用非晶状热塑性薄膜36,该薄膜表现出允许其与TPC部件32、34中的每一者的连接表面共固结的性质。非晶状热塑性薄膜36在或高于固结所要求的温度下(即,TPC部件的熔化温度Tm,其通常可以在从大约650°F到800°F之间的范围中)与TPC部件32、34中的每一者的连接表面共固结,以便准备下面讨论的第二连接过程的TPC部件32、34。非晶状热塑性薄膜36表现出在低于大约500°F的温度下通过将两个非晶状热塑性薄膜36融合在一起允许TPC部件32、34连接在一起的性质,从而避免在连接过程期间需要再熔化TPC部件32、34两者之一。通过避免在连接过程期间需要再熔化TPC部件32、34,可以维持TPC部件32、34的形状和质量。
在又一实施例中,稍后更详细讨论,可以使用非晶状热塑性薄膜36,该薄膜36表现出允许其将TPC基板连接到未固化的热固性预浸材料(未示出)的表面或连接到期望形状的热固性预浸材料上的环氧薄膜粘合剂(未示出)的层的性质。热塑性薄膜36在热固性预浸材料或环氧薄膜粘合剂的固化温度(该温度可以是例如但不限于,大约350°F)下将TPC基板连接到未固化的热固性预浸材料或连接到环氧薄膜粘合剂的层。非晶状热塑性薄膜36可以包含韧性、刚性、相对高温度的工程材料,诸如但不限于,具有良好的热稳定性和蠕变性能的合适等级的PES(聚醚砜)。非晶状热塑性薄膜36还具有在高达180℃的温度下承受负载长时间段的能力,以及在高达210℃的温度下保持机械性质的能力。
现同时参考图1-3,TPC部件32、34中的每一者包含由保持在半晶状热塑性基39中的增强件层48形成的TPC预浸材料的固结叠层。TPC部件32、34中的每一者包括由形成连接表面37(图2)的非晶状热塑性薄膜36覆盖且与其共固结的面33。非晶状热塑性薄膜36可以包含共固结在一起以形成适于特定应用的期望的厚度“t”的非晶状热塑性材料的一层或更多层。在一种应用中,例如但不限于,厚度“t”可以在大约5mm与7mm之间。
TPC部件面33中的每个因此富含可以填充面33中的任何裂缝、开口或空隙35的非晶状热塑性树脂。与TPC部件32、34的面33预固结的非晶状热塑性薄膜36可以是先前描述的类型。当TPC部件32、34的连接表面37(图2)面对面装配并按压在一起并且非晶状热塑性薄膜36如图3所示被融合在一起时,形成连接TPC部件32、34的融合的热塑性接合部31。
如将在下面解释的,非晶状热塑性薄膜36在预固结过程期间在半晶状树脂39的熔化温度Tm下分别与对应的TPC部件32、34固结。然而,通过将TPC结构30加热到高于非晶状热塑性薄膜36的玻璃转化温度Tg,但大体低于半晶状热塑性树脂39的熔化温度Tm,预固结的TPC部件32、34随后连接在一起。当装配TPC部件32、34时,非晶状热塑性薄膜36的附加层(未示出)可以被放置在连接表面37之间,以便引起制造和/或装配容差。薄膜36的这些附加层将与已经与TCP部件32、34预固结的薄膜层融合。
注意,现参考图4-7,其图形化地图示说明集成的TPC结构30(图1)的制造,该制造需要最小表面加工且可以使用常规烤炉、真空包装和/或高压锅加工而执行。如图4所示,在非晶状热塑性薄膜36a放置在叠层32a的面33上之前,装配半晶状TPC预浸材料的叠层32a。通过使用常规技术(诸如高压锅加工或烤炉内的真空袋加工),TPC预浸材料的装配的叠层32a和薄膜36a被加热到TPC预浸材料的至少熔化温度,同时承受固结压力。将TPC预浸材料加热到其熔化温度还软化非晶状热塑性薄膜36a,并且施加的压力导致TCP预浸材料的装配的叠层32a和薄膜36固结在一起,如图5所示。第二TCP部件34以如与上面刚描述的第一TCP部件32相同的方式装配和预固结。
如上所述,TPC部件32、34中的每一者已经被预固结,如图6所示通过放置由以面对面彼此接触的部件32、34上的非晶状热塑性薄膜36a、36b形成的连接表面37,装配TPC部件32、34。如图7所示,在两个TPC部件32、34已经装配在一起的情况下,它们然后被加热且承受固结压力。两个TPC部件32、34被加热到至少薄膜36a、36b的玻璃转化温度Tg,但大体低于半晶状TPC的熔化温度Tm的温度。例如,两个TPC部件32、34可以被加热到大于418°F和大约500°F之间的温度,其中薄膜36a、36b的玻璃转化温度Tg大约418°F。可以仅使用施加必需的固结压力所需要的工具执行与图4-7结合描述的连接过程,因为两个TPC部件32、34是预固结的且仅需要压缩和固结两个非晶状热塑性薄膜36a、36b的足够压力。
图8图示说明将第一和第二TPC部件32、34连接在一起的方法的整体步骤。在步骤38处开始,产生第一TPC部件32,如先前描述的,这包含共固结非晶状热塑性薄膜36a和半晶状TPC预浸材料的第一叠层32a。在步骤40处,产生第二TPC部件34,这包含共固结第二非晶状热塑性薄膜36b和半晶状TPC预浸材料的第二叠层32b。在步骤42处,通过将薄膜36a、36b的连接表面37以面对面接触的方式放置在一起,装配第一和第二TPC部件32、34。虽然图8中未示出,但非晶状热塑性薄膜36的附加层可以与连接表面37中的一者或两者共固结,其步骤38、40引起装配容差。然后,在44处,通过对第一和第二TPC部件32、34施加压力,将非晶状热塑性薄膜压缩在一起。最后,在步骤46处,通过将薄膜36a、36b加热到高于其玻璃转化温度Tg但低于大约500°F的温度的温度,将非晶状热塑性薄膜36a、36b融合在一起。
注意,现参考图9和图10,其示出使用先前描述的类型的非晶状热塑性薄膜连接两个半晶状TPC部件的所公开的方法的一种典型应用。在该示例中,两个半晶状TPC部件分别包含帽型TCP纵梁50和TCP蒙皮56。在图示说明的示例中,纵梁50和蒙皮56大体上是直的,然而在另一些示例中,根据应用,纵梁50和蒙皮56可以具有一个或更多个弯曲部或轮廓。纵梁50包括一对横向延伸的凸缘52、54,非晶状热塑性薄膜36a在类似于先前结合图4-8描述的制造过程中预固结到上述凸缘。类似地,一对隔开的非晶状热塑性薄膜36b与和凸缘52、54对齐的蒙皮56预固结。
纵梁50和蒙皮56均已经与其相应的薄膜36a、36b预固结,纵梁50然后被放置54在蒙皮56上,以便非晶状热塑性薄膜36a、36b对齐并且彼此面对面接触。
特别地,参考图10,简易的上部和下部工具58、60被分别放置在凸缘52、54和蒙皮56的底部上,以准备执行第二连接过程,其中通过使薄膜36a、36b融合在一起,纵梁50被连接到蒙皮56。这里应当观察到,上部和下部工具58、60仅需要接触非晶状热塑性薄膜36a、36b位于的区域中的凸缘52、54和蒙皮56。
薄膜36a、36b被加热到低于大约500°F、但至少到其玻璃转化温度Tg的温度,该Tg低于完全固结的半晶状TPC纵梁50和蒙皮56的熔化温度Tm。该加热可以通过将装配的纵梁50和蒙皮56放置在高压锅或烤炉中实现,尽管使用红外线加热、加热的工具或其它技术可能在薄膜36a、36b的区域中施加局部热。当上部和下部工具58、60被加热到高于其玻璃转化温度Tg时,通过由任何合适的工具施加的固结压力62,将上部和下部工具58、60压在一起,以便将薄膜36a、36b压缩在一起并且从而将它们融合。通过使用机械手段(诸如压力机(未示出)或真空包装和/或高压锅压力),必需的固结压力62可以被施加到工具58、60。将两个薄膜36a、36b固结在一起可以需要相对低水平的压力(例如,等于或小于大约100psi)。
图11和图12图示说明使完全固结的半晶状TPC I-横梁64与两个半晶状TPC蒙皮56a、56b连接的方法的另一应用。I-横梁64中的每一个包括由中心腹板66连接的一对隔开的凸缘或盖帽68。如图11最优示出的,根据所公开的方法,I-横梁64和蒙皮56a、56b被预制造并且然后在第二连接操作中以相对低的加工温度和压力被连接在一起。在非晶状热塑性薄膜36a被放置在盖帽68中的每一个的上方之前,通过铺设和形成TPC预浸材料,I-横梁64中的每一个被预制造。如先前描述的,薄膜36a然后与横梁64共固结,其中TPC I-横梁铺层被加热到其熔化温度(通常大约650°F或更高),并且固结压力通过合适的工具(未示出)施加,以便TPC铺层与非晶状热塑性薄膜36a一起固结。半晶状TPC蒙皮56a、56b以类似的方式制造。使用TPC预浸材料的叠层铺设蒙皮56a、56b,并且非晶状热塑性薄膜36b在横梁64连接到蒙皮56a、56b的位置处被应用到蒙皮56a、56b。通过将TPC预浸材料铺层和薄膜36b加热到TPC预浸材料的熔化温度,蒙皮56a、56b和薄膜36b然后共固结,其中TPC预浸材料承受使用任何合适的工具施加的固结压力。这里应当注意,虽然I-横梁64被示为连接到一对蒙皮56a、56b,但在另一些示例中,I-横梁64可以连接到仅单个蒙皮56。此外,通过使用所公开的方法和非晶状热塑性薄膜36,具有其它横截面形状的复合横梁的盖帽、凸缘或其它表面可以连接到一个或更多个复合蒙皮。
特别地,参考图12,类似于图9和图10中示出的应用,通过使用相对简易的上部和下部工具70、72,I-横梁64可以连接到蒙皮56a、56b以将固结压力76施加到装配的I-横梁64和蒙皮56a、56b。通过使用机械手段(诸如,压力机(未示出)、真空包装和/或高压锅加工),固结压力76可以被施加到工具70、72。必需的加热可以使用热的局部应用或在烤炉或高压锅内实现。由于I-横梁64和蒙皮56a、56b被预固结,因此仅需要足够的施加压力以影响半晶状热塑性薄膜36a、36b的固结,该压力例如等于或小于大约100psi。类似地,由于I-横梁64和蒙皮56a、56b已经被预固结,因此不需要将固结的半晶状TPC预加热到其熔化温度,而仅需要将薄膜36a、36b加热到其低于大约475°F的玻璃转化温度。进一步地,由于I-横梁64和蒙皮56a、56b两者被预固结,因此形成或固结I-横梁64或蒙皮56a、56b中任一者不需要昂贵和/或复杂的工具。任选地,将侧部工具74提供在腹板66的每一侧上,以便避免腹板66的不期望的变形且/或通过I-横梁64将施加的负载更有效地传递到薄膜36a、36b之间的界面是可以期望的。
现参考图13,通过在热固性复合部件82的固化温度下将半晶状TPC部件80连接到热固性复合部件82,采用非晶状热塑性薄膜84的所公开的连接方法可以用于制造复合结构78。通常,热固性复合部件82固化的温度低于半晶状TPC部件80的玻璃转化温度Tg,通常小于大约400°F。非晶状热塑性薄膜84在半晶状TPC部件80的固化温度下保持玻璃状。形成半晶状TPC部件80的基的树脂在固化期间达到最小粘度,并且具有朝向非晶状热塑性薄膜84的非常好的亲和力。由于该亲和力,热固性树脂使非晶状热塑性薄膜84的表面变湿。在固化后,在非晶状热塑性薄膜84和半晶状TPC部件80的热固性树脂之间获得强粘合,从而在半晶状TPC部件80和热固性部件82之间产生融合的热塑性接合部31。在一些实施例中,可以发生热固性树脂到非晶状热塑性薄膜84内的一些分配,这可以增强粘合。
图14图示说明连接TPC部件80与热固性部件82的方法的整体步骤。在步骤86处开始,第一复合部件80通过共固结非晶状热塑性薄膜36和TPC预浸材料的叠层形成。在步骤88处,第二复合部件82通过(例如)铺设热固性复合预浸材料的叠层形成。热固性复合预浸材料可以包含,例如但不限于热固性树脂,诸如以单向或双向纤维(诸如碳纤维)增强的环氧树脂,然而,其它热固性树脂和纤维材料也是可能的。通常,热固性树脂可以具有低于大约400°F的固化温度,例如大约350°F。
在步骤90处,通过紧贴热固性复合预浸材料的叠层放置TPC部件80的非晶状热塑性薄膜36,装配第一和第二复合部件80、82。虽然图14中未示出,但非晶状热塑性薄膜36的附加层任选地可以被放置在热固性复合预浸材料的叠层上。薄膜36的这种附加层稍后与先前已经与TPC预浸材料的叠层共固结的薄膜36融合在一起。薄膜36的这种附加层可以用于补偿固结期间出现的制造和/或装配容差和/或失配问题,从而假定融合的热塑性接合部31是连续的且在整个部分具有预选厚度。在步骤92处,通过将热固性预浸材料和TPC部件82一起加热到热固性树脂的固化温度,热固性复合预浸材料的叠层被固化。在该固化温度下,热固性树脂朝向玻璃状非晶状热塑性薄膜36的亲和力导致形成融合的热塑性接合部31,该接合部31在TPC部件80和固化的热固性复合部件82之间形成。因此,可以认识到,在步骤92处热固性复合预浸材料的固化期间,预固结的TPC部件80不再熔化,因为热固性树脂的固化温度小于TPC部件80的熔化温度Tm。
图15和图16图示说明使用融合的热塑性接合部31将预固结的TPC部件连接到热固性复合部件的方法的一种应用,该接合部31在如结合图13和图14先前描述的热固性复合部件的固化期间形成。在该示例中,由热固性复合材料(诸如但不限于碳纤维环氧树脂)形成的帽纵梁94连接到包含TPC预浸材料的预固结的叠层48的预固结的TPC蒙皮98。帽纵梁94包括横向延伸的凸缘96。非晶状热塑性薄膜36在对应于将凸缘96放置在蒙皮98上的位置处共固结在蒙皮98的表面上。非晶状热塑性薄膜36可以是先前描述的类型且被选择以适合用于制造纵梁94的热固性复合材料的固化温度。热固性复合帽纵梁94可以包含纤维增强的热固性树脂的多层叠层,该热固性树脂被铺放且形成期望形状的帽纵梁94。未固化的帽纵梁94然后被放置100在预固结的TPC蒙皮98上,其中凸缘96与薄膜36以面对面接触。
特别地,现参考图16,具有配合纵梁94的外模线的腔的工具102被放置在纵梁94上方,并且可移动心轴104可以被放置在纵梁94内,以便在固化过程期间对施加到帽纵梁94的固结力106起反作用。在固化期间,工具102与心轴104一起协助维持帽纵梁94的形状。通过使用常规高压锅或除高压锅外的加工技术,帽纵梁94和蒙皮98的装配承受热和压力的组合。在固化期间,热固性纵梁94被加热到热固性树脂的固化温度,该固化温度可以是大约350°F。在固化期间,固化温度足以引起非晶状热塑性薄膜36变成玻璃状且与粘性热固性树脂融合,从而在纵梁94和蒙皮98之间形成融合的热塑性接合部31。在固化过程期间,TPC蒙皮98维持其形状并且不会分层或使期望的质量变松,因为其在热固性纵梁94的固化所需要的相对低的温度下不再熔化。
图17图示说明使用非晶状热塑性薄膜36以在两个复合部件之间形成融合的热塑性接合部31的公开的连接方法的又一种应用。在该示例中,预固结的TPC层压件帽纵梁108通过薄膜36连接到热固性复合层压件蒙皮112。简易的上部工具114用于对纵梁108的凸缘110施加压力118,以便在固化期间迫使薄膜36紧贴热固性复合蒙皮112被预固结在凸缘110上。可以在固化过程期间采用下部工具116以维持热固性复合蒙皮112的形状。另外,可以将内部心轴状工具104放置在纵梁108的内侧,支承在热固性复合蒙皮112上,以便在固结和固化期间将固结压力传送到纵梁108的帽部分108a下方的蒙皮112。在固化期间,热固性复合蒙皮112被加热到其固化温度(通常大约350°F,该温度足以引起薄膜36变成玻璃状且与蒙皮112的粘性热固性树脂融合),从而形成强的、稳健的、融合的热塑性接合部31。
图18图示说明公开的方法的另一种应用,其中通过使用先前描述的非晶状热塑性薄膜36,TCP I-横梁120连接到热固性复合蒙皮112a、112b。该应用类似于先前结合图11和图12描述的应用。然而,在该示例中,附加工具可以用于在固化过程期间维持蒙皮112a、112b的形状,其中蒙皮112a、112b的热固性树脂变粘且与玻璃状非晶状热塑性薄膜36融合。附加工具包含共同啮合并包含蒙皮112a、112b的表面的上部和下部工具126、128,中心工具130和外部工具132。侧部工具134也可以定位在腹板122的相对侧上,以便避免腹板122的不期望的变形,且在固化期间有助于分配施加到非晶状热塑性薄膜36的固结力。
虽然先前描述的应用涉及将TPC部件连接到热固性复合部件,但也许可以采用公开的方法将TPC部件连接到由其它材料(诸如但不限于,金属和陶瓷)形成的部件。因此,参考图19,可以采用先前描述的非晶状热塑性薄膜36以制造复合结构136,该复合结构包括在TCP部件138和由非热塑性材料(诸如但不限于,金属或陶瓷)形成的部件140之间形成的融合的热塑性接合部31。
在步骤142处开始,非晶状热塑性薄膜36与半晶状TPC预浸材料的叠层共固结。在144处,通过紧贴非热塑性部件140放置共固结的非晶状热塑性薄膜36,使用非热塑性部件140装配共固结的TPC预浸材料和薄膜36。在步骤146处,压力被施加到共固结的TPC叠层/薄膜和非热塑性部件140的组件上,以便紧贴非热塑性部件140压薄膜36。在步骤148处,非晶状塑料薄膜36被加热到低于大约500°F但至少到其玻璃转化温度的温度,从而引起其流动。流动的薄膜36在预固结的TCP部件138和非热塑性部件140之间形成融合的热塑性接合部31。
图21图示说明公开的方法的另一种应用,其中采用非晶状热塑性薄膜36制造可以具有改善的粘结线厚度一致性和/或韧性的热固性复合结构150。非晶状热塑性薄膜36用于在两个热固性复合部件152之间产生融合的热塑性接合部31。可以通过图22中示出的方法产生热固性复合结构150。在步骤156、158处,分别形成热固性预浸材料的第一和第二叠层。在步骤160处,非晶状热塑性薄膜36被放置在未固化的热固性预浸材料的第一和第二叠层的连接表面之间。在步骤162处,热固性预浸材料的第一和第二叠层与非晶状热塑性薄膜一起固结和热共固化。在固化过程期间,预浸材料和薄膜被加热到热固性树脂的固化温度,通常大约350°F,在该温度下非晶状热塑性薄膜36变成玻璃状且与粘性热固性树脂融合。由真空包装或高压锅加工施加的固结压力迫使热固性预浸材料的两个叠层紧贴薄膜36,以有助于热固性树脂与热塑性薄膜融合。因为非晶状热塑性薄膜36能够以受控的厚度预加工,融合的热塑性接合部31可以具有既一致又可以受控的粘结线厚度。相比于依赖粘结粘合剂的接合部,热塑性接合部31还可以表现出改善的韧性。进一步地,非晶状热塑性薄膜36可以被选择成具有可以小于热固性复合部件152、154的硬度的期望硬度,从而允许融合的热塑性接合部31更好地吸收由于复合结构经历的冲击、振动和/或撞击而产生的能量。因此,热塑性复合结构150可以表现出改善的抗冲击性。
本公开的实施例可以发现在各种潜在应用中使用,特别是在运输工业中,包括例如航通航天、海运、汽车应用和复合部件被连接在一起的其它应用。在飞行器工业中,公开的连接方法可以用于产生低成本、高性能的集成的结构,诸如各种横截面形状的加强筋,用于门、飞行控制结构、机翼和机身结构的抗扭翼盒。因此,现参考图23和图24,本公开的实施例可以用在如图23所示的飞行器制造和使用方法164和如图24所示的飞行器166的背景下。在预生产期间,示例性方法164可以包括飞行器166的规格和设计168以及材料采购170。在生产期间,发生飞行器166的部件和子组件制造172和系统集成174。此后,飞行器166可以经历认证和交付176,以便投入使用178。当由顾客使用时,飞行器166被安排日常维护和保养180,这也可以包括修改、重新配置、翻新等。
方法164的每个过程可以由系统集成商、第三方和/或操作者(例如,顾客)来执行或实施。为了本描述的目的,系统集成商可以包括但不限于任何数量的飞行器制造商和主系统分包商;第三方可以包括但不限于任何数量的销售商、分包商和供应商;并且操作者可以是航空公司、租赁公司、军事实体、服务组织等。
如图24所示,由示例性方法164生产的飞行器166可以包括具有多个系统184的机身182和内部186。高水平系统184的示例包括推进系统188、电气系统190、液压系统192和环境系统194中的一个或更多个。可以包括任何数量的其它系统。虽然示出航空航天示例,但本公开的原则可以应用到其它工业,诸如海运和汽车工业。
可以在生产和使用方法164的任一或更多个阶段期间采用本文呈现的系统和方法。例如,对应于生产过程172的部件或子组件可以以类似于当飞行器166投入使用时生产的部件或子组件的方式被制造或生产。另外,一个或更多个装置实施例、方法实施例或其组合可以在生产阶段172和174期间被利用,例如,通过大体加速飞行器166的装配或降低飞行器166的成本。类似地,当飞行器166投入使用时,装置实施例、方法实施例或其组合中的一个或更多个可以被利用,例如但不限于维护和保养180。
为了说明和描述的目的,不同的说明性实施例的描述已被呈现,并且不意在详尽或限制公开形式的实施例。许多修改和变体对本领域普通技术人员将是显而易见的。进一步地,不同的说明性实施例相比于其它说明性实施例可以提供不同的优点。为了更好地解释实施例的原则、实际应用并且为了确保本领域其他普通技术人员理解具有不同修改的各种实施例的本公开适合于预期的特定用途,选择和描述选定的一个或多个实施例。
Claims (36)
1.一种连接两个热塑性部件的方法,其包含:
通过将第一非晶状热塑性薄膜放置在热塑性预浸材料的第一叠层上且共固结所述第一非晶状热塑性薄膜和热塑性预浸材料的所述第一叠层,产生第一热塑性复合部件;
通过将第二非晶状热塑性薄膜放置在热塑性预浸材料的第二叠层上且共固结所述第二非晶状热塑性薄膜和热塑性预浸材料的所述第二叠层,产生第二热塑性复合部件;
装配所述第一热塑性复合部件和所述第二热塑性复合部件,其包括彼此紧贴放置所述第一非晶状热塑性薄膜和所述第二非晶状热塑性薄膜;
通过对所述第一热塑性复合部件和所述第二热塑性复合部件施加压力,彼此紧贴压所述第一非晶状热塑性薄膜和所述第二非晶状热塑性薄膜;以及
在低于大约475°F的温度下使所述第一非晶状热塑性薄膜和所述第二非晶状热塑性薄膜融合在一起。
2.根据权利要求1所述的方法,其中产生所述第一热塑性复合部件包括:
紧贴热塑性预浸材料的所述第一叠层的连接表面放置所述第一非晶状热塑性薄膜,以及
共固结所述第一非晶状热塑性薄膜和热塑性预浸材料的所述第一叠层包括将热塑性预浸材料的所述第一叠层加热到其所述第一叠层中的所述预浸材料的熔化温度并且压缩热塑性预浸材料的所述第一叠层和所述第一非晶状热塑性薄膜。
3.根据权利要求1或2所述的方法,其中共固结所述第二非晶状热塑性薄膜和热塑性预浸材料的所述第二叠层包括:
将所述第二非晶状热塑性薄膜加热到其玻璃转化温度,
将所述第二热塑性预浸材料加热到其熔化温度,以及
压缩热塑性预浸材料的所述第二叠层和所述第二非晶状热塑性薄膜。
4.根据权利要求2所述的方法,其中将热塑性预浸材料的所述第一叠层加热到其熔化温度包括将热塑性预浸材料的所述第一叠层加热到大于大约650°F的温度。
5.根据任意前述权利要求所述的方法,其中:
所述第一热塑性预浸材料和所述第二热塑性预浸材料中的每一者是半晶状的,以及
所述第一非晶状热塑性薄膜和所述第二非晶状热塑性薄膜中的每一者是PES。
6.根据任意前述权利要求所述的方法,其中所述第一热塑性预浸材料和所述第二热塑性预浸材料中的每一者是PEEK、PEKK和PPS中的一者。
7.根据任意前述权利要求所述的方法,其中所述第一非晶状热塑性薄膜和所述第二非晶状热塑性薄膜中的每一者具有在大约5mm和7mm之间的厚度。
8.一种集成的热塑性结构,其具有由任一前述权利要求的方法连接的热塑性部件。
9.一种连接热塑性复合部件与热固性复合部件的方法,其包含:
通过共固结非晶状热塑性薄膜和半晶状热塑性预浸材料的叠层,形成第一复合部件;
形成包括热固性预浸材料的叠层的第二复合部件;
装配所述第一部件和所述第二部件,其包括紧贴热固性预浸材料的所述叠层放置所述非晶状热塑性薄膜;以及
固化热固性预浸材料的所述叠层。
10.根据权利要求9所述的方法,其中:
共固结所述非晶状热塑性薄膜和半晶状热塑性预浸材料的所述叠层包括:
紧贴半晶状热塑性预浸材料的所述叠层上的连接表面放置所述非晶状热塑性薄膜,
将半晶状热塑性预浸材料的所述叠层加热到其熔化温度,
将所述非晶状热塑性薄膜加热到其玻璃转化温度;以及
压缩所述非晶状热塑性薄膜和半晶状热塑性预浸材料的所述叠层,
以及
固化热固性预浸材料的所述叠层包括将热固性预浸材料的所述叠层加热到足以固化所述热塑性预浸材料的温度。
11.根据权利要求9或权利要求10所述的方法,其中通过在低于大约400°F的温度下热固化,来执行固化热固性预浸材料的所述叠层。
12.根据权利要求9到11中任一项所述的方法,包括在所述热固性预浸材料的固化温度下,使所述非晶状热塑性薄膜和热固性预浸材料的所述叠层融合。
13.根据权利要求9到12中任一项所述的方法,其中所述非晶状热塑性薄膜是PES。
14.根据权利要求9到13中任一项所述的方法,进一步包含:
将所述非晶状热塑性薄膜和半晶状热塑性预浸材料的叠层压缩在一起。
15.根据权利要求9到14中任一项所述的方法,进一步包含:
将非晶状热塑性薄膜放置在热固性预浸材料的所述叠层上,并且
其中装配所述第一部件和所述第二部件包括紧贴热固性预浸材料的所述叠层上的非晶状热塑性薄膜将所述非晶状热塑性薄膜放置所述第一复合部件上。
16.根据权利要求9到15中任一项所述的方法,其中:
所述非晶状热塑性薄膜是PES,并且
所述热固性预浸材料是聚芳醚酮。
17.根据权利要求9到16中任一项所述的方法,其中将半晶状热塑性预浸材料的所述叠层加热到其熔化温度包括将半晶状热塑性预浸材料的所述叠层加热到至少大约650°F的温度。
18.一种复合结构,其由权利要求9到17中任一项的连接方法产生。
19.一种使热塑性复合部件粘附到非热塑性部件的方法,其包含:
共固结非晶状热塑性薄膜和半晶状热塑性预浸材料的叠层;
通过装配所述共固结的非晶状热塑性薄膜和具有非热塑性部件的热塑性预浸材料的叠层形成组件,包括紧贴所述非热塑性部件放置所述非晶状热塑性薄膜;
对所述组件施加压力以迫使所述非晶状热塑性薄膜紧贴所述非热塑性部件;以及
使所述非晶状热塑性薄膜融合到所述非热塑性部件。
20.根据权利要求19所述的方法,其中通过将所述非晶状热塑性薄膜加热到低于大约475°F的温度,执行所述融合。
21.根据权利要求19或权利要求20所述的方法,其中所述共固结通过以下方式被执行:
将所述非晶状热塑性薄膜和半晶状热塑性预浸材料的所述叠层加热到所述半晶状热塑性预浸材料的至少所述熔化温度,以及
将所述非晶状热塑性薄膜和半晶状热塑性预浸材料的所述叠层压缩在一起。
22.根据权利要求19到21中任一项所述的方法,其中所述非晶状热塑性薄膜是PES。
23.根据权利要求19到22中任一项所述的方法,其中所述非热塑性部件是以下其中之一:
热固性复合材料,
金属,和
陶瓷。
24.一种连接两个热固性复合部件的方法,其包含:
形成热固性预浸材料的第一叠层;
形成热固性预浸材料的第二叠层;
将热塑性薄膜放置在热固性预浸材料的所述第一叠层和所述第二叠层之间;以及
将热固性预浸材料的所述第一叠层和所述第二叠层与所述热塑性薄膜固结在一起并且将其热共固化。
25.根据权利要求24所述的方法,其中所述热塑性薄膜是非晶状的且在热固性预浸材料的所述第一叠层和所述第二叠层的固化温度处变成玻璃状。
26.根据权利要求24或权利要求25所述的方法,其中所述热塑性薄膜是PES。
27.根据权利要求24到26中任一项所述的方法,其中通过将热固性预浸材料的所述第一叠层和所述第二叠层以及所述热塑性薄膜加热到小于大约500°F的温度,执行所述热共固化。
28.一种复合结构,其具有由权利要求24到26中任一项的方法连接的两个热固性复合部件。
29.一种具有改善的抗冲击性的复合结构,其包含:
第一共固化的热固性复合层压件和第二共固化的热固性复合层压件;和
所述共固化的热固性复合层压件之间的一层热塑性材料。
30.一种复合结构,其包含:
热塑性复合层压件;
热固性复合层压件;和
使所述热塑性复合层压件与所述热固性复合层压件连接的非晶状热塑性薄膜层。
31.一种将第一热塑性复合部件连接到第二热塑性复合部件的方法,其包含:
在超过大约650°F的第一温度下且在等于或大于大约100psi的第一压力下,共固结第一非晶状热塑性薄膜和第一纤维增强的半晶状热塑性聚合物基复合结构,以形成包括第一非晶状热塑性富聚合物表面的所述第一热塑性复合部件;
在超过大约650°F的第二温度下且在等于或大于大约100psi的第二压力下,共固结第二非晶状热塑性薄膜和第二纤维增强的半晶状热塑性聚合物基复合结构,以形成包括第二非晶状热塑性富聚合物表面的所述第二热塑性复合部件;
使所述第一热塑性复合部件的所述第一非晶状热塑性富聚合物表面和所述第二热塑性复合部件的所述第二非晶状热塑性富聚合物表面配合;以及
在大约450°F和500°F之间的温度下加热所述第一热塑性复合部件和所述第二热塑性复合部件且在大约14.7psi和150psi之间的压力下将所述第一热塑性复合部件和所述第二热塑性复合部件压缩在一起一段时间,直至充分粘合所述第一非晶状热塑性富聚合物表面和所述第二非晶状热塑性富聚合物表面,而不损害所述第一热塑性复合部件和所述第二热塑性复合部件。
32.根据权利要求31所述的方法,其中在大约450°F和500°F之间的温度下,在高压烤炉中执行所述第一热塑性复合部件和所述第二热塑性复合部件加热的步骤,且在大约14.7psi和150psi之间的压力下,在高压烤炉中执行所述第一热塑性复合部件和所述第二热塑性复合部件压缩在一起的步骤。
33.根据权利要求31或权利要求32所述的方法,其中在大约450°F和500°F之间的温度下,使用烤炉和真空袋执行所述第一热塑性复合部件和所述第二热塑性复合部件加热的步骤,且在大约14.7psi和150psi之间的压力下,使用烤炉和真空袋执行所述第一热塑性复合部件和所述第二热塑性复合部件压缩在一起的步骤。
34.根据权利要求31到33中任一项所述的方法,其中在大约460°F和500°F之间的温度下,使用烤炉和机械压力执行所述第一热塑性复合部件和所述第二热塑性复合部件加热的步骤,且在大约14.7psi和150psi之间的压力下,使用烤炉和机械压力执行所述第一热塑性复合部件和所述第二热塑性复合部件相互偏置的步骤。
35.一种将热塑性复合部件连接到未固化的热固性复合部件的方法,所述方法包含:
在超过大约500°F的温度下且在等于或大于大约100psi的压力下,共固结非晶状热塑性薄膜和纤维增强的半晶状热塑性聚合物基复合结构,以形成具有非晶状热塑性富聚合物表面的热塑性复合部件;
使所述热塑性复合部件的所述非晶状热塑性富聚合物表面和所述未固化的热固性复合部件配合;以及
在大约350°F的温度下加热且在等于或小于100psi的压力下相互偏置所述热塑性复合部件和所述未固化的热固性复合部件一段时间,直至足以固化所述未固化的热固性复合部件且粘合到所述非晶状热塑性富聚合物表面,而不损害所述热塑性复合部件。
36.根据权利要求35所述的方法,其中所述未固化的热固性复合部件包括热固性环氧树脂基且所述非晶状热塑性薄膜可与其相容。
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- 2013-10-16 JP JP2015545045A patent/JP6411359B2/ja active Active
- 2013-10-16 CN CN201380062049.3A patent/CN104822511A/zh active Pending
- 2013-10-16 WO PCT/US2013/065238 patent/WO2014088704A2/en active Application Filing
- 2013-10-16 EP EP13783208.5A patent/EP2931497B1/en active Active
- 2013-10-16 CA CA2888974A patent/CA2888974C/en active Active
- 2013-10-16 BR BR112015012036-9A patent/BR112015012036B1/pt active IP Right Grant
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Cited By (5)
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CN106313517A (zh) * | 2015-07-07 | 2017-01-11 | 中国科学院高能物理研究所 | 一种尼龙膜、尼龙膜的焊接方法及乙烯丙烯酸共聚物膜在尼龙膜焊接中的应用 |
CN108794786A (zh) * | 2017-05-01 | 2018-11-13 | 波音公司 | 用热塑性薄膜涂层固化的复合材料 |
CN108794786B (zh) * | 2017-05-01 | 2022-09-06 | 波音公司 | 用热塑性薄膜涂层固化的复合材料 |
CN111491617A (zh) * | 2017-09-29 | 2020-08-04 | 森玛治疗公司 | 细胞容纳装置 |
CN110014713A (zh) * | 2018-01-09 | 2019-07-16 | 波音公司 | 具有紫外线防护的热塑性复合层压材料及形成其的方法 |
Also Published As
Publication number | Publication date |
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EP2931497A2 (en) | 2015-10-21 |
BR112015012036B1 (pt) | 2021-09-08 |
KR20150091309A (ko) | 2015-08-10 |
WO2014088704A3 (en) | 2015-01-15 |
JP6411359B2 (ja) | 2018-10-24 |
JP2015536265A (ja) | 2015-12-21 |
BR112015012036A8 (pt) | 2019-10-01 |
EP2931497B1 (en) | 2021-03-24 |
WO2014088704A2 (en) | 2014-06-12 |
CA2888974C (en) | 2020-12-15 |
BR112015012036A2 (pt) | 2017-07-11 |
CA2888974A1 (en) | 2014-06-12 |
US20150298388A1 (en) | 2015-10-22 |
KR102248479B1 (ko) | 2021-05-06 |
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