CN105221294A - 用于喷气式发动机反推装置的热成形叶栅 - Google Patents

用于喷气式发动机反推装置的热成形叶栅 Download PDF

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CN105221294A
CN105221294A CN201510249918.4A CN201510249918A CN105221294A CN 105221294 A CN105221294 A CN 105221294A CN 201510249918 A CN201510249918 A CN 201510249918A CN 105221294 A CN105221294 A CN 105221294A
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blade
thermoplastic
strong plate
curing
instrument
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CN105221294B (zh
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A·W·巴特尔
R·D·莫罗
A·J·斯科特
A·D·屈罗多
T·A·奥拉尼扬
L·J·英格兰
R·D·威尔克森
R·L·维斯特博格
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Boeing Co
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/50General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/63Internally supporting the article during joining
    • B29C66/634Internally supporting the article during joining using an inflatable core
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00Moulds or cores; Details thereof or accessories therefor
    • B29C33/44Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
    • B29C33/48Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles with means for collapsing or disassembling
    • B29C33/50Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles with means for collapsing or disassembling elastic or flexible
    • B29C33/505Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles with means for collapsing or disassembling elastic or flexible cores or mandrels, e.g. inflatable
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00Moulds or cores; Details thereof or accessories therefor
    • B29C33/44Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
    • B29C33/48Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles with means for collapsing or disassembling
    • B29C33/485Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles with means for collapsing or disassembling cores or mandrels
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00Moulds or cores; Details thereof or accessories therefor
    • B29C33/44Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
    • B29C33/52Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles soluble or fusible
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/14Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles in several steps
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C53/00Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/80Component parts, details or accessories; Auxiliary operations
    • B29C53/82Cores or mandrels
    • B29C53/821Mandrels especially adapted for winding and joining
    • B29C53/822Single use mandrels, e.g. destructible, becoming part of the wound articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C53/00Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/80Component parts, details or accessories; Auxiliary operations
    • B29C53/82Cores or mandrels
    • B29C53/821Mandrels especially adapted for winding and joining
    • B29C53/824Mandrels especially adapted for winding and joining collapsible, e.g. elastic or inflatable; with removable parts, e.g. for regular shaped, straight tubular articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/40General 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
    • B29C66/49Internally supporting the, e.g. tubular, article during joining
    • B29C66/494Internally supporting the, e.g. tubular, article during joining using an inflatable core
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06Fibrous reinforcements only
    • B29C70/08Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/081Combinations of fibres of continuous or substantial length and short fibres
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/30Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B29C70/342Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using isostatic pressure
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29DPRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00Subject matter not provided for in other groups of this subclass
    • B29D99/001Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
    • B29D99/0014Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings provided with ridges or ribs, e.g. joined ribs
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01DNON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12Blades
    • F01D5/28Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/282Selecting composite materials, e.g. blades with reinforcing filaments
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02KJET-PROPULSION PLANTS
    • F02K1/00Plants characterised by the form or arrangement of the jet pipe or nozzle; Jet pipes or nozzles peculiar thereto
    • F02K1/54Nozzles having means for reversing jet thrust
    • F02K1/56Reversing jet main flow
    • F02K1/62Reversing jet main flow by blocking the rearward discharge by means of flaps
    • F02K1/625Reversing jet main flow by blocking the rearward discharge by means of flaps the aft end of the engine cowling being movable to uncover openings for the reversed flow
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02KJET-PROPULSION PLANTS
    • F02K1/00Plants characterised by the form or arrangement of the jet pipe or nozzle; Jet pipes or nozzles peculiar thereto
    • F02K1/54Nozzles having means for reversing jet thrust
    • F02K1/64Reversing fan flow
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02KJET-PROPULSION PLANTS
    • F02K1/00Plants characterised by the form or arrangement of the jet pipe or nozzle; Jet pipes or nozzles peculiar thereto
    • F02K1/54Nozzles having means for reversing jet thrust
    • F02K1/64Reversing fan flow
    • F02K1/70Reversing fan flow using thrust reverser flaps or doors mounted on the fan housing
    • F02K1/72Reversing fan flow using thrust reverser flaps or doors mounted on the fan housing the aft end of the fan housing being movable to uncover openings in the fan housing for the reversed flow
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32Component parts, details or accessories; Auxiliary operations
    • B29C43/36Moulds for making articles of definite length, i.e. discrete articles
    • B29C2043/3665Moulds for making articles of definite length, i.e. discrete articles cores or inserts, e.g. pins, mandrels, sliders
    • B29C2043/3668Moulds for making articles of definite length, i.e. discrete articles cores or inserts, e.g. pins, mandrels, sliders destructible or fusible
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2101/00Use of unspecified macromolecular compounds as moulding material
    • B29K2101/12Thermoplastic materials
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0872Prepregs
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
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    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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  • Mechanical Engineering (AREA)
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Abstract

本发明提供用于喷气式发动机反推装置的热成形叶栅。用于喷气式发动机反推装置的叶栅通过共固化预共固化的热塑强固板和叶片来制造。所述强固板利用连续纤维来增强,而所述叶片利用不连续纤维来增强。

Description

用于喷气式发动机反推装置的热成形叶栅
技术领域
本公开总体上涉及用于喷气式发动机的反推装置,并且更具体地涉及叶栅(cascade)型反推装置以及制造叶栅的方法。
背景技术
具有喷气式发动机的飞机通常配备有反推装置,其增加飞机着陆期间的阻力,由此缩减飞行器的速度。反推装置通过有效地逆转穿过喷气式发动机的废气的流动来增加阻力。在称为叶栅型的一类反推装置中,喷气式发动机舱上的转换整流罩(transcowl)向后平移以暴露由多个开放格板形成的叶栅。闭合阻流门致使穿过发动机的气流的旁路部分转向通过格板中的一连串周向排列的叶栅叶片,这些叶栅叶片被导向成向前重新定向气流,并由此产生反向推力。
制造叶栅格板耗时、劳动密集并由此而昂贵。当前叶栅格板利用纤维增强热固树脂来制造,其需要许多加工步骤和专门设备。例如,使用热固塑料需要融化预浸料坯、预固化强固板(strongback)、手工铺叠各个叶片、压塑成型以共同固化强固板至叶片,以及二次固化。
因此,需要这样一种用于喷气式发动机反推装置的叶栅,其构造简单并且生成起来不太昂贵。还需要一种制造叶栅的低成本方法,其缩减触摸劳力并且需要很少加工步骤和很少加工设备。
发明内容
本公开实施方式提供了一种供在反推装置中使用的轻质叶栅,其制造简单并且需要更少加工步骤来生成。复杂的、三维的、全热塑复合叶栅可以利用与不连续长纤维热塑复合格板共固化的连续纤维强固板来快速制造。该强固板可以与格板分开制造,由此改进制造流程。格板中的强固板和叶片可以被模制成任何希望形状,以便沿任何希望方向重新定向旁路空气。该格板可以单个地或者以模块化子组件组来制造。因为预固化的强固板和格板能以单个工件制造,所以它们可以被组合成具有开口槽的最终高温固化工具,以相对于各个格板的叶片准确地索引刚性强固板。利用组合的另选硬工具嵌件和可溶心轴可实现期望的索引。
根据一个公开实施方式,提供了一种用于喷气式发动机反推装置的叶栅。所述叶栅包括与多个叶片共固化的多个强固板。每一个所述强固板都由具有连续纤维增强的聚合物树脂形成。每一个所述叶片都由具有不连续纤维增强的聚合物树脂(如热塑性材料)形成。所述叶片可以以多个模块化叶片组件布置。所述不连续纤维增强包括随机取向的短纤维。所述强固板组件和所述叶片在彼此固化之前被预固化。所述强固板组件利用连续纤维来增强。
根据另一公开实施方式,提供了一种制造用于喷气式发动机反推装置的叶栅格板的方法。该方法包括以下步骤:制造多个热塑叶片,制造多个热塑强固板,以及共固化所述叶片和所述强固板。制造所述多个热塑叶片的步骤可以通过压塑成型利用不连续纤维增强的热塑树脂来执行。制造所述多个强固板的步骤可以通过连续压塑成型用连续纤维增强的热塑树脂来执行。所述共固化通过以下步骤来执行:将所述热塑叶片和所述热塑强固板装载到压塑成型工具中,加热所述热塑叶片和热塑强固板中的每一个,以及利用所述压塑成型工具共固化所述叶片和所述强固板,以对着所述热塑强固板压缩所述热塑叶片。将所述热塑叶片和所述热塑强固板装载到压塑成型工具中的步骤包括以下步骤:将一组硬工具嵌件放置到第一组叶片腔中,并且将一组可膨胀可溶心轴放置到第二组叶片腔中。所述方法还可以包括以下步骤:在所述叶片和所述强固板已经共固化之后将其冷却,并且从所述压塑成型工具去除所述叶栅格板,这包括溶解所述可溶心轴。所述方法还可以包括以下步骤:在所述压塑成型加工工具内相对于所述强固板索引所述叶片。索引所述叶片包括将一组硬工具嵌件插入到由所述叶片形成的空腔中的步骤。
根据又一实施方式,提供了一种用于共固化多个强固板和多个叶片的装置。该装置包括一工具,该工具包括以相互关系固定的多个硬工具嵌件,所述多个硬工具嵌件能够插入由所述叶片形成的第一组空腔中。所述装置还包括多个心轴,所述多个心轴能够单个地插入由所述叶片形成的第二组空腔中。所述心轴可以是可溶化的。所述工具包括工具基体,并且所述多个硬工具嵌件被固定至所述工具基体。
而且,本公开包括根据下列条款的实施方式:
条款1、一种用于喷气式发动机反推装置的叶栅,该叶栅包括:
多个强固板,每一个强固板都由具有连续纤维增强的聚合物树脂形成;和
接合至所述强固板的多个叶片,并且每一个叶片都由具有不连续纤维增强的聚合物树脂形成。
条款2、根据条款1所述的叶栅,其中,所述聚合物树脂是热塑性树脂。
条款3、根据条款2所述的叶栅,其中,所述强固板和所述叶片被共固化。
条款4、根据条款1所述的叶栅,其中,所述多个叶片被布置在与所述多个强固板共固化的多个模块化叶片组件中。
条款5、根据条款1所述的叶栅,其中,所述不连续纤维增强包括随机取向的短纤维。
条款6、一种用于喷气式发动机反推装置的叶栅,该叶栅包括:
预固化的热塑强固板组件;和
与所述强固板共固化的预固化热塑叶片。
条款7、根据条款6所述的叶栅,其中,所述强固板组件利用连续纤维来增强。
条款8、根据条款6所述的叶栅,其中,所述叶片利用不连续纤维来增强。
条款9、根据条款6所述的叶栅,其中,所述叶片被布置为多个叶片组件,所述多个叶片组件中的每一个都包括多个叶片并且位于所述强固板之间且与所述强固板一起固化。
条款10、一种制造用于喷气式发动机反推装置的叶栅格板的方法,该方法包括以下步骤:
制造多个热塑叶片;
制造多个热塑强固板;以及
共固化所述叶片和所述强固板。
条款11、根据条款10所述的方法,其中,制造多个热塑叶片的步骤通过压塑成型用不连续纤维增强的热塑树脂来执行。
条款12、根据条款10所述的方法,其中,制造多个热塑强固板的步骤通过连续压塑成型用连续纤维增强的热塑树脂来执行。
条款13、根据条款10所述的方法,其中,共固化所述热塑叶片和所述热塑强固板的步骤包括:
将所述热塑叶片和所述热塑强固板装载到压塑成型工具中;
加热各所述热塑叶片和所述热塑强固板;以及
利用所述压塑成型工具共固化所述叶片和所述强固板,以对着所述热塑强固板压缩所述热塑叶片。
条款14、根据条款13所述的方法,其中,将所述热塑叶片和所述热塑强固板装载到压塑成型工具中的步骤包括:
将一组硬工具嵌件放置到第一组叶片腔中;并且
将一组可膨胀的可溶心轴放置到第二组叶片腔中。
条款15、根据条款14所述的方法,所述方法还包括以下步骤:
在所述叶片和所述强固板已经共固化之后将其冷却;并且
从所述压塑成型工具去除所述叶栅格板,这包括溶解所述可溶心轴。
条款16、根据条款13所述的方法,所述方法还包括以下步骤:
在所述压塑成型工具内相对于所述强固板索引所述叶片。
条款17、根据条款16所述的方法,其中,索引所述叶片包括将一组硬工具嵌件插入到由所述叶片形成的空腔中。
条款18、一种用于共固化多个强固板和多个叶片的装置,该装置包括:
工具,该工具包括以相互关系固定的多个硬工具嵌件,所述多个硬工具嵌件能够插入由所述叶片形成的第一组空腔中;和
多个心轴,所述多个心轴能够单个地插入由所述叶片形成的第二组空腔中。
条款19、根据条款18所述的装置,其中,所述心轴是可溶的。
条款20、根据条款18所述的装置,其中,所述工具包括工具基体,并且所述多个硬工具嵌件被固定至所述工具基体。
这些特征、功能以及优点可以在本公开的不同实施方式中独立地实现,或者可以在其它实施方式中组合,其中进一步的细节可以参照下列描述和附图而清楚。
附图说明
例示性实施方式的被认为新颖的特征在所附权利要求中加以阐述。然而,当结合附图阅读时,该例示性实施方式以及优选使用模式、进一步的目的及其优点将通过参照本公开的例示性实施方式的下列详细描述而最佳地理解,其中:
图1是飞机喷气式发动机、已经向后移位以暴露叶栅型反推装置的转换整流罩的侧视图的图示。
图2是图1所示喷气式发动机的后端的立体图的图示。
图3是图1和2所示喷气式发动机的一部分的纵截面图,例示了穿过反推装置的气流。
图4是反推装置的叶栅格板形成部分的俯视立体图的图示。
图5是图4中命名为“图5”的区域的图示。
图5A是图5中命名为“图5A”的区域的图示。
图5B是图5中命名为“图5B”的区域的图示。
图6是强固板组件的立体图的图示。
图7是模块化叶片组件的立体图的图示。
图8是叶片组件的另选实施方式的立体图的图示,示出了单个叶片子组件的安装。
图9是示出要放置在硬工具上的叶栅格板的截面图的图示。
图10是与图9类似但示出了已经定位在硬工具上的叶栅格板的图示。
图11是与图10类似但示出了要插入叶栅格板中的开放叶片腔中的可膨胀的可溶心轴的图示。
图12是与图11类似但示出了已经插入到开放叶片腔中的可膨胀的可溶心轴的图示。
图13是示出了为共固化做准备的、已经与预共固化的强固板组件组装在一起的预共固化叶片的俯视图的图示。
图14是与图13类似但示出了已经插入到叶片腔中的硬工具嵌件和可膨胀的可溶心轴的另选位置的图示。
图15是概括示出被用于共固化预共固化叶片和预共固化强固板组件的工具的部件的框图的图示。
图16是概括示出制造叶栅格板的方法步骤的流程图的图示。
图17是飞行器制造和保养方法的流程图的图示。
图18是飞行器的框图的图示。
具体实施方式
首先参照图1至图3,飞行器喷气式发动机20包括发动机舱22和转换整流罩24,该转换整流罩向后平移以暴露叶栅型反推装置26。反推装置26包括多个周向排列的反推叶栅格板28,有时称为叶栅篮。
在正常飞行操作期间,转换整流罩24处于闭合向前位置,接合转换整流罩24与机舱22并由此覆盖叶栅格板28。在着陆期间,转换整流罩24通过致动器杆30从其闭合位置移动至其开放的向后延伸位置(图1至图3所示)。打开转换整流罩24暴露叶栅格板28至周围环境。随着转换整流罩24已经移位至其打开位置,通过闭合周向定位的阻流门32来启用反推装置26。闭合阻流门32防止了旁路废气沿其正常方向流出喷嘴34,强制废气穿过叶栅格板28,如图3中的箭头36所示。每一个叶栅格板28都包括叶片44,该叶片向前并且可选地快速向外引导废气流,废气流方向出现逆转。废气流的这种逆转致使帮助飞行器减速的推力逆转。
下面,将注意力转向图4和图5,其例示了叶栅格板28之一的附加细节,一起示出了示出轴向向前方向、径向向上方向以及侧向圆周方向的相关坐标系25。叶栅格板28沿侧向圆周方向弯曲,并且包括多个轴向延伸的强固板44、在强固板44之间延伸的多个叶片46,以及分别在前端和后端的安装法兰40、42。该安装法兰40、42允许叶栅格板28环绕发动机舱22绕周向排列并排安装。
强固板44被设计成反作用叶栅格板28上的大多数载荷,而叶片46被设计成反作用反推期间的相对最小载荷。强固板44包括稍后讨论的连续纤维增强,而叶片46包括不连续纤维增强。强固板44与叶片46一起形成旁路空气流过并且重新定向的多个叶片腔48。
强固板44大致彼此平行地延伸并且沿侧向圆周方向隔开。在公开的实施方式中,每一个强固板44都是平坦的并且与径向向上方向对准,然而,在其它实施方式中,强固板44可以不平坦和/或可以倾斜期望程度,以便沿侧向圆周方向指引气流。如下将更详细讨论的,强固板44与安装法兰40、42形成一体。叶片46沿轴向向前方向彼此隔开,并且皆可以相对于径向向上方向倾斜或者整形成杯状(参见图5),以便沿轴向向前方向重新定向旁路气流,来产生反向推力。
下面,具体参照图5、5A以及5B,强固板44和叶片46可以包括诸如适当纤维增强热塑树脂的聚合物树脂,包括但不限于PEI(聚醚酰亚胺(polyetherimide))、PPS(聚苯硫醚(polyphenylenesulphide))、PES(聚醚砜(polyethersulfone))、PEEK(聚醚醚酮(polyetheretherketone))、PEKK(聚醚酮(polyetherketone))以及PEKK-FC(聚醚酮-fc级)。如图5A所示,叶片46利用可以随机取向的不连续长纤维35来增强。不连续纤维35可以包括具有适于该应用的长度的碳、金属、玻璃或陶瓷纤维中的一种或更多种。例如,在一个实施方式中,纤维35可以是切碎的薄片,宽度和长度分别为1/2英寸和1/2英寸,而在另一实施方式中,宽度和长度分别为1/16英寸和1/2英寸。纤维35可以具有不同长度,并且可以具有相同或不同的纤维厚度或直径。纤维相对于热塑基质的体积可以随着特定应用的性能需求而改变。所选择的热塑复合材料可以采用纤维形式、胶带半预浸料(tapesemi-preg)或其它形式。
如图5B所示,强固板44与法兰40、42一起可以利用连续单向纤维45增强,该连续单向纤维可以与被用于增强叶片46的不连续纤维35的材料相同或不同。强固板44和法兰40、42可以是预共固化在一起的具有不同纤维取向的多个层板。如下将讨论的,叶片46可以被预共固化,并且接着在稍后的压塑成型操作中与预共固化的强固板44共固化。
下面,参照图6,热塑强固板44与法兰40、42一起可以利用合适的热成型形成工艺(诸如而非限制的连续压塑成型)而制造为单个的预共固化热塑强固板组件56。强固板组件56在沿轴向方向延伸的相邻强固板44之间形成有开放式强固板槽58。如先前所讨论的,强固板44可以倾斜,以便将旁路气流朝着侧向圆周方向引导。
参照图7,预共固化热塑叶片46可以被制造为多个单元式预共固化的模块化叶片组件50,其中每一个都包括多个单个叶片46,这些叶片接合至在各自的端部通过端壁52连接在一起的间隔开的侧壁54。该模块化叶片组件50具有和强固板槽58大致相同的几何形状和尺寸。模块化叶片组件50可以通过压塑成型热塑复合树脂(包括之前描述的任何纤维增强热塑材料)而制作为单元式模块。为了组装叶片组件50与强固板组件56,将每一个叶片组件50放置在一个强固板槽58中,并且加载到稍后描述的用于共固化叶片组件50和强固板组件56的工具中。
下面,将注意力指向图8,其例示了将单个叶片46安装在相邻强固板44之间的另选方法。在这个实施方式中,单个叶片子组件60可以通过压塑成型或其它热成型技术来制造。单个叶片子组件60放置在强固板槽58内的期望位置处,并且在合适工具内索引,以保持叶片子组件60相对于强固板组件56的位置。每一个叶片子组件60都包括具有一体模制的侧壁54的叶片46,其接触强固板44并且与强固板44共固化。每一个叶片子组件60都是利用不连续长纤维增强的预共固化热塑性塑料,如先前所讨论的。
下面,参照图9至图12,强固板组件56和叶片子组件60(或模块化叶片组件50)利用硬工具70和采用可膨胀可溶心轴78的形式的可溶工具嵌件的组合共固化。可膨胀可溶心轴78可以由常规材料形成,该材料可以在完成共固化工序之后溶解并且洗掉,如通过使心轴78经受诸如水的溶解液体。该可膨胀可溶心轴78缩减工具成本,然而,在一些实施方式中,心轴78可以是硬工具而非可溶的。硬工具70包括固定在工具基体74上的硬工具嵌件72。该硬工具嵌件72和可膨胀的可溶心轴78具有大致匹配叶片腔48的截面几何形状。当在炉、压机或高压釜中加热时,工具嵌件72、78膨胀,并由此对着强固板44压缩叶片子组件60的侧壁54。该工具和预共固化的强固板组件56及叶片子组件60可以利用任何不同技术来组装。
例如,如图9所示,叶栅格板组件66可以预先组装,其后,如图9所示,硬工具嵌件72被插入68到交替的叶片腔48中。图10示出了已经插入到叶片腔48中的硬工具嵌件72,并且叶栅格板组件66安置在工具基体74上。接下来,如图11所示,将可膨胀可溶心轴78插入到其余开放式叶片腔48中,其后,如图12所示,所有叶片腔48中具有工具嵌件,并且工具和格板组件66的组件准备好放置在压塑成型装置(未示出)中,以执行最终共固化工序。用于将格板组件66的部件与工具组装在一起的其它技术也是可以的。
图13示出了在将工具嵌件72、78插入到叶片腔48中之前组装的一部分。在一个实施方式中,如图14所示,工具嵌件72、78可以在叶片腔48中按交替方式放置。在加工工具与格板组件66的部件的组装期间,硬工具嵌件72起作用以相对于彼此并相对于强固板组件56索引叶片子组件60。
下面,参照图15,在工具嵌件72和可溶心轴78已插入到了叶栅格板组件66的交替叶片腔48中的情况下,叶栅格板组件66可以放置在固化工具中并且加载到压塑压机75中,压塑压机75利用顶部工具80、底部工具82以及侧部工具84、86向压塑格板组件66施加压力P。使用交替硬工具嵌件72和可溶心轴78帮助在共固化之前定位格板28的部件,以提供可重复性和准确布置,并且帮助保证部件在最终共固化阶段期间不浮动、移动或再熔化。
图16概括例示了制造上述类型叶栅格板28的方法的总体步骤。在步骤88,叶片46可以通过压塑成型用不连续长纤维35增强的合适热塑树脂来制造。类似的是,在步骤90中,强固板44可以通过连续压塑成型利用连续纤维45(如单向预浸料坯)增强的合适热塑树脂来制造。在叶片46和强固板44已经在步骤88和90中分开地预共固化的情况下,提供钢制压塑成型工具,其包括硬工具嵌件72。在步骤94,将预共固化叶片46和强固板44装载到压塑成型工具中,其中,硬工具嵌件72作为用于相对于彼此并且相对于强固板44适当定位叶片46的索引特征部或定位特征部。
接下来,在步骤96,将采用可膨胀可溶心轴78形式的第二组工具嵌件插入到尚未填充硬工具嵌件72的其余开放叶片腔中,以便填充这些开放叶片腔中。在步骤98,将该工具在烤炉、加热液压机以及/或高压釜中加热至热塑性材料的熔化温度,为最终固化做准备。在步骤100,使用热和压力,以将强固板44和叶片46共固化成同质叶栅格板组件28,在此期间,硬工具嵌件72和心轴78膨胀以对着叶片46施加压力。
对着叶片46施加的压力对着强固板组件56的IML(内模线)向外压挤叶片46,由此将叶片46和强固板44共固化成同质连续纤维和不连续纤维、全热塑复合叶栅格板28。在叶片46和强固板44完全共固化的情况下,接着在步骤102,将工具冷却,由此冷却叶片46和强固板44。接着,将固化的叶栅格板28从工具去除,并且洗掉心轴78。在步骤104,必要时修整固化的叶栅格板组件28。
本公开的实施方式可以在多种潜在应用方面使用,特别是在运输行业方面,包括例如航空和航天、海运、汽车应用以及可以使用网格型面板的其它应用。由此,下面,参照图17和图18,本公开的实施方式可以在如图17所示的飞行器制造和养护方法106和如图18所示的飞行器108的背景下使用。本公开实施方式的飞行器应用例如可以包括但不限于用于喷气式发动机反推装置。在前期制造期间,在前期生产过程中,示例性方法106可包括飞行器108的规格和设计110及材料采购112。在生产过程中,进行飞行器108的部件和子组件制造114以及系统整合116。此后,飞行器108可经过检定和交付118以便投入服役120。在由客户保养期间,飞行器108被安排进行例行维护检修122(这也可包括改造、重构、翻新等)。
可由系统集成商、第三方及/或操作员(例如客户)进行或执行示例性方法106的各个过程。为了本描述之目的,系统集成商可包括但不限于任一数量的飞行器制造商与主系统分包商;第三方可包括但不限于任一数量的供应商、转包商以及供货商;并且操作员可以是航空公司、租赁公司、军事实体、服务组织等。
如图18所示,由示例性方法106生产的飞行器108可包括具有多个系统126与内饰128的机体124。高级系统126的实施例包括推进系统130、电气系统132、液压系统134以及环境系统136中的一个或多个。可包括任一数量的其它系统。尽管示出了航空航天的实施例,但是本发明的原理可尤其应用于诸如汽车工业及造船工业之类的其它工业。
在此实施的系统与方法可在制造和维护方法106的任一个或多个阶段中采用。例如,能以类似飞行器108在保养时生产部件或子组件的方式装配或制造对应于部件和子组件制造114的部件或子组件。而且,可在生产阶段114和116期间利用所述设备、方法的一个或多个方面或者这些方面的组合,例如大幅地加快飞行器108的装配或减少飞行器108的成本。类似地,可在例如但不限于飞行器108在保养时(例如维护检修122时)利用所述设备、方法的一个或多个方面或者这些方面的组合。
出于例示和描述的目的,提供了不同例示性实施方式的描述,而不是旨在穷尽或将这些实施方式限制于所公开的形式。许多变型和变更对本领域普通技术人员是显而易见的。而且,与其它例示性实施方式相比,不同的例示性实施方式可以提供不同的优点。所选的实施方式是为了最佳地说明该实施方式的原理、实践应用并且使得本领域普通技术人员能够理解针对具有如适于所构想的具体用途的各种变型的各种实施方式来理解本公开而选出的。

Claims (15)

1.一种用于喷气式发动机反推装置的叶栅,该叶栅包括:
多个强固板,每一个强固板都由具有连续纤维增强的聚合物树脂形成;和
接合至所述强固板的多个叶片,并且每一个叶片都由具有不连续纤维增强的聚合物树脂形成。
2.根据权利要求1所述的叶栅,其中,所述聚合物树脂是热塑性树脂。
3.根据权利要求1或2所述的叶栅,其中,所述强固板和所述叶片被共固化。
4.根据权利要求1或2所述的叶栅,其中,所述多个叶片被布置在与所述多个强固板共固化的多个模块化叶片组件中。
5.根据权利要求1或2所述的叶栅,其中,所述不连续纤维增强包括随机取向的短纤维。
6.一种制造用于喷气式发动机反推装置的叶栅格板的方法,该方法包括:
制造多个热塑叶片;
制造多个热塑强固板;以及
共固化所述叶片和所述强固板。
7.根据权利要求6所述的方法,其中,制造多个热塑叶片的步骤通过压塑成型用不连续纤维增强的热塑树脂来执行。
8.根据权利要求6或7所述的方法,其中,制造多个热塑强固板的步骤通过连续压塑成型用连续纤维增强的热塑树脂来执行。
9.根据权利要求6或7所述的方法,其中,共固化所述热塑叶片和所述热塑强固板的步骤包括:
将所述热塑叶片和所述热塑强固板装载到压塑成型工具中;
加热各所述热塑叶片和所述热塑强固板;以及
利用所述压塑成型工具共固化所述叶片和所述强固板,以对着所述热塑强固板压缩所述热塑叶片。
10.根据权利要求9所述的方法,其中,将所述热塑叶片和所述热塑强固板装载到压塑成型工具中的步骤包括:
将一组硬工具嵌件放置到第一组叶片腔中;并且
将一组可膨胀的可溶心轴放置到第二组叶片腔中。
11.根据权利要求10所述的方法,所述方法还包括:
在所述叶片和所述强固板已经共固化之后将其冷却;并且
从所述压塑成型工具去除所述叶栅格板,这包括溶解所述可溶心轴。
12.根据权利要求9所述的方法,所述方法还包括:
在所述压塑成型工具内相对于所述强固板索引所述叶片。
13.一种用于共固化多个强固板和多个叶片的装置,该装置包括:
工具,该工具包括以相互关系固定的多个硬工具嵌件,所述多个硬工具嵌件能够插入由所述叶片形成的第一组空腔中;和
多个心轴,所述多个心轴能够单个地插入由所述叶片形成的第二组空腔中。
14.根据权利要求13所述的装置,其中,所述心轴是可溶的。
15.根据权利要求13或14所述的装置,其中,所述工具包括工具基体,并且所述多个硬工具嵌件被固定至所述工具基体。
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