CN106079478A - 通过布置在真空袋外部的固化工具制造复合结构件的方法 - Google Patents

通过布置在真空袋外部的固化工具制造复合结构件的方法 Download PDF

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CN106079478A
CN106079478A CN201610273672.9A CN201610273672A CN106079478A CN 106079478 A CN106079478 A CN 106079478A CN 201610273672 A CN201610273672 A CN 201610273672A CN 106079478 A CN106079478 A CN 106079478A
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约朗达·米格斯查里内斯
弗朗西斯科·哈维尔·约尔丹卡尼塞罗
奥古斯托·佩雷斯帕斯托
安格尔·巴勃罗·戈多
劳拉·阿尔瓦雷斯安托农
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Airbus Operations GmbH
Airbus Operations SL
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    • B29C70/34—Shaping 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
    • B29C70/342—Shaping 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
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    • B29C70/443—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding and impregnating by vacuum or injection
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Abstract

本发明涉及一种结构件的制造方法，该结构件通过将第二结构部件(11)共同结合至第一结构部件(13)而形成。所述方法包括以下步骤：a)制备用于每个第二结构部件(11)的组合体(19)，其中，组合体(19)的预成形件(20)布置在固化工具(21、21’)之间，预成形件(20)由用于形成真空袋的合适材料的带材(23)包围，因此，固化工具(21、21’)与袋相接触并且不与预成形件相接触；b)将所述组合体(19)定位在第一结构部件(13)上并且将所述带材(23)与互补件连接而形成用于完整结构件的真空袋(31)；c)对所得到的组件应用高压釜处理周期。

Description

通过布置在真空袋外部的固化工具制造复合结构件的方法
技术领域
本发明涉及用于通过布置在真空袋外部的固化工具制造复合材料的结构件比如加强板的方法。
背景技术
对于制造复合材料的加强板——比如在飞行器升力面中使用的加强板——而言，共同结合方法以及二次共同结合方法和共同固化方法是已知的，在制造复合材料的加强板的过程中，处于未固化状态的加强元件连接至处于固化状态的蒙皮。
在关于这种板的已知的共同结合方法中，使用了与加强元件直接接触的固化工具并且虽然总体上得到了满意的结果，但是不能避免如下一些问题：比如涉及T形形状的加强件的所谓的“墨西哥帽”现象、共同结合线的不均匀性以及在桁条件的脚部中存在靠近固化工具的非工作区域。
本发明旨在解决这些问题。
发明内容
本发明提供一种复合结构件的制造方法，所述复合结构件通过将第一结构部件比如飞行器机翼的覆盖件的蒙皮共同结合至飞行器机翼第二结构部件比如加强桁条件而连接形成。
所述方法的基本特征如下：
a)制备用于每个第二结构部件(桁条件)的组合体，其中，组合体的预成形件布置在固化工具之间，预成形件由用以形成真空袋的合适的材料的带材包围，就像针对每个桁条件具有单一真空袋，因此固化工具与袋相接触并且不与预成形件相接触；
b)将所述组合体定位在第一结构部件(蒙皮)上并且通过将所述带材与互补件连接而形成用于结构件的真空袋；
c)对所得到的组件应用高压釜处理周期以执行第二结构部件(桁条件)至第一结构部件(蒙皮)的共同结合。
有利地，用于形成真空袋的合适材料的所述带材和所述互补件包括：防渗塑料膜；隔离膜，该隔离膜或者是可剥离的或者在其内表面上进行了糙面精整；以及充气组织，该充气组织布置在两个膜之间，该充气组织的密度低于在真空袋中使用的不与处于未固化状态的复合部件直接接触的充气组织的密度。
在具有T形形状的第二结构部件(桁条件)的实施方式中，所述固化工具为两个角型材，并且所述互补件包括第一互补件和第二互补件，第一互补件的宽度与接连布置的带材的宽度相同，第二互补件用以覆盖边缘区域。
在一个实施方式中，在所述组合体的定位步骤期间，所述带材和所述第一互补件具有应用在其两者的侧边缘处的两个密封胶带以能够实现带材与第一互补件的连结。
根据参照附图出于说明目的的实施方式的以下详细描述，本发明的其他特征和优点将变得清楚。
附图说明
图1为复合结构件比如飞行器机翼的覆盖件的示意性平面图，其中，多个第二结构元件(桁条件)被共同结合至第一结构部件(蒙皮)。
图2a至图2b为示出组合体的准备阶段的基本步骤的示意性立面图，其中，第二结构元件的预成形件——该预成形件由用于形成真空袋的合适的材料的带材包围——设置在固化工具之间，并且图2c为示出将所述组合体在第一结构部件上的定位的示意性立面图。
图3为复合结构件的部分示意性立面图，其图示了制造方法的步骤，其中，通过将用于形成真空袋的合适材料的不同的带材与互补件连接而形成覆盖所述结构件的真空袋。
图4为在使复合结构件经受高压釜处理周期之前的复合结构件的示意性平面图，其特别地示出了用于形成真空袋的带材和部件。
具体实施方式
现将对结构件10——比如飞行器机翼的覆盖件(参见图1)——的根据本发明的制造方法进行描述，该结构件10由复合材料的蒙皮13(第一结构部件)形成，该蒙皮13由复合材料的T形形状的桁条件11(第二结构部件)加强。
所述方法的基本步骤如下：
a)制备用于每个桁条件11的组合体19(参见图2c)，其中，组合体19的预成形件20(由热成形过程制造)设置在固化工具21、21’之间，该预成形件20除了脚部15的基部之外由用于形成真空袋的合适材料的带材23包绕，固化工具21、21’是由钢或INVAR(不胀钢)制成的角型材构造的，并且固化工具21、21’设置有夹持件33，夹持件33可以调节固化工具21、21’之间的距离，使得固化工具21、21’可以处于三个位置：打开位置、中间位置和闭合位置。
可以使用设备40执行该阶段，设备40包括将组合体19安置在梁41上的支承模块43、43’，支承模块43、43’进而支承固定装置45、45’，该固定装置45、45’用于将带材23的侧边缘固定至固化工具21、21’。
在第一步骤中(参见图2a)，带材23安置在固化工具21、21’上并且带材23在其侧边缘处由所述固定装置45、45’固定至固化工具21、21’。
在第二步骤中(参见图2b)，预成形件20安置在带材23内。在预成形件20的安置期间通过保持带材23的侧边缘固定至固化工具21、21’，保证了带材23与预成形件20的腹板17的对准。在安置预成形件20之后，在预成形件20的脚部15上设置粘合剂层(图中未示出)。
在先前的步骤中，夹持件33保持在打开位置中并且在第二步骤结束时改变为中间位置。
在这个阶段中，实现了带材23适配于预成形件20的几何形状，从而避免了在高压釜处理周期期间会使真空袋破损的所谓的“桥”。
b)将组合体19定位在蒙皮13(其处于固化状态)上，使得预成形件20的脚部15的粘合剂层能够与蒙皮13相接触，从而执行预成形件20至蒙皮13的共同结合，并且通过将每个组合体19的带材23和与带材23的材料相同材料的第一互补件25及第二互补件26连接而形成针对整个组件的真空袋31，以覆盖整个蒙皮13(参见图3和图4)。第一互补件25为那些组合体19的带材23的延续部分，其中，组合体19的预成形件20不在蒙皮13的整个可用长度上延伸，并且第二互补件26为需要使覆盖全部蒙皮13的真空袋31完整的互补件。
这个阶段需要使设备40移动至工位，在此工位上，蒙皮13(处于固化状态)位于模具14上，并且一旦设备40定位在用于每个预成形件20所设想的位置上，使设备40旋转180度并且使设备40沿竖向移动以将组合体19安置在蒙皮13上(参见图2c)。
在将组合体19安置在蒙皮13上之后，真空袋31是通过将带材23与第一互补件25连接而形成的，对于每个预成形件20而言，带材23与第一互补件25在其两者的侧边缘处连接。为此，在我们描述的本发明的实施方式中，带材23和第一互补件25在其两者的侧边缘上带有密封胶带。
在对带材23和第一互补件25进行这种布置和适当地定尺寸时，带材23的边缘和第一互补件25的边缘的中的一个边缘可以在其上侧(相对于蒙皮13)具有密封胶带，由此，通过安置在其下侧具有密封胶带的连续的带材23，两个密封胶带彼此面对，从而形成连接区域32(参见图3)，连接区域32仅需要被施加轻微的压力(例如，通过辊子)以进行连接。
带材23以及第一互补件25和第二互补件26包括由防渗塑料材料制成的膜、待与预成形件20相接触作为辅助材料的隔离膜以及布置在两个膜之间的充气组织(aeratortissue)。辅助材料与在真空袋中使用的不与未固化部件直接接触的那些辅助材料不同，原因在于这些未固化部件的表面精加工取决于所述辅助材料。特别地，隔离膜必须进行糙面精整或是可剥离的，并且该充气组织的密度应当低于那些使用时不与处于未固化状态的复合部件直接接触的充气组织的密度，从而很好地适合于复合部件的范围界限。
c)对从先前阶段所得的组件应用高压釜处理周期以执行第二结构部件11至第一结构部件13的共同结合。
在这个阶段，夹持件33处于闭合位置以对预成形件20的腹板17施加压力。
本发明的优点包括以下内容：
-消除了在背景技术中提到的问题：“墨西哥帽(Mexican hat)”、共同结合线不均匀性以及在桁条件的脚部处存在非工作区域。通过减少桁条件的脚部的“死区”，确保了共同结合线的均匀性以及最终结构的尺寸质量，尤其是确保了桁条件的尺寸质量。
-极大地简化了固化工具21、21’的几何形状，原因在于固化工具21、21’没有模制桁条件的预成形件20。固化工具21、21’的基本功能是防止其腹板偏离于竖直平面，并且有助于真空袋尽可能紧密地匹配于桁条件的范围界限。固化工具21、21’不必覆盖腹板的顶部。
-固化工具21，21’可以由钢制成，而不是由INVAR(不胀钢)制成，这意味着更低的成本。
虽然已经结合各种实施方式描述了本发明，但从说明书中将可以理解的是，可以作出元件的组合、变型或改进，并且这些元件的组合、变型或改进在如由所附权利要求所限定的本发明的范围内。

Claims (8)

1.一种用于制造复合材料的结构件(10)的方法，所述结构件(10)通过将处于未固化状态的多个第二结构部件(11)以共同结合的方式连接至处于固化状态的第一结构部件(13)而由所述第一结构部件(13)和所述第二结构部件(11)形成，所述方法包括以下步骤：
a)制备用于每个第二结构部件(11)的组合体(19)，所述组合体(19)由预成形件(20)形成，所述组合体(19)的所述预成形件(20)布置在固化工具(21、21’)之间，在所述固化工具(21、21’)上预先安置有用以形成真空袋的合适的材料的带材(23)，使得所述预成形件(20)除了待连接至所述第一结构部件(13)的表面之外均由所述带材(23)包围，所述待连接至所述第一结构部件(13)的所述表面上设置有用于共同结合的粘合剂层，所述带材(23)的尺寸设置成使得至少所述结构件(10)的位于所述第二结构部件(11)周围的区域能够由所述带材(23)覆盖；
b)在预先设定用于所述第二结构部件(11)和所述第一结构部件(13)附接的区域中将所述第二结构部件(11)的所述组合体(19)安置在所述第一结构部件(13)上，并且将每个第二结构部件(11)的所述带材(23)与相同材料制成的互补件连接以形成真空袋(31)，使得所述真空袋(31)完全地覆盖所述第一结构部件(13)；
c)对由前述步骤得到的组件应用高压釜处理周期，以执行所述第二结构部件(11)至所述第一结构部件(13)的共同结合。
2.根据权利要求1所述的方法，其中，所述预成形件(20)通过热成形过程制成。
3.根据权利要求1至2中的任一项所述的方法，其中，用于形成真空袋的合适材料的所述带材(23)和所述互补件包括防渗塑料膜、位于所述真空袋的内表面上的隔离膜以及布置在两个所述膜之间的充气组织，所述隔离膜是可剥离的或经糙面精整，并且所述充气组织的密度低于在真空袋中使用的不与处于未固化状态的复合部件直接接触的充气组织的密度。
4.根据权利要求1至3中的任一项所述的方法，其中：
所述第二结构部件(11)呈T形形状并且通过脚部(15)附接至所述第一结构部件(13)；
所述固化工具(21、21’)为适于所述第二结构部件(11)的形状的两个角型材；
所述互补件包括第一互补件(25)和第二互补件(26)，所述第一互补件(25)的宽度等于与所述第一互补件(25)接连布置的所述第二结构部件(11)的所述带材(23)的宽度，所述第二互补件(26)用以覆盖边缘区域。
5.根据权利要求1至4中的任一项所述的方法，其中：
所述带材(23)和所述第一互补件(25)具有应用在所述带材(23)和所述第一互补件(25)的侧边缘处的两个密封胶带；
接连的所述带材(23)和所述第一互补件(25)布置成使得在接连的所述带材(23)和所述第一互补件(25)的相邻的边缘中，接连的所述带材(23)和所述第一互补件(25)中的每一者的具有密封胶带的面相接触，以便于接连的所述带材(23)和所述第一互补件(25)的连结。
6.根据权利要求1至5中的任一项所述的方法，其中，在步骤a)中，所述带材(23)被安置成使得所述带材(23)的侧边缘固定至所述固化工具(21、21’)以确保在所述预成形件(20)的安置期间所述带材(23)与所述预成形件(20)的合适的对准。
7.根据权利要求1至6中的任一项所述的方法，其中：
在步骤a)中，所述固化工具(21、21’)以便于所述预成形件(20)插入的距离设置；
在步骤b)中，所述固化工具(21、21’)以允许保持位于所述固化工具(21、21’)之间的所述预成形件(20)的距离设置；
在步骤c)中，所述固化工具(21、21’)以允许对位于所述固化工具(21、21’)之间的所述预成形件(20)施加预定压力的距离设置。
8.根据权利要求1至7中的任一项所述的方法，其中，所述结构件(10)为飞行器机翼的覆盖件，所述第一结构部件(13)为蒙皮并且所述第二结构部件(11)为加强纵向桁条件。
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