CN106232343B - 具有带有不对称树脂分布的可固化复合蒙皮的复合夹层板 - Google Patents

具有带有不对称树脂分布的可固化复合蒙皮的复合夹层板 Download PDF

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CN106232343B
CN106232343B CN201580020658.1A CN201580020658A CN106232343B CN 106232343 B CN106232343 B CN 106232343B CN 201580020658 A CN201580020658 A CN 201580020658A CN 106232343 B CN106232343 B CN 106232343B
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resin
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CN106232343A (zh
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A·S·巴特罗莫
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Be Space Flight Co
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Abstract

一种复合板包括被夹在一对蒙皮之间的蜂窝芯材，该对蒙皮在没有单独的粘合剂层的情况下被直接附接至芯材。蒙皮用不均匀地分布在第一表面和第二表面之间的树脂材料浸渍，并且在具有更多树脂分布的表面和芯材之间建立直接接触，从而减少重量并且消除合并它们之间的粘合剂层的制造步骤。

Description

具有带有不对称树脂分布的可固化复合蒙皮的复合夹层板
相关申请的交叉引用
本申请基于并要求于2014年2月27日提交的美国临时专利申请No.61/945,344以及于2015年2月25日提交的美国专利申请No.14/631,770的优先权，所述专利申请的全部内容以引用方式并入。
背景技术
复合夹层板用于需要高强度和轻重量的各种各样的应用中。为了更大的强度，这些板可包括轻质蜂窝芯材，因为轻质蜂窝芯材具有高的强度重量比以及抗疲劳破坏性。这些板特别适合于飞机制造工业。蜂窝芯材可以由各种各样的材料制成，将蜂窝结构夹在其间的面板也是一样。
通常，粘合剂用于将面板粘结至芯材。粘合剂必须刚性地将饰面或蒙皮附接至芯材，以便负荷从一个饰面传输到另一个饰面。如果粘合剂失效，则板的强度受到严重地损害。由于相对小的表面区域，在该表面区域上蜂窝的边缘接触面板，因而粘合剂在使用蜂窝作为芯材的夹层板中是特别关键的。
用于将复合面板施加到蜂窝的一个过程涉及形成预浸片材，该预浸片材包括至少一个纤维增强层和未固化树脂基质。预浸料为用于织物增强物的常见术语，该织物增强物已经利用树脂体系进行预浸渍。树脂体系通常为已包括适当固化剂的环氧树脂。因此，在不添加附加树脂并且在没有典型手工铺放所需的步骤的情况下，织物准备铺放到模具中。这些预浸渍的复合织物和条带或“预浸料”用于大量的飞机应用中。膜粘合剂通常添加到预浸蜂窝芯材，并且然后通过在升高的温度下固化预浸树脂和粘合剂树脂两者来将该膜粘合剂粘结至蜂窝。膜粘合剂能够作为单独层片的层或者作为预浸片材的整体部分施加。
一种将面板粘结至蜂窝的替代方法涉及将粘合剂施加至蜂窝的边缘。粘合剂通常通过将蜂窝的边缘“浸渍”在粘合剂中进行施加。用于该类型粘结的粘合剂通常被称为“浸渍”树脂或粘合剂。该方法的优点在于粘合剂仅位于蜂窝接触面板的地方，而不是分布在整个面板之上。该方法通常用于将非粘性面板诸如铝和其他金属面板粘结至蜂窝。
一种此类复合板为由加利福尼亚州科洛纳市的Teklam公司提供的A502板，其旨在用于初级和次级航空航天应用中。Teklam A502板包括0.02″厚度的2024T3包层铝饰面和四分之一英寸的5052-0015-3.4铝蜂窝芯材。数据表和进一步的信息请参见http：//www.teklam.com/teklam_A502_panel.html。该板具有均匀分布的低树脂含量，其中辅助膜粘合剂用于粘结所述层。膜和粘合剂能够以如下进行表示：
上述示例中的增强物和树脂的总重为0.050lbs/sq ft(0.02的预浸料和0.03的粘合剂)。该板的制造需要切割这两种材料并且将这两种材料铺放到芯材上，这增加了制造成本。从上述内容可以看出层树脂以均匀分布的方式横跨芯材施加，尽管事实是没有必要这样做。膜粘合剂的包括是必需的，但给板增加了额外重量。在航空航天工业中存在对改进的板的需要，该改进的板通过优化树脂和粘合剂重量以及沿板的芯材的分布具有减少的重量。
发明内容
本发明为具有单向预浸复合板的复合板，其中树脂以不同的量选择性地施加在配对材料的接触表面上，以使板最优化。差别树脂施加的使用允许从板中消除粘合剂膜，从而改善板的重量特性而没有强度损失。所得的板对具有改进的制造效率的轻质、高强度、低成本的复合板而言是最优化的。
附图说明
图1为现有技术蜂窝芯材复合板的正视透视图；
图2为用于本发明的板的蜂窝芯材的正视透视图；以及
图3为示出树脂在蒙皮上的差别分布的板的横截面视图。
具体实施方式
图1示出具有蜂窝材料的芯材的现有技术蜂窝复合板，蜂窝材料的芯材被夹在将外蒙皮粘结至板的两个粘合剂膜之间。在该配置中，蒙皮和粘合剂膜两者均必须在固化步骤之前被精确地切割和相匹配。切割和固化过程的细节通常在名称为用于形成蜂窝复合夹层板的方法(Method For Forming A Honeycomb Composite Sandwich Panel)的美国专利No.7,186,310中有所描述，所述专利的内容以引用方式全部并入本文。
图2示出改进的复合板20，其包括蜂窝芯材10和一对预浸树脂织物片材或蒙皮14。蜂窝芯材10包括带有重复的几何形状(例如六边形12)的薄壁格栅(thin walledlattice)。蜂窝芯材为利用芳族聚酰胺纤维纸材制造的极其轻质、高强度结构，芳族聚酰胺纤维纸材用耐热树脂进行浸渍，该耐热树脂诸如在一些情况下为酚醛树脂，并且在其他情况下为铝、钢、聚苯乙烯或聚丙烯芯材。芯材10提供航空航天应用和复合夹层板的其他应用所需要的必要刚度和强度重量比。
图3示出本发明的板，其中蜂窝芯材10在本发明中被夹在单向预浸蒙皮14的层片之间。预浸材料选自若干不同的高强度、低重量的选项，并且通常包括所选择的纤维方向、重量以及总树脂含量。在传统的树脂纤维蒙皮中，树脂含量总是遍及预浸料均匀地分布，使得一个表面上的树脂量等于另一表面上的树脂量。然而，本发明在预浸料的外表面和相对于夹层板的内表面上选择性地建立不同的树脂量。当树脂横跨板并且遍及飞机结构施加时，该树脂差别能够导致显著的重量减轻。
蒙皮14由薄金属或碳增强单向织物组成，该碳增强单向织物在内侧和外侧两者上用树脂材料预浸渍。在本发明中织物具有内树脂层18和外树脂层16，内树脂层18具有在内表面或内部表面上每平方英尺产生重量为0.030磅树脂的厚度，外树脂层16具有在夹层板的外表面或外部表面上每平方英尺产生重量为0.010磅树脂的厚度。通过供应差别树脂厚度，板能够在没有单独的粘合剂片材的情况下固化，并且由此从板20中消除粘合剂层的重量。
在前述示例中，例如，在先前示例中0.050lbs/sq ft的树脂已经减少了百分之二十成为0.040lbs/sq ft。此外，消除对施加粘合剂膜的需要大大减少了用于制造复合板的成本和时间。通过在纤维的相对侧上允许不同的树脂量，板能够通过消除粘合剂膜来减少重量和成本。附加益处为仅存在需要切割并铺放到芯材上的单一材料(预浸料14)，从而在成形过程中节省费用和时间。本发明的板20能够用于取代或代替将单向预浸料和粘合剂膜的使用进行合并的任何板。此类板的示例包括飞机地板镶板，但在工业中其他示例也有很多。
本发明允许树脂遍及现有技术中不可用的蒙皮材料的非常有目的性的放置。这产生成本和重量的显著节省，航空航天工业中的关键因素，同时保持最佳的性能。本发明也排除了围绕膜粘合剂的使用设计板以实现充足的粘结强度的需要。
本发明的前述具体实施方式并非旨在限于任何具体附图或描述的实施例。普通技术人员将容易设想前述示例的许多修改和变型，并且本发明的范围旨在涵盖所有此类修改和变型。因此，本发明的范围通过所附权利要求的文字使用其在这里与描述和叙述一致的通常意义进行恰当地限定。

Claims (13)

1.一种复合板，其包括：
芯材，所述芯材具有重复的几何形状，其中所述芯材的上表面包括所述重复的几何形状的开放栅格，并且所述芯材的下表面包括所述重复的几何形状的开放栅格；
第一蒙皮，所述第一蒙皮在没有单独的粘合剂膜的情况下被直接附接至所述芯材的所述上表面，以及第二蒙皮，所述第二蒙皮在没有单独的粘合剂膜的情况下被直接附接至所述芯材的所述下表面，所述第一蒙皮和所述第二蒙皮中的每个在内表面和外表面上均具有热固性树脂；以及
其中所述第一蒙皮和所述第二蒙皮的所述内表面上的所述热固性树脂的厚度大于所述第一蒙皮和所述第二蒙皮的所述外表面上的所述热固性树脂的厚度。
2.根据权利要求1所述的复合板，其中所述芯材为具有重复的六边形形状的蜂窝结构。
3.根据权利要求1所述的复合板，其中所述第一蒙皮和所述第二蒙皮为单向碳素纤维织物。
4.根据权利要求1所述的复合板，其中所述第一蒙皮和所述第二蒙皮的所述内表面上的热固性树脂的层比所述第一蒙皮和所述第二蒙皮的所述外表面上的所述热固性树脂的层大至少0.02磅每平方英尺。
5.根据权利要求1所述的复合板，其中内树脂层的重量与外树脂层的重量的比为3：1。
6.根据权利要求1所述的复合板，其中所述树脂为耐热酚醛树脂。
7.一种在不使用粘合剂膜层的情况下产生复合板的方法，其包括：
将堆叠的结构堆叠在模具的下半模上，所述堆叠的结构包括第一预浸片材、具有重复的几何形状的芯材以及第二预浸片材，其中
所述芯材的上表面包括所述重复的几何形状的开放栅格，
所述芯材的下表面包括所述重复的几何形状的开放栅格，以及
所述第一预浸片材和第二预浸片材在相应的内表面和相应的外表面上均具有热固性树脂，其中所述内表面上的所述热固性树脂的厚度大于所述外表面上的所述热固性树脂的厚度，其中，在堆叠时，
所述第一预浸片材的所述内表面在没有单独的粘合剂膜的情况下直接邻接所述芯材的所述下表面，以及
所述第二预浸片材的所述内表面在没有单独的粘合剂膜的情况下直接邻接所述芯材的所述上表面；以及
在所述模具中固化所述堆叠的结构。
8.根据权利要求7所述的方法，进一步包括：形成所述第一预浸片材和所述第二预浸片材，以各自具有内树脂层的重量与外树脂层的重量为3：1的比。
9.根据权利要求7所述的方法，进一步包括：形成所述第一预浸片材和所述第二预浸片材，以在所述内表面上具有热固性树脂的相应层，所述内表面上的热固性树脂的相应层比所述外表面上的所述热固性树脂的相应层大至少0.02磅每平方英尺。
10.根据权利要求7所述的方法，进一步包括：使用单向织物形成所述第一预浸片材和所述第二预浸片材。
11.根据权利要求10所述的方法，其中所述单向织物为单向碳素纤维织物。
12.根据权利要求7所述的方法，进一步包括：使用耐热酚醛树脂形成所述第一预浸片材和所述第二预浸片材。
13.根据权利要求7所述的方法，其中所述芯材为具有重复的六边形形状的蜂窝结构。
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