CN106393843A - 复合结构件 - Google Patents

复合结构件 Download PDF

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Publication number
CN106393843A
CN106393843A CN201610585327.9A CN201610585327A CN106393843A CN 106393843 A CN106393843 A CN 106393843A CN 201610585327 A CN201610585327 A CN 201610585327A CN 106393843 A CN106393843 A CN 106393843A
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CN
China
Prior art keywords
insert
synusia
stack
structural member
matrix material
Prior art date
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.)
Pending
Application number
CN201610585327.9A
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English (en)
Inventor
乔纳森·普赖斯
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Airbus Operations Ltd
Original Assignee
Airbus Operations Ltd
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Filing date
Publication date
Application filed by Airbus Operations Ltd filed Critical Airbus Operations Ltd
Publication of CN106393843A publication Critical patent/CN106393843A/zh
Pending legal-status Critical Current

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • General Engineering & Computer Science (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Laminated Bodies (AREA)
  • Moulding By Coating Moulds (AREA)

Abstract

本发明提供了一种结构件，其包括由纤维增强基体材料构成的复合层片的堆叠件。该结构件包括多个加强插入件和多个孔。每个加强插入件均嵌入堆叠件中并且结合至该堆叠件，并且每个孔均贯穿加强插入件中的相应一个加强插入件。每个加强插入件均接合至支承层。支承层由与复合层片不同的材料形成并且浸渍有与复合层片相同的基体材料。支承层在结构件的组装期间承载插入件，并且支承层会有助于堆叠件的灌注和/或固化过程。

Description

复合结构件
技术领域
本发明涉及复合结构件以及制造复合结构件的方法。
背景技术
层压的纤维增强复合结构件如飞行器机翼蒙皮在其整个厚度的适应高负载引入的能力方面受到限制。这限制了这些结构件能够工作时的应变水平。
传统上，这些结构件机械地紧固(例如通过螺栓来紧固)至其他工件，螺栓穿过结构件中的加工孔。对结构件的受限的螺栓承载能力的传统解决方案是在孔位置处局部地增大结构件的厚度。这可能导致增加重量和成本的低效解决方案。
发明内容
本发明的第一方面提供了一种结构件，该结构件包括由纤维增强基体材料构成的复合层片的堆叠件。该结构件包括多个加强插入件和多个孔，其中，每个加强插入件均嵌入堆叠件中并结合至该堆叠件，并且每个孔均贯穿加强插入件中的相应一个加强插入件。每个加强插入件均接合至支承层。支承层由与复合层片不同的材料形成并且浸渍有与复合层片相同的基体材料。支承层在结构件的组装期间承载插入件，并且支承层会有助于堆叠件的灌注和/或固化过程。
加强插入件提高了结构件的紧固件承载能力。因此，结构件的插入件周围的厚度的局部增大可以被避免或者至少被最小化。
通常，加强插入件在结构件的固化期间共同结合至堆叠件的基体材料，而非通过与堆叠件的基体材料不同的粘合剂二次结合至堆叠件。换言之，加强插入件通常与堆叠件的基体材料直接接触。
支承层可以位于堆叠件的顶部或底部处，但更通常地，支承层嵌入堆叠件中，其中，堆叠件的第一复合层片和第二复合层片定位在多孔支承层的相反两侧上，并且第一复合层片和第二复合层片结合至每个加强插入件。通常，支承层位于堆叠件的一半厚度的位置处——换言之，位于堆叠件的中部处。
通常，支承层是金属支承层。
支承层可以是能够浸渍有基体材料的格栅或网状物、穿有孔的板、或者任何其他多孔结构件。
插入件可以穿过堆叠件的整个厚度，但更通常地，在加强插入件的相反端部处设置有纤维增强基体材料的一对包覆层片，其中，每个加强插入件均结合至包覆层片，并且每个孔均贯穿所述一对包覆层片以及穿过加强插入件中的相应一个加强插入件。
通常，每个加强插入件均具有侧面和一对端面；堆叠件的至少两个复合层片具有结合至加强插入件的侧面的内部边缘；该结构件还包括由纤维增强基体材料构成的一对包覆层片，所述一对包覆层片结合至加强插入件的端面；并且每个孔均贯穿所述一对包覆层片。
加强插入件可以由金属或者任何其他合适的加强材料——例如诸如Tufnol(R)之类的聚合物材料——制成。
纤维增强基体材料用纤维来增强，其可以是碳、玻璃或任何其他合适的纤维增强材料。通常，纤维增强材料与形成加强插入件的材料不同。
通常，基体材料是诸如环氧树脂之类的热固性材料或者酯基系统。替代性地，基体材料可以是热塑性材料。
通常，堆叠件的至少两个复合层片具有结合至加强插入件的内部边缘。最优选地，堆叠件的至少四个复合层片具有结合至加强插入件的内部边缘。所述内部边缘通常为切割边缘。
本发明的第二方面提供了一种接合件，该接合件包括：工件；以及根据本发明的第一方面的结构件，该结构件通过紧固件如螺栓接合至工件，每个紧固件均具有穿过所述孔中的相应一个孔的杆部。
本发明的第三方面提供了一种制造本发明的第一方面的结构件的方法，该方法包括：将由纤维增强基体材料构成的复合层片的堆叠件铺设到铺层工具上，其中，多个加强插入件嵌入堆叠件中，其中，加强插入件在其嵌入堆叠件中之前由多孔支承层承载；对基体材料进行加热和固化，使得加强插入件共同结合至堆叠件，并且使得多孔支承层浸渍有基体材料；以及在基体材料已固化之后，形成多个孔，每个孔均贯穿加强插入件中的相应一个加强插入件。
本发明的第四方面提供了一种制造本发明的第一方面的结构件的方法，该方法包括：将干纤维层片的堆叠件铺设到铺层工具上，其中，多个加强插入件嵌入堆叠件中，其中，加强插入件在其嵌入堆叠件中之前由多孔支承层承载；用基体材料对干纤维层片的堆叠件进行灌注，该基体材料流动以与加强插入件接触并且浸渍多孔支承层；对基体材料进行固化，使得加强插入件共同结合至堆叠件；以及在基体材料已固化之后，形成多个孔，每个孔均贯穿加强插入件中的相应一个加强插入件。
在基体材料已固化之后在加强插入件中形成孔确保了基体材料不会流到孔中。这也使在任何包覆层片中能够同时形成孔。
通常，所述孔通过材料的去除——例如，通过诸如钻削之类的加工过程——来形成。
通常，整个堆叠件在加强插入件共同结合至基体材料的同时被固化。换言之，不需要两个单独的固化周期——用以使堆叠件固化的一个固化周期以及用以形成与加强插入件的结合的另一固化周期。
通常，基体材料在其固化之前流动以与加强插入件紧密接触，使得加强插入件共同结合至基体材料。
可选地，复合层片或干纤维层片在加强插入件嵌入堆叠件中之前预成形有用于容置加强插入件的孔。这些孔可以通过切割来预成形。
加强插入件可以在层片中的一些层片或所有层片已铺设到铺层工具上之后嵌入堆叠件中，或者加强插入件可以在层片铺设到铺层工具上时嵌入堆叠件中。
加强插入件可以通过下述方式嵌入堆叠件中：将加强插入件插入到堆叠件中的预成形孔中以及/或者将复合层片或干纤维层片铺设到铺层工具上以使得插入件在层片被铺设到铺层工具上时被接纳在层片中的预成形孔中。
由多孔支承层承载的加强插入件可以一个接一个地嵌入堆叠件中，但更通常地，这些加强插入件同时嵌入堆叠件中。
多孔支承层可以位于复合层片或干纤维层片的堆叠件的顶部或底部处，但更通常地，多孔支承层嵌入堆叠件中，其中，堆叠件的第一层片和第二层片定位在多孔支承层的相反两侧上，并且第一层片和第二层片在基体材料固化时共同结合至加强插入件。
加强插入件可以在加强插入件嵌入堆叠件中之前通过焊接或任何其他合适的方法接合至多孔支承层。
通常，基体材料是热固性材料如环氧树脂或者通过热作用固化的酯基系统。替代性地，基体材料可以是通过允许其冷却下来并凝固来固化的热塑性材料。
附图说明
现在将参照附图对本发明的实施方式进行描述，在附图中：
图1是根据本发明的实施方式的结构件的截面图；
图2至图4示出了制造图1的结构件的方法中的初始步骤；
图5是支承格栅的平面图；
图6至图8示出了制造图1的结构件的方法的最终步骤；
图9是图1的结构件的平面图；
图10示出了利用定位销来制造结构件的替代性方法；
图11示出了结合有图1的结构件的接合件的一部分；
图12是示出了图11的接合件的更多细节的平面图；以及
图13是根据本发明的另一实施方式的没有包覆层片的结构件的截面图。
具体实施方式
图1示出了结构件1，该结构件1包括由纤维增强基体材料构成的复合层片的堆叠件3。柱状加强插入件4嵌入堆叠件3中并且结合至堆叠件3。孔6贯穿每个加强插入件4。
图2示出了制造结构件1的方法中的第一阶段。首先，将三个包覆层片10至12铺设到铺层工具2上。每个包覆层片10至12均为由预浸渍有环氧树脂基体材料的强化纤维层构成的所谓的“预浸渍件”。在该示例中，每个增强层均是单向碳纤维层，但是替代性地，所述纤维可以是编织的或无皱褶的。上包覆层片12中的碳纤维在图2的截面的平面中延伸并以13表示，并且该上包覆层片12的环氧树脂基体材料以14表示。另一方面，包覆层片11中的碳纤维横向于该截面的平面延伸并以15表示。单向纤维的方向根据所需的结构件性能来选择。在图2的示例中，层片10、12的单向纤维沿相同方向延伸，并且包覆层片11的纤维横向于该方向延伸。可以设置纤维以+/-45度延伸的另外的层片，如现有技术中公知的。在该示例中，示出了三个包覆层片10至12，但是通常可以铺设任意数目的包覆层片，包括仅单个包覆层片。
图3示出了该制造方法中的下一阶段。将三个内部复合层片20至22一个接一个地铺设到包覆层片12的顶部上。在每个层片20至22中通过超声刀或其他的层片切割工具预切割出圆形孔20a至22a。每个层片20至22均具有位于孔的边缘处的圆形的内部切割边缘20b至22b。层片20至22以孔20a至22a对准的方式铺设，如图3中所示。
图4中示出了下一制造阶段。在图5中以平面图示出的多孔金属支承格栅5在所需位置中被切割有多个孔27。柱状金属加强插入件4接着配装到每个孔27中并且焊接至格栅5。支承格栅5在图4中以截面图示出，并且支承格栅5包括由孔隙7隔开的金属支柱6网。支柱6和孔隙7的尺寸可以与示出的支柱6和小孔7的尺寸不同。如图4中所示，支承格栅5在每个插入件4同时配装到内部层片20至22中的相应的对准的一组孔20a至孔22a中时支承插入件4。当插入件4完全插入时，支承格栅5接触上面的内部层片22。
图6中示出了下一阶段。将第二组的三个内部复合层片30至32铺设到支承格栅5的顶部上。层片30至32具有预切孔(像第一组层片中的孔20a至22a一样)，并且加强插入件4在层片30至32一层接一层地铺设时接纳在这些孔中。三个包覆层片40至42接着铺设在加强插入件的顶部上。
接下来，将真空袋铺设到堆叠件上并且将真空袋排空以压缩堆叠件，接着对堆叠件进行加热使得热固性环氧树脂基体材料熔化，并且随后使堆叠件固化以提供图7中示出的加固结构件。熔化的基体材料在层片之间熔合并且随后通过共固化将层片结合在一起。基体材料的加热还使基体材料浸渍支承格栅5中的孔隙7，如图7中所示。基体材料还流动以与加强插入件4紧密接触，使得在基体材料固化时，包覆层片12、40共同结合至加强插入件的端面45，并且内部层片20至22、30至32的圆形内部切割边缘共同结合至加强插入件的柱状侧部46。
在图8中示出的最终制造步骤中，穿过该结构件钻削出孔6，每个孔6均穿过上包覆层片40至42、加强插入件4中的相应一个加强插入件以及下包覆层片10至12。如图中9所示，孔6是圆形的，并且孔6与嵌入的加强插入件的在图9中以虚线示出的柱状侧部46同轴。
图10示出了穿过替代性结构件的截面图，该替代性结构件与图1的结构件类似，除了为每个插入件都设置有柱状定位销50之外。定位销插入到在铺层工具2的上表面中适当定位的筒状凹部中。如图10中所示，下包覆层片(该包覆层片预成形有用于容纳定位销的适当定位的孔)铺设到定位销上，并且每个加强插入件4均类似地具有面向下的凹部，该凹部接纳柱状定位销中的相应一个柱状定位销的的上端部。定位销在固化过程期间留在原位并且随后在钻削孔6时被钻出。
图11示出了包括图1的结构件的接合件的一部分。结构件1通过具有杆部60的螺栓接合至金属工件63，该杆部60穿过孔6并穿过工件63，如图11中所示。该紧固件具有埋入工件内的头部61以及与螺母62配合的尾部，如图11中所示。作为示例，结构件1可以是飞行器机翼蒙皮，并且工件63可以是主起落架结构件或发动机吊架结构件。
图11是接合件的放大视图，仅示出了单个紧固件60至62，而图12是示出了通过多个紧固件接合至工件63的结构件1的展开图，每个紧固件均具有穿过插入件中的相应一个插入件的杆部60。
图13示出了替代性结构件1a，该替代性结构件1a与图1的结构件1类似，除了没有包覆层片之外。图12的结构件的特征在其他方面相同并且用相同的附图标记加上字母“a”来标记。因此，将不对图12的结构件进行更详细的描述。
参照图2至图8的上述方法利用预浸渍的复合层片来形成结构件1，但是在制造图1的结构件的替代性方法中，可以利用树脂灌注法。代替将预浸渍件铺设到铺层工具上，将干纤维层片的堆叠件以与嵌入的加强插入件4类似的方式铺设。在堆叠件已组装好之后，用环氧树脂基体材料对堆叠件进行灌注，该环氧树脂基体材料流动以与加强插入件接触并且浸渍支承格栅5。多孔的支承格栅5有助于基体材料在灌注过程期间在堆叠件的整个厚度上流动。因此，当利用树脂灌注法时，格栅5提供了两个明显优势：第一，格栅5提供了准确地且在单个步骤中安装加强插入件的便利方式；第二，格栅5对树脂灌注过程提供帮助。
在以上给出的示例中，孔6是钻削出的空隙，但是在替代性实施方式中，孔6可以形成有螺纹以接纳带外螺纹的紧固件杆部。
尽管图11和图12的接合件将复合结构件1接合至金属工件，但是该接合件可以形成有任何其他工件，包括具有加强金属插入件的类似复合结构件。
尽管上文已经参照一个或更多个优选实施方式对本发明进行了描述，但将理解的是，在不背离本发明的如所附权利要求中限定的范围的情况下可以做出各种变型或改型。

Claims (15)

1.一种结构件，包括：由纤维增强基体材料构成的复合层片的堆叠件；多个加强插入件，其中，每个加强插入件均嵌入所述堆叠件中并且结合至所述堆叠件；多个孔，其中，每个孔均贯穿所述加强插入件中的相应一个加强插入件；以及支承层，每个加强插入件均接合至所述支承层，其中，所述支承层由与所述复合层片不同的材料形成并且浸渍有与所述复合层片相同的基体材料。
2.根据权利要求1所述的结构件，其中，所述支承层嵌入所述堆叠件中，其中，所述堆叠件的第一复合层片和第二复合层片定位在所述支承层的相反两侧上，并且所述第一复合层片和所述第二复合层片结合至每个加强插入件。
3.根据权利要求1或2所述的结构件，其中，所述支承层是金属支承层。
4.根据任一前述权利要求所述的结构件，还包括位于所述加强插入件的相反端部处的由纤维增强基体材料构成的一对包覆层片，其中，每个加强插入件均结合至所述包覆层片，并且每个孔均贯穿所述一对包覆层片。
5.根据任一前述权利要求所述的结构件，其中，每个加强插入件均是金属加强插入件。
6.根据任一前述权利要求所述的结构件，其中，所述堆叠件的至少两个复合层片具有结合至所述加强插入件的内部边缘。
7.根据权利要求1所述的结构件，其中，每个加强插入件均具有侧面以及一对端面；所述堆叠件的至少两个复合层片具有结合至所述加强插入件的所述侧面的内部边缘；所述结构件还包括由纤维增强基体材料构成的一对包覆层片，所述一对包覆层片结合至所述加强插入件的所述端面；并且每个孔均贯穿所述一对包覆层片。
8.根据任一前述权利要求所述的结构件，其中，所述支承层是格栅、网状物或穿孔板。
9.一种接合件，包括：工件；以及根据任一前述权利要求所述的结构件，所述结构件通过多个紧固件接合至所述工件，每个紧固件均具有穿过所述孔中的相应一个孔的杆部。
10.一种制造根据权利要求1所述的结构件的方法，所述方法包括：将由纤维增强基体材料构成的复合层片的堆叠件铺设到铺层工具上，其中，多个加强插入件嵌入所述堆叠件中，其中，所述加强插入件在所述加强插入件嵌入所述堆叠件中之前由多孔支承层承载；对所述基体材料进行加热和固化，使得所述加强插入件共同结合至所述堆叠件，并且使得所述多孔支承层浸渍有所述基体材料；以及在所述基体材料已固化之后，形成多个孔，每个孔均贯穿所述加强插入件中的相应一个加强插入件。
11.一种制造根据权利要求1所述的结构件的方法，所述方法包括：将干纤维层片的堆叠件铺设到铺层工具上，其中，多个加强插入件嵌入所述堆叠件中，其中，所述加强插入件在所述加强插入件嵌入所述堆叠件中之前由多孔支承层承载；用基体材料对所述干纤维层片的堆叠件进行灌注，所述基体材料流动以与所述加强插入件接触并且浸渍所述多孔支承层；对所述基体材料进行固化，使得所述加强插入件共同结合至所述堆叠件；以及在所述基体材料已固化之后，形成多个孔，每个孔均贯穿所述加强插入件中的相应一个加强插入件。
12.根据权利要求10或11所述的方法，其中，所述多孔支承层嵌入所述堆叠件中，其中，所述堆叠件的第一层片和第二层片定位在所述多孔支承层的相反两侧上，并且所述第一层片和所述第二层片在所述基体材料固化时共同结合至所述加强插入件。
13.根据权利要求10、11或12所述的方法，其中，由所述多孔支承层承载的所述加强插入件同时嵌入所述堆叠件中。
14.根据权利要求10、11、12或13所述的方法，还包括在所述加强插入件嵌入所述堆叠件中之前将所述加强插入件接合至所述多孔支承层。
15.根据权利要求14所述的方法，其中，所述加强插入件通过焊接接合至所述多孔支承层。
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