CN107253354A - 具有短纤维增强表面的中空结构芯 - Google Patents

具有短纤维增强表面的中空结构芯 Download PDF

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CN107253354A
CN107253354A CN201710486391.6A CN201710486391A CN107253354A CN 107253354 A CN107253354 A CN 107253354A CN 201710486391 A CN201710486391 A CN 201710486391A CN 107253354 A CN107253354 A CN 107253354A
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core
top laminate
base lamina
fiber
composite
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普罗比尔·库马尔·古哈
菲利普·邦特
多米尼克·布瓦耶
克里斯托弗·约翰斯顿
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History Of Olympic Game Pinwei (tangshan) Structure Composite Materials Co Ltd
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History Of Olympic Game Pinwei (tangshan) Structure Composite Materials Co Ltd
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Abstract

具有短纤维增强表面的中空结构芯。提供一种形成一复合夹层面板组合的方法包括于一开孔基质芯的相对侧面定位设置一顶部薄片和一底部薄片。将所述的顶部薄片、底部薄片和芯暴露于一热源处伴随一夹紧压力到所述的顶部薄片和所述的底部薄片的施加。然后去除所述的热源并维持所述的夹紧压力一段时间。当所述的顶部薄片、底部薄片和芯已冷却并融合在一起时去除所述的夹紧压力。还提供了由这一方法制成的一组合。

Description

具有短纤维增强表面的中空结构芯
本申请为申请日是2014.12.08、申请号是201480073997.1、发明创造名称是“具有短纤维增强表面的中空结构芯”的发明专利申请的分案申请。
与之相关的专利申请
本申请主张2013年12月6日递交的序列号为61/912,749的美国临时申请的优先权，据此，其内容通过引用的方式并入。
技术领域
本发明通常涉及复合材料，特别是涉及一种具有侧面薄片(side sheets)的复合夹层结构(composite sandwich structure)和一种介于中间的由与侧面薄片相同的复合材料制成的中空结构芯支撑基质(open area core support matrix)。
背景技术
在汽车、运输和物流为基础的行业中为了制造地面和空中运输均适用的更高燃油效率的车辆，重量减轻(Weight savings)一直是一个主要的焦点。为了实现这些重量减轻(Weight savings)，轻重量的复合材料已被采用以取代金属结构的和面体(surface body)的组件与面板。复合材料是两种或以上具有显著不同的物理或化学性质的构成材料(constituent materials)制成的,当构成材料结合时,产生的一种具有单个组份(theindividual components)所不具备的特性的材料。单个组分(the individualcomponents)在成品结构(finished structure)中保持独立且有区别的。一种复合材料可能因为很多原因成为优选：常见的例子包括相比较于传统的材料时更强的、更轻的、或更便宜的材料。一种夹层-结构复合材料(sandwich-structured composite)是一类特殊的通过连接两个薄但坚硬的面板到一种重量轻但厚的芯以制成的复合材料。该芯材料(corematerial)通常是一种低强度的材料，但其较高的厚度提供该夹层复合材料(sandwichcomposite)高抗弯刚度(bending stiffness)以及整体低密度(overall low density)。
尽管夹层复合材料(sandwich composite)为一种较轻质量的组件提供了上述的高抗弯刚度与一较低总密度，但由于用于外部面板壁(outer skin walls)和芯的急需材料(desperate materials)以及其不同的热膨胀系数引入了热应力该夹层复合材料的热循环性能不是最佳的。因此，存在一个优化热循环性能的一种改进的夹层复合结构的需要。
发明内容
提供一种形成一复合夹层面板组合的方法包括于一开孔基质芯的相对侧面定位设置一顶部薄片和一底部薄片。将所述的顶部薄片、底部薄片和芯暴露于一热源处伴随一夹紧压力到所述的顶部薄片和所述的底部薄片的施加。然后去除所述的热源并维持所述的夹紧压力一段时间。当所述的顶部薄片、底部薄片和芯已冷却并融合在一起时去除所述的夹紧压力。还提供了由这一方法制成的一组合(assembly)。
附图说明
图1为根据本发明的一个实施例的移除所述的顶部薄片的一部分以显示蜂窝状的复合材料芯的一复合夹层的局部透视图；以及
图2为根据本发明的实施例的形成所述的复合夹层结构的一生产方法的一流程图。
具体实施方式
本发明具有实用性，作为一改进的复合夹层面板结构有两个侧面薄片夹入一种介于中间的由与该顶部的和底部的薄片相同的复合材料制成的中空结构芯支撑基质以改善热循环性能和减轻成形部分(formed part)的压力。本发明的实施例的夹层复合结构由包括聚丙烯、尼龙、聚碳酸酯、聚乙烯、丙烯腈丁二烯苯乙烯(acrylonitrile butadienestyrene)、聚丁烯、交联聚乙烯(polyethylene cross linked)、聚氯乙烯、氯化聚氯乙烯、聚偏二氟乙烯、和包含任何上述的嵌段共聚物(block copolymers)的热塑性聚合物制成。
如本发明中所用的，应用于一类型的聚合物的术语“相同的”旨在表示在两种聚合物中存在一种以多数存在的共同单体组分(monomeric subunit)。可以理解的是，某些但不是所有的实例的相同的聚合物也具有一个在10％以内的介于玻璃化转变温度、重均分子量(weight average molecular weight)(Mw)、交联密度中的一种或多种之间的特性。在其它情况下，该组件由相同的热塑性的原料制成。
本发明的实施例夹层可以将所述的芯和顶部的/底部的薄片用短纤维强化。在某些实施方案中，该纤维为未取向的并且在聚合物中为无规的。用于在所述的复合夹层中增强成形的部分(formed part)的纤维包括玻璃、碳、和其他合成纤维、以及天然纤维。天然纤维示例性地包括椰子纤维、竹纤维、甘蔗纤维、香蕉皮纤维、以及它们的组合。所述的中空结构芯支撑基质(open area core support matrix)可以由各种图案示例性地包括蜂窝状、菱形、正方形、三角形、平行四边形、圆形和它们的组合的图案制成。
应该理解的是，在实施例中设置了值的范围，该范围旨在不仅仅包括该范围的端点值，还包含该范围的明确包含在该范围中的，并且随该范围的最后有效数字改变的中间值。举例来说，从1到4的列举范围旨在包括1～2、1～3、2～4、3～4和1～4。
在某些本发明的实施例中，单元壁(cell wall)的厚度与一单元中空结构模型(cell open area shape)的最大线性范围之比介于0.01-10：1之间。在本发明的这些实施例中一个单元壁(cell wall)的厚度范围为0.1mm到100mm。
在某些本发明的夹层的实施例中，所述的中空芯区域(open core area)可以用相变材料(PCM)填充。相变材料被用来控制和调节物体相对于该物体的周围环境(ambientenvironment)的温度。一PCM具有一相当可观的熔融潜热(latent heat of fusion)，并且可设计为具有在该物体的所期望的工作温度(operating temperature)可调节范围内的一恒定的熔融温度(Tm)。根据环境温度(ambient temperatures)和/或该物体内的温度，PCM根据需要在一基本恒定的熔融温度，Tm，从物体中吸收热量、或对物体释放热量以提供物体更好的的温度稳定性，保持它较长时间在其最佳工作温度(operating temperature)范围之内。通常，当PCMs达到它们的相变温度(它们的熔化温度)时它们在一几乎恒定的温度吸收大量的热量。PCM和含有该物质的本发明结构中固相和液相均同时存在并且熔化的潜热要么被吸收(熔融)要么被释放(冻结)因此与周围相比保持一个窄的温度范围。该PCM继续吸收热量而没有一个显著的温度上的上升直到所有材料被转化为液相。当一液体材料周围的环境温度(ambient temperatures)下降时，PCM凝固，释放其储存的潜热。
现在参照附图，图1为本发明的复合夹层10具有被附上一顶部薄片14和一底部薄片16的一蜂窝状芯12的一个实施例的一局部透视图。该顶部薄片14的一部分被去除以显示出蜂窝状复合芯12。该顶部薄片14和底部薄片16由与该芯12相同的热塑性聚合物制成。该热塑性聚合物可用包括合成的(synthetic)、玻璃、碳、和天然纤维的未取向的纤维强化。在顶部薄片14和底部薄片16以及该芯12中该相同的复合材料的使用确保当它们被加入一夹层10时在材料之间的一热匹配，从而改善了该夹层10的热循环性能。热塑性材料的使用使得在制造夹层10期间该顶部薄片14和底部薄片16内表面18可热熔化到该芯12。
图2是根据本发明的实施方式用以形成复合夹层结构的一生产过程(productionprocess)20的流程图。该过程20由在该芯附近定位设置所述的顶部的和底部的薄片(步骤22)开始然后暴露安排一红外热源处以软化热塑性塑料(thermoplastic)(步骤24)。在步骤26中，一夹紧压力被施加到仍然软化的热塑性塑料(thermoplastic)以便压紧薄片到该芯并保持接触。在步骤28中，仍然施加夹紧压力随着热塑性部件冷却并融合在一起。一旦部件已经冷却下来，且一融合的夹层已经形成，夹具被去除(步骤30)。可以理解的是，相对的压台(platens)易于用于施加动态热和压力。该压台易于根据需要被加热和被冷却以达到所述的薄片和所述的芯之间的融合而不会造成开放芯基质区域的塌缩(collapse)。
可以理解的是，可使用一等离子体源以不仅提供热量，而且提供介于一个薄片和该开孔基质芯(open pore matrix core)之间的自由基键合位点。这种等离子体源于本领域是常规的。
上面的描述是本发明的特定的具体实施方案的说明，但是此处并不意味着在实践中的限制。上述的的权利要求，包括其所有等同物，旨在限定本发明的范围。

Claims (5)

1.一种复合夹层面板组合，所述的组合包括：
熔合于一开孔基质芯的相对侧面的一顶部薄片和一底部薄片；以及
在所述的顶部薄片、所述的底部薄片和所述的芯中的至少一个中的纤维；
所述的顶部薄片、所述的底部薄片或所述的芯均由相同的热塑性聚合物材料制成，
所述的顶部薄片、所述的底部薄片或所述的芯中的至少一个还包含纤维，所述的纤维仅为玻璃纤维。
2.根据权利要求1所述的组合，其特征在于，所述的热塑性聚合物为一聚丙烯、或一尼龙材料中的至少一种。
3.根据权利要求1所述的组合，其特征在于，所述的纤维为未取向的。
4.根据权利要求1所述的组合，其特征在于，所述的芯为一蜂窝状、菱形、正方形、三角形、平行四边形或圆形中的至少一种图案。
5.根据权利要求1至4中任一项所述的组合，其特征在于，还包括在所述的芯内部的一相变材料。
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