CN107914429A - 一种飞行汽车用轻质高强折叠翼材料及其制备方法 - Google Patents
一种飞行汽车用轻质高强折叠翼材料及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种飞行汽车用轻质高强折叠翼材料的制备方法,涉及机械领域,包括复合材料层和蒙皮层,所述复合材料层包括N层单向碳纤维层、2N层正交碳纤维层以及一个蜂窝夹层,所述蜂窝夹层铺设在复合材料层的中间且蜂窝夹层两侧分别为2层正交纤维层,正交纤维层的外侧铺设有所述的单向纤维层,本发明还公开了上述机翼材料的制备方法,本发明的复合材料采用多向碳纤维预浸料,提高了机翼部件在多方向的抗拉、抗压及抗剪切能力,同时,采用经特殊设计的铺设顺序,进一步提高了复合材料整体性能的均衡性,经本发明的工艺生产出的材料不仅具有良好的高温热稳定性、化学稳定性、阻燃性能等,还具有优良的力学性能。
Description
技术领域
本发明涉及复合材料技术领域,具体涉及一种飞行汽车用轻质高强折叠翼材料和一种飞行汽车用轻质高强折叠翼材料的制备方法。
背景技术
复合材料是由两种或两种以上物理和化学性质不同的物质组合而成的一种多相固体材料。复合材料的组分材料虽然保持其相对独立性,但复合材料的性能却不是组分材料性能的简单相加,而是有着重要的改进。在复合材料中,通常有一相为连续相,称为基体;另外一相为分散相,称为增强材料。飞机结构上使用的复合材料主要是纤维增强复合材料。
飞机结构上使用的复合材料的基体主要是树脂基体。在复合材料结构件成型过程中,树脂基体参与化学反应并固化成型为结构。树脂基体对纤维起支撑、保护作用并传递载荷。环氧树脂是最早用于飞机结构复合材料的树脂基体。环氧树脂基体成型工艺性优良,耐湿热性能好,易于维护修理,价格便宜,所以至今在飞机结构用复合材料中,仍占主导地位。
强度、重量和成本是决定使用哪种材料制造飞机的重要因素。复合材料相比传统金属材料,最大的优势在于它有更高的比强度。采用复合材料的部件可以在满足同样强度要求的情况下,设计得比金属材料的部件更轻。一般来说,采用复合材料部件代替铝制部件,可以减轻大约 20%的结构重量。同时随着复合材料工业的发展,碳纤维等高强度高模量的纤维原料价格逐渐下降,使得复合材料的强度价格比也开始超过了铝。在满足同等强度要求的情况下,复合材料部件的原料成本价格低于一般金属材料部件。
中国专利公开号为CN206265287U公开了一种无人机用碳纤维复合材料翼梁,包括由镁铝合金制成的空腔状的翼前梁和翼后梁;所述翼前梁和翼后梁之间固定有多根中间肋骨板;所述翼前梁和翼后梁包括中梁和外梁;所述外梁尾部一体制成E型接口,所述中梁前端一体制成有Y型接口;所述E型接口与Y型接口嵌合,且通过多个合金螺栓垂直锁定;所述翼前梁和翼后梁外围设置有三维机织碳纤维环氧树脂复合材料层。该种无人机用碳纤维复合材料翼梁,采用镁铝合金和碳纤维材料复合,既能够实现质量上的轻量化,同时能够提供翼梁韧性和强度,外梁通过螺栓与中梁连接,将机翼产生的升力传递至中粱,而中粱通过螺栓与机身固定,通过外碳纤维编织层使翼梁能够形成一体化
又如中国专利公开号为CN104626605B公开了一种复合材料机翼整体成型工艺方法及工装,采用金属阴模和硅橡胶阳模辅助成型:首先制造阴模,并利用阴模制造阳模;清理阴模上下模型面喷涂脱模剂;在阴模上、下模型面上分别铺贴复合材料机翼上下翼面;在机翼下翼面上放置阳模和机翼前缘零件;将阴模上模与下模对合;对合后的阴模、阳模和复合材料机翼产品放入热压罐中固化;固化后脱模,经过修边得到复合材料机翼;实现了较小尺寸复合材料机翼的整体成型,减轻了复合材料机翼的整体重量,提高了复合材料机翼的结构强度。整体成型的复合材料机翼内部质量好,外部翼型型面尺寸精准,同时能严格控制复合材料机翼产品铺层厚度,复合材料机翼的整体成型质量稳定可靠。
上述两种工艺中,前者采用了镁铝合金+碳纤维材料进行复合,虽然在连接方式上采用了特殊的工艺,但是其仍然采用金属+复合材料的方式,在相同体积的情况下,重量增加,并不适用与飞行汽车方面;后者通过优化成型工装来实现复合材料力学性能和精度的提升,但是没有公开具体的材料组成,故不具有比较意义。
发明内容
本发明所要解决的问题是提供一种质轻、高比强度且工艺简单的飞行汽车用轻质高强折叠翼材料及其制备方法。
为了实现上述目的,本发明采取的技术方案为:所提供的一种飞行汽车用轻质高强折叠翼材料,包括复合材料层和蒙皮层,所述蒙皮层设于复合材料层的外侧,所述复合材料层包括N层单向碳纤维层、2N层正交碳纤维层以及一个蜂窝夹层,所述蜂窝夹层铺设在复合材料层的中间且蜂窝夹层两侧分别为2层正交纤维层,正交纤维层的外侧铺设有所述的单向纤维层,其中,6≤N≤8且N为正整数。
一种飞行汽车用轻质高强折叠翼材料的制备方法,包括如下步骤:
(1)将单向碳纤维层和正交纤维层用偶联剂进行表面处理后,浸入到环氧树脂体系中进行浸渍,得到不同纤维走向的碳纤维环氧树脂预浸料;
(2)将所述碳纤维环氧树脂预浸料进行预烘干;
(3)将蜂窝夹层置于模具内,接着将上述预烘干后的碳纤维环氧树脂预浸料铺设在蜂窝夹层的一侧,其中,铺设顺序为:先两层正交碳纤维环氧树脂预浸料,再一层单向碳纤维环氧树脂预浸料;
(4)待蜂窝夹层的一侧铺设完成后,再按步骤(3)的方法铺设蜂窝夹层的另一侧;
(5)整个铺设过程完成后,将复合材料置于热压机内热压成型,得到所述的折叠翼材料。
优选的,所述单向碳纤维环氧树脂预浸料的厚度为0.328-0.420mm,所述正交碳纤维环氧树脂预浸料的厚度为0.412-0.460mm,所述蜂窝夹层的厚度为10-12mm。
优选的,所述蜂窝夹层具体为Nomex蜂窝。
优选的,所述步骤(2)中预烘干的工艺条件为:62-65℃的温度下预烘40-45min。
优选的,所述步骤(5)中热压成型的工艺参数为:在温度为93-98℃、压力为3-5MPa条件下压制60-70min。
优选的,所述步骤(5)中热压成型的工艺参数优选为:在温度为95℃、压力为4 MPa条件下压制68min。
本发明的有益效果:
(1)本发明的复合材料采用多向碳纤维预浸料,提高了机翼部件在多方向的抗拉、抗压及抗剪切能力,同时,采用经特殊设计的铺设顺序,进一步提高了复合材料整体性能的均衡性,此外,还引入了蜂窝夹层结构,其具有高刚度重量比的高效率结构,虽然厚度是普通层叠结构的多倍,但是其强度增加的更多,重量也仅仅增加了一点点,工艺和经济上更为划算。
(2)采用本发明的工艺步骤,生产出的机翼材料,不仅具有良好的高温热稳定性、化学稳定性、阻燃性能等,还具有优良的力学性能,且密度相比常用的金属材料、金属复合材料分别低20-30%和10%-15%,大大减轻了重量,抗疲劳性也得到了提高,在32%以上。
具体实施方式
为了加深对本发明的理解,下面将结合实施例对本发明作进一步详述,该实施例仅用于解释本发明,并不构成对本发明保护范围的限定。
实施例1
一种飞行汽车用轻质高强折叠翼材料,包括复合材料层和蒙皮层,所述蒙皮层设于复合材料层的外侧,所述复合材料层包括N层单向碳纤维层、2N层正交碳纤维层以及一个蜂窝夹层,所述蜂窝夹层铺设在复合材料层的中间且蜂窝夹层两侧分别为2层正交纤维层,正交纤维层的外侧铺设有所述的单向纤维层,其中, N=6。
一种飞行汽车用轻质高强折叠翼材料的制备方法,包括如下步骤:
(1)将单向碳纤维层和正交纤维层用偶联剂进行表面处理后,浸入到环氧树脂体系中进行浸渍,得到不同纤维走向的碳纤维环氧树脂预浸料;
(2)将所述碳纤维环氧树脂预浸料进行预烘干,工艺条件为:62℃的温度下预烘45min;
(3)将蜂窝夹层置于模具内,接着将上述预烘干后的碳纤维环氧树脂预浸料铺设在蜂窝夹层的一侧,其中,铺设顺序为:先两层正交碳纤维环氧树脂预浸料,再一层单向碳纤维环氧树脂预浸料;
(4)待蜂窝夹层的一侧铺设完成后,再按步骤(3)的方法铺设蜂窝夹层的另一侧;
(5)整个铺设过程完成后,将复合材料置于热压机内热压成型,得到所述的折叠翼材料,热压成型的工艺参数为:在温度为93℃、压力为3 MPa条件下压制70min。
在本实施例中,所述单向碳纤维环氧树脂预浸料的厚度为0.328mm,所述正交碳纤维环氧树脂预浸料的厚度为0.412mm,所述蜂窝夹层的厚度为10mm。
在本实施例中,所述蜂窝夹层具体为Nomex蜂窝。
实施例2
一种飞行汽车用轻质高强折叠翼材料,包括复合材料层和蒙皮层,所述蒙皮层设于复合材料层的外侧,所述复合材料层包括N层单向碳纤维层、2N层正交碳纤维层以及一个蜂窝夹层,所述蜂窝夹层铺设在复合材料层的中间且蜂窝夹层两侧分别为2层正交纤维层,正交纤维层的外侧铺设有所述的单向纤维层,其中, N=6。
一种飞行汽车用轻质高强折叠翼材料的制备方法,包括如下步骤:
(1)将单向碳纤维层和正交纤维层用偶联剂进行表面处理后,浸入到环氧树脂体系中进行浸渍,得到不同纤维走向的碳纤维环氧树脂预浸料;
(2)将所述碳纤维环氧树脂预浸料进行预烘干,工艺条件为:63℃的温度下预烘42min;
(3)将蜂窝夹层置于模具内,接着将上述预烘干后的碳纤维环氧树脂预浸料铺设在蜂窝夹层的一侧,其中,铺设顺序为:先两层正交碳纤维环氧树脂预浸料,再一层单向碳纤维环氧树脂预浸料;
(4)待蜂窝夹层的一侧铺设完成后,再按步骤(3)的方法铺设蜂窝夹层的另一侧;
(5)整个铺设过程完成后,将复合材料置于热压机内热压成型,得到所述的折叠翼材料,热压成型的工艺参数为:在温度为95℃、压力为4 MPa条件下压制62min。
在本实施例中,所述单向碳纤维环氧树脂预浸料的厚度为0.340mm,所述正交碳纤维环氧树脂预浸料的厚度为0.420mm,所述蜂窝夹层的厚度为11mm。
在本实施例中,所述蜂窝夹层具体为Nomex蜂窝。
实施例3
一种飞行汽车用轻质高强折叠翼材料,包括复合材料层和蒙皮层,所述蒙皮层设于复合材料层的外侧,所述复合材料层包括N层单向碳纤维层、2N层正交碳纤维层以及一个蜂窝夹层,所述蜂窝夹层铺设在复合材料层的中间且蜂窝夹层两侧分别为2层正交纤维层,正交纤维层的外侧铺设有所述的单向纤维层,其中, N=6。
一种飞行汽车用轻质高强折叠翼材料的制备方法,包括如下步骤:
(1)将单向碳纤维层和正交纤维层用偶联剂进行表面处理后,浸入到环氧树脂体系中进行浸渍,得到不同纤维走向的碳纤维环氧树脂预浸料;
(2)将所述碳纤维环氧树脂预浸料进行预烘干,工艺条件为:64℃的温度下预烘44min;
(3)将蜂窝夹层置于模具内,接着将上述预烘干后的碳纤维环氧树脂预浸料铺设在蜂窝夹层的一侧,其中,铺设顺序为:先两层正交碳纤维环氧树脂预浸料,再一层单向碳纤维环氧树脂预浸料;
(4)待蜂窝夹层的一侧铺设完成后,再按步骤(3)的方法铺设蜂窝夹层的另一侧;
(5)整个铺设过程完成后,将复合材料置于热压机内热压成型,得到所述的折叠翼材料,热压成型的工艺参数为:在温度为95℃、压力为4 MPa条件下压制68min。
在本实施例中,所述单向碳纤维环氧树脂预浸料的厚度为0.362mm,所述正交碳纤维环氧树脂预浸料的厚度为0.452mm,所述蜂窝夹层的厚度为11mm。
在本实施例中,所述蜂窝夹层具体为Nomex蜂窝。
实施例4
一种飞行汽车用轻质高强折叠翼材料,包括复合材料层和蒙皮层,所述蒙皮层设于复合材料层的外侧,所述复合材料层包括N层单向碳纤维层、2N层正交碳纤维层以及一个蜂窝夹层,所述蜂窝夹层铺设在复合材料层的中间且蜂窝夹层两侧分别为2层正交纤维层,正交纤维层的外侧铺设有所述的单向纤维层,其中, N=6。
一种飞行汽车用轻质高强折叠翼材料的制备方法,包括如下步骤:
(1)将单向碳纤维层和正交纤维层用偶联剂进行表面处理后,浸入到环氧树脂体系中进行浸渍,得到不同纤维走向的碳纤维环氧树脂预浸料;
(2)将所述碳纤维环氧树脂预浸料进行预烘干,工艺条件为: 65℃的温度下预烘40min;
(3)将蜂窝夹层置于模具内,接着将上述预烘干后的碳纤维环氧树脂预浸料铺设在蜂窝夹层的一侧,其中,铺设顺序为:先两层正交碳纤维环氧树脂预浸料,再一层单向碳纤维环氧树脂预浸料;
(4)待蜂窝夹层的一侧铺设完成后,再按步骤(3)的方法铺设蜂窝夹层的另一侧;
(5)整个铺设过程完成后,将复合材料置于热压机内热压成型,得到所述的折叠翼材料,热压成型的工艺参数为:在温度为98℃、压力为5 MPa条件下压制60min。
在本实施例中,所述单向碳纤维环氧树脂预浸料的厚度为0.420mm,所述正交碳纤维环氧树脂预浸料的厚度为0.460mm,所述蜂窝夹层的厚度为12mm。
在本实施例中,所述蜂窝夹层具体为Nomex蜂窝。
性能测试结果如下:
显然本发明具体实现并不受上述方式的限制,只要采用了本发明的方法构思和技术方案进行的各种非实质性的改进,或未经改进将本发明的构思和技术方案直接应用于其它场合的,均在本发明的保护范围之内。
Claims (7)
1.一种飞行汽车用轻质高强折叠翼材料,其特征在于,包括复合材料层和蒙皮层,所述蒙皮层设于复合材料层的外侧,所述复合材料层包括N层单向碳纤维层、2N层正交碳纤维层以及一个蜂窝夹层,所述蜂窝夹层铺设在复合材料层的中间且蜂窝夹层两侧分别为2层正交纤维层,正交纤维层的外侧铺设有所述的单向纤维层,其中,6≤N≤8且N为正整数。
2.一种飞行汽车用轻质高强折叠翼材料的制备方法,其特征在于,包括如下步骤:
(1)将单向碳纤维层和正交纤维层用偶联剂进行表面处理后,浸入到环氧树脂体系中进行浸渍,得到不同纤维走向的碳纤维环氧树脂预浸料;
(2)将所述碳纤维环氧树脂预浸料进行预烘干;
(3)将蜂窝夹层置于模具内,接着将上述预烘干后的碳纤维环氧树脂预浸料铺设在蜂窝夹层的一侧,其中,铺设顺序为:先两层正交碳纤维环氧树脂预浸料,再一层单向碳纤维环氧树脂预浸料;
(4)待蜂窝夹层的一侧铺设完成后,再按步骤(3)的方法铺设蜂窝夹层的另一侧;
(5)整个铺设过程完成后,将复合材料置于热压机内热压成型,得到所述的折叠翼材料。
3.根据权利要求书2所述的一种飞行汽车用轻质高强折叠翼材料的制备方法,其特征在于,所述单向碳纤维环氧树脂预浸料的厚度为0.328-0.420mm,所述正交碳纤维环氧树脂预浸料的厚度为0.412-0.460mm,所述蜂窝夹层的厚度为10-12mm。
4.根据权利要求书3所述的一种飞行汽车用轻质高强折叠翼材料的制备方法,其特征在于,所述蜂窝夹层具体为Nomex蜂窝。
5.根据权利要求书2所述的一种飞行汽车用轻质高强折叠翼材料的制备方法,其特征在于,所述步骤(2)中预烘干的工艺条件为:62-65℃的温度下预烘40-45min。
6.根据权利要求书2所述的一种飞行汽车用轻质高强折叠翼材料的制备方法,其特征在于,所述步骤(5)中热压成型的工艺参数为:在温度为93-98℃、压力为3-5 MPa条件下压制60-70min。
7.根据权利要求书6所述的一种飞行汽车用轻质高强折叠翼材料的制备方法,其特征在于,所述步骤(5)中热压成型的工艺参数优选为:在温度为95℃、压力为4 MPa条件下压制68min。
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