CN109922945B - 复合载具本体 - Google Patents

复合载具本体 Download PDF

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Publication number
CN109922945B
CN109922945B CN201780067648.2A CN201780067648A CN109922945B CN 109922945 B CN109922945 B CN 109922945B CN 201780067648 A CN201780067648 A CN 201780067648A CN 109922945 B CN109922945 B CN 109922945B
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China
Prior art keywords
continuous fibers
skin
carrier body
fibers
airfoil
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CN201780067648.2A
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English (en)
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CN109922945A (zh
Inventor
肯尼思·泰勒
赖安·C·斯托科特
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Continuous Composite Co
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Continuous Composite Co
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Abstract

本发明公开了一种载具本体，其可具有由彼此结合的多个叠覆层形成的骨架。多个叠覆层中的每一个可以由涂覆有基质材料的连续纤维制成。连续纤维的轨迹在多个叠覆层的相邻层之间可以不同。

Description

复合载具本体
相关申请的交叉引用
本专利申请要求于2016年11月3日提交的序列号为62/417,056的美国临时专利申请的优先权，其全部内容通过引用并入本申请。
技术领域
本发明总体上涉及一种载具本体，更具体地，涉及一种由复合材料制成的载具本体。
背景技术
载具本体(例如，飞机本体、汽车本体或船本体)通常包括赋予车辆形状的内部骨架，以及覆盖骨架并提供光滑外表面的表皮。现代载具本体由不同材料的组合制成，包括复合材料。例如，骨架通常由木材、铝或不锈钢制成，而表皮通常由嵌入树脂基质内的纤维(例如碳纤维或玻璃纤维)制成。
拉挤成型是制造载具本体的直骨架部件(例如，横梁，纵梁等)的常用方式。在拉挤成型制造过程中，单根纤维股线、股线编织物和/或织物从相应的线轴拉动穿过树脂浴和固定模具。然后允许树脂固化并硬化。由于在固化之前拉动纤维，因此这些纤维中的一些在固化完成后可以保持一定拉伸应力水平。该拉伸应力可以增加骨架部件在拉动纤维所沿的方向上的强度。
在已经形成内部骨架之后，通常使用真空辅助树脂传递模塑(VARTM)过程来制造载具本体的表皮。在VARTM过程中，将纤维材料片手动拉动在内部骨架上，然后将纤维材料片固定到适当位置。然后将已固定材料用液体基质(例如，热固性树脂或加热的热塑性塑料)手动涂覆，用真空袋覆盖以促进液体基质的浸渍并允许固化和硬化。
虽然拉挤成型制造和VARTM在某些情况下可以成为生产载具本体部分的可接受方式，但它们也存在问题。特别地，VARTM生产的表皮通常附接至拉挤骨架部件和/或通过金属紧固件(例如，螺钉、铆钉和夹子)加固。金属紧固件的使用可以驱动骨架设计并增加载具本体的重量和成本。此外，各种载具本体部件可能需要通过专门设计的硬件彼此连接，这也可能是沉重且昂贵的。此外，在制造之后可能需要将电子器件(例如，传感器、加热器、电引线等)添加到载具本体，这可能进一步增加重量、成本和不可靠性。最后，传统的拉挤成型和VARTM制造过程在载具本体的设计和/或使用方面可能提供很小的灵活性。
所公开的复合材料载具本体旨在克服上述一个或多个问题和/或现有技术的其他问题。
发明内容
在一个方面，本公开涉及一种载具本体。载具本体可包括由彼此结合的多个叠覆层形成的骨架。多个叠覆层中的每一个可以由涂覆有基质材料的连续纤维制成。连续纤维的轨迹可以在多个叠覆层的相邻层之间不同。
在另一方面，本发明涉及另一种载具本体。该载具本体可包括由彼此结合的多个叠覆层形成的骨架。多个叠覆层中的每一个可以由涂覆有基质材料的连续纤维制成。载具本体还可包括形成在由涂覆有基质材料的连续纤维片制成在内部骨架上的表皮。多个叠覆层可包括形成骨架横截面的中心开口的周界的第一类型层，以及形成骨架的具有周界的横截面以及位于周界的节点之间的横梁件的第二类型层。第一类型层可以与多个叠覆层中的第二类型层交替。
在另一方面，本公开涉及另一种载具本体。该载具本体可包括内部骨架，该内部骨架具有肋，该肋具有相反支撑表面、相反支具、以及连接支撑表面和支具的横梁件。相反支撑表面、相反支具和横梁件可以使用中间出离工具路径通过至少一个连续纤维形成。载具本体还可包括形成在内部骨架上的表皮。表皮可包括基质材料和多个连续纤维，所述多个连续纤维包裹在基质材料内并且分层设置成大致平行于载具本体表面。
附图说明
图1是示例性载具本体的示意图；
图2-5是图1的载具本体在制造期间的示例性部分的示意图；
图6是可用于制造图1的载具本体的示例性纤维的横截面图示；以及
图7-9是图1的载具本体的另外的示例性部分的示意图。
具体实施方式
图1示出了示例性载具本体(“本体”)10。在所公开的实施例中，本体10是飞行器本体(例如，飞机本体或无人机本体)。然而，可以想到，如果需要，本体10可以是另一种类型(例如，汽车本体，船本体等)。本体10，无论其构造和预期用途，可包括由外部表皮18覆盖的内部骨架16(例如，翼梁、肋、纵桁、隔板、桁架、纵梁等)制成的一个或多个部件(例如，机身12、一个或多个翼14等)。在一些实施例中，本体10的部件可以单独制造并随后连接在一起(例如，通过螺纹紧固、铆接等)。在其他实施例中，本体部件可以一起制造为整体一体结构(例如，在缺少至少一些破坏的情况下不能拆卸的结构)。
如图2所示，本体10的一个或多个部件可以通过增材制造过程制造。例如，骨架16可以由第一增材制造过程制造，而表皮18可以由第二且不同的增材制造过程制造。如果需要，可以预期骨架16和表皮18都可以由相同的增材制造过程制造。
第一增材制造过程可以是拉挤成型和/或挤出过程，其由复合材料(例如，具有基质M和至少一种连续纤维F的材料)形成中空管状结构20。特别地，一个或多个头部22可以联接到支撑件24(例如，到机械臂)，该支撑件24能够在结构20的排出期间沿多个方向移动一个或多个头部22，使得得到的结构20的纵向轴线26是三维的。例如，在美国专利申请号13/975,300和15/130,207以及PCT申请号2016042909中公开了这种头部，所有这些都通过引用整体并入本文。
一个或多个头部22可以被配置成接收或以其他方式包含基质材料M。基质材料M可以包括可固化的任何类型的液体树脂(例如，零挥发性有机化合物树脂)。示例性树脂包括环氧树脂、聚酯树脂、阳离子环氧树脂、丙烯酸酯化环氧树脂、氨基甲酸酯、酯、热塑性塑料、光聚合物、聚环氧化物、热固性丙烯酸酯、热固物、双马来酰亚胺、硅等。在一个实施例中，一个或多个头部22内部的基质材料M的压力可以由外部装置(例如，挤出机或其他类型的泵)产生，该外部装置通过对应导管流体连接到一个或多个头部22(未示出)。然而，在另一个实施例中，压力可以通过类似类型的装置完全在一个或多个头部22内部产生和/或仅仅是作用在基质材料M上的重力的结果。在一些情况下，一个或多个头部22内部的基质材料M可能需要保持冷却和/或阴暗以抑制过早固化；而在其他情况下，基质材料M可能由于同样的原因需要保温。在任一种情况下，一个或多个头部22可以被特殊配置的(例如，绝热的、冷却的和/或加热的)以满足这些需求。
存储在一个或多个头部22内部的基质材料M可用于涂覆任何数量的连续纤维F，并且与纤维F一起构成复合结构20的壁。纤维F可包括单个股线，数个股线的丝束或粗纱，或许多股线的编织物。股线可包括例如碳纤维、植物纤维、木纤维、矿物纤维、玻璃纤维、金属线、SiC陶瓷纤维、玄武岩纤维等。根据需要，纤维F可以在纤维F位于一个或多个头部22内部时、纤维F正通过一个或多个头部22时、和/或纤维F从一个或多个头部22排出时涂覆基质材料M。在一些实施方式中，填料材料(例如短切纤维)可在基质材料M涂覆纤维F之前和/或之后与基质材料M混合。基质材料、干燥纤维、已经涂覆有基质材料M的纤维和/或填料可以本领域技术人员显而易见的任何方式输送到一个或多个头部22中。然后，基质涂覆的纤维F可以经过位于一个或多个头部22的口部处的集中分流器(未示出)，在口部处，通过一个或多个固化增强器27(例如UV灯和/或超声发射器)使树脂固化(例如，从内向外、从外向内，或两者)。
在图2的示例中，结构20在翼14的长度方向上延伸并且构成骨架16的至少一部分。每个结构20可以与另一个结构20相邻排出和/或与先前排出的结构20叠覆，并且随后固化，使得邻近结构20内的液态树脂结合在一起。任何数量的结构20可以组合在一起并且具有产生翼14的期望骨架形状所需的任何轨迹。
在一些实施例中，填充材料(例如，绝缘体、导体、光学元件、表面面漆等)可以在形成结构20的同时沉积在结构20的内部和/或外部。例如，中空轴(未示出)可以延伸穿过相关联的一个或多个头部22中的任何一个的中心和/或在相关联的一个或多个头部22中的任何一个上方延伸。然后可以将材料供应部(例如，液体供应部、泡沫供应部、固体供应部、气体供应部等)与中空轴的一端连接，并且材料被迫穿过中空轴并到达特定表面上(即，结构20的内表面和/或外表面)。如果需要，预期用于固化结构20的相同一个或多个固化增强器27也可用于固化填充材料，或者为此目的可以使用一个或多个额外专用固化增强器(未示出)。填充材料可以允许结构20中的一个或多个用作燃料箱、燃料通道、电导管、通风管道等。
用于制造图2的示例性翼14的第二增材制造过程也可以是拉挤成型和/或挤出过程。然而，代替生产中空管状结构20，第二增材制造过程可用于在管状结构20上(和/或在骨架16的其他特征上)排出复合材料的径迹，带材和/或片材，从而制造表皮18。特别地，一个或多个头部28可以联接到支撑件30(例如，联接到悬台架)，该支撑件30能够在制造表皮18期间沿多个方向移动一个或多个头部28，从而使产生的表皮18轮廓是三维的。
头部28可以类似于头部22并且构造成接收或以其他方式包含基质材料M(例如，包含在头部22内的相同基质材料M)。存储在一个或多个头部28内部的基质材料M可用于涂覆任何数量的单独纤维F，从而允许纤维F构成排出径迹、带材和/或片材的集中增强物。纤维F可包括单个股线、数个股线的丝束或粗纱，或多个股线的编织物。股线可包括例如碳纤维、植物纤维、木纤维、矿物纤维、玻璃纤维、金属线等。根据需要，纤维F可以在纤维F位于一个或多个头部28内部时、纤维F通过一个或多个头部28时、和/或纤维F从一个或多个头部28排出时涂覆有基质材料M。基质材料、干燥纤维和/或已经涂覆有基质材料的纤维可以以本领域技术人员显而易见的任何方式输送到一个或多个头部28中。然后，基质涂覆的纤维F可以穿过一个或多个圆形孔、矩形孔、三角形孔或另一种弯曲或多边形形状的孔，在这些孔中，纤维F被压在一起并通过一个或多个固化增强器27使树脂固化。
在图3所示的另一个示例性实施例中，仅使用单个增材制造过程来制造翼14。具体地，上述第二制造过程用于使用连续纤维F和基质材料M附加地构建骨架16的层(例如，翼梁和/或纵桁)并且使用由相同或不同的连续纤维F和基质材料M制成的附加构建的表皮层18覆盖骨架16。构成骨架16的纤维F可以在骨架16的外表面上继续以成为表皮18的一部分，使得通过连续纤维F在骨架16和表皮18之间形成连续的机械连接。以这种方式，可以减少将表皮18连接到骨架16所需的紧固件的数量(如果没有消除的话)。预期支撑件24和/或支撑件30可用于在翼14的制造期间(或在制造本体10的任何其他部件期间)移动任何数量的头部28。
如上所述，第一和第二增材制造过程可以是挤出或拉挤成型过程。例如，当在支撑件24和/或30的移动期间从一个或多个头部22和/或一个或多个头部28推动液体树脂基质M和相关的连续纤维F时，可以发生挤出。在将一段的树脂涂覆的纤维连接到锚固件(未示出)并固化之后，然后使一个或多个头部22和/或一个或多个头部(28)远离锚固件移动之后，可以发生拉挤成型。一个或多个头部22和/或一个或多个头部28远离锚固件的移动导致纤维F连同涂覆基质材料M一道从相应的一个或多个头部拉出。
在一些实施例中，可以选择性地实施拉挤成型以在构成骨架16和/或表皮18的纤维F中产生张力并且在固化之后保留张力。特别地，当纤维F从相应的一个或多个头部拉出时，可以使纤维F拉伸。这种拉伸可在纤维F内产生张力。只要围绕纤维F的基质M在纤维F被拉伸的同时固化和硬化，则该张力中的至少一些保留在纤维F中并起到增加所得复合结构强度的作用。
通过常规拉挤成型方法制造的结构可以仅增加单一方向(例如，在手动树脂浸渍和固化之前将纤维拉动穿过对应模具所沿的一个方向)上的强度。然而，在所公开的实施例中，可以在每根纤维F的轴向方向上实现由相应纤维F内的残余张力引起的本体10的骨架16和/或表皮18(例如，在翼14内)的增加强度。并且因为每根纤维F在从一个或多个头部22和/或28排出时可以沿不同方向拉动，因此可以在多个(例如，无数个)不同方向上实现与张力相关的强度增加。
通过常规拉挤成型方法制造的结构可以仅具有增加到单一水平的强度(例如，达到与在手动树脂浸渍和固化之前通过牵拉机拉伸纤维布的量成比例的水平)。然而，在所公开的实施例中，因为围绕每根纤维F的基质M可以在排出时立即固化和硬化，所以拉动纤维F的力可以沿着纤维F的长度连续变化，使得相同纤维F的不同部段被拉伸不同的量。因此，在每根纤维F的不同部段中的每一个内引起的拉伸应力也可以是不同的，从而导致在本体10的骨架16和/或表皮18的不同区段内的可变强度。这在本体10的可变负载区域中是有益的(例如，在翼14和机身12的交接处、翼14的中心内、在翼14的前缘处等)。
图4示出了一种示例性方式，其中表皮18的纤维F可以被设置成提供翼14的期望特性。在该示例中，纤维F有机地设置(例如，以树生长的方式或以身体中血液静脉所分布的方式)。具体地，设置在翼14的结构16上的纤维F可以锚固在与机身12的交接处并且在一般的前/后中心处。然后可以将纤维F拉向翼14的远侧尖端，并远离前/后中心(例如，朝向翼14的前缘或后缘)，其中不同的纤维F朝向远侧尖端延伸不同的距离。另外，因为排出的基质材料M可以在从头部28排出后立即固化并且粘合到结构16或先前排出的表皮层18，所以可以控制头部28在排出期间的移动以产生纤维F的弯曲的径迹。预期纤维F可在翼14的远侧终止点处完全绕过翼14，然后沿着纤维F的初始径迹的镜像拉回机身12。有机排列纤维的这种设置可以位于翼14的顶侧、下侧，和/或位于翼14的多个位置处的横截面周界。通过这种设置，在机身12附近可以存在比在翼14的远侧尖端附近更大密度的纤维F。因此，翼14可以在机身12附近并且在大致在前/后中心附近更厚，并且朝向远侧尖端以及前缘和后缘逐渐变细。根据需要，可以采用其他设置和/或纤维分配方案。
在图5所示的一个示例性实施例中，构成本体10的一个或多个部分的复合材料内的一些纤维F具有独特的特性。例如，虽然翼14的大部分可包括结构型纤维Fs(例如，碳纤维、玻璃纤维或凯夫拉纤维)，但翼14的一些部分可包括另一种类型的纤维F(例如，导电纤维Fec、光学纤维Fo、形状记忆纤维Fsm等)。另一种类型的纤维F可以在关键位置处与结构型纤维Fs选择性地交织。例如，导电纤维Fec可以位于翼14的前缘和/或较薄部分处，并且用作加热电极，其可以连接到电源并用于从翼14移除冰。可替代地，导电纤维Fec可以位于高应力区域(例如，在翼14和机身12的交接处)并且用作应变仪以检测本体10的负载。以类似的方式，光学纤维Fo可以位于高应力区域和能量束穿过光学纤维Fo。当本体10弯曲时，光学纤维Fo可以被挤压和/或闭合，从而产生指示弯曲的光学反馈信号。在又一个实施例中，由形状记忆合金(例如，Nitonol)制成的纤维Fsm可以与结构型纤维Fs交织并且选择性地供能(例如，通过电或热)以引起本体10的弯曲(例如，受控的拉动和/或推动)，这导致期望的空气动力学性能(例如，转向、定向、升高控制、稳定性、阻力等)。如图6所示，如果需要，可以预期导电纤维Fec，光学纤维Fo和/或形状记忆纤维Fsm可以涂覆有另一种材料(例如，绝缘层、强度增强层等)。还可以预期的是，其他电气部件(例如，电阻器、电容器等)可以在排出纤维Fec、纤维Fo和/或纤维Fsm期间通过头部22、28挤出和/或自动拾取和设置(例如，经由与头部22和/或28相关联的附件)。在这些情况下，可以选择性地调节这些部件和/或纤维Fec、纤维Fo和/或纤维Fsm的操作，例如通过调节纤维的形状、张力和/或尺寸。
通过常规拉挤成型和/或挤出方法制造的结构可能受限于相关纤维的定向。也就是说，纤维通常可以是叠覆的并且设置于平行层中。然而，在图5所示的实施例中，因为围绕每根纤维F的基质M可以在排出时立即固化和硬化，所以可以使纤维F延伸到自由空间而无需额外支撑。也就是说，纤维F可以不需要设置在彼此叠置在平坦层中。因此，构成骨架16和/或表皮18的纤维F可以在三维方向上沿彼此垂直的方向上定向。例如，图5示出了在垂直于翼14的表面的方向上延伸的纤维Fn。这可以允许纤维层的互锁和/或产生独特的(例如，湍流增强的)表面纹理。
如上所述并在图5中示出，在一些实施例中，本体10可以制造为整体一体结构。例如，翼14可以与机身12一起制造(例如，同时并不分离地制造)。特别地，当一个或多个支撑件24和/或30在骨架16上移动任何数量的头部28以形成表皮18(参见图2)时，一个或多个头部28可以从一个翼14在机身12上方或下方经过并且持续跨越相反的翼14。在这种情况下，从一个或多个头部28排出的纤维F可以在翼14和机身12上连续。这个过程可以重复任何次数，使得数百万(如果不是数亿)纤维F延伸通过翼14和机身12之间的交接点，从而形成强大的机械连接，而无需使用专门的硬件和/或重型紧固件。
在图5所示的示例性实施例中，构成本体10的一个或多个部分的复合材料内的基质M具有独特的特性。例如，虽然大部分翼14可包括结构型基质Ms(例如，传统的UV可固化液态树脂，例如丙烯酸酯化环氧树脂)，但翼14的一些部分可包括另一种类型的基质M(例如，热解基质Mp、保持一定灵活性的基质Mf等)。另一种类型的基质M可以选择性地用于在关键位置涂覆纤维F。例如，当头部28接近翼14的前缘和/或机身12的鼻部时，则可以将热解基质Mp供给到头部28中，使得所得到的复合材料可以在这些区域中用作隔热罩。在另一个示例中，当头部28接近翼14的后缘(例如，设置形状记忆纤维Fsm的位置)时，柔性基质Mf可以被供给到头部28中，使得所得到的复合材料可以更柔性并且选择性地翘曲或者扭曲以提供上述所需的空气动力学特性。
图7示出了骨架16的示例性部件32，其可以通过使用头部28和支撑件30来制造。虽然被描绘和描述为翼14的肋，但是部件32可以是翼14和/或机身12的另一个骨架部件。在该示例中，部件32包括相反外支撑表面34，相反内支具36，以及互连支撑表面34和/或支具36的多个横梁件38。应该注意的是，外支撑表面34和/或内支具36可以具有任何所需的形状，例如弯曲的、平的、阶梯状的等。还可以设想，如果需要，外支撑表面34和内支撑表面34可以形成一个或多个连续表面。例如，支撑表面34中的一个或多个可以是弯曲的并且通常与支具36中的一个或多个相切(例如，在肋的前端和/或尾端)。尽管横梁件38示出为大致笔直的并且相对于支撑表面34和支具36以约45°定向，但是可以想到，横梁件38也可以弯曲和/或以另一角度定向。应该注意的是，虽然示出了七个相邻且几乎相同的部件32构成所公开的肋，但是任何数量的相同或不同部件32(例如，仅一个部件32)可用于此目的。
部件32可以沿着独特的工具路径形成，该工具路径允许使用连续纤维并且在低重量配置中提供高强度。特别地，部件32可以使用中间出离策略来制造。图8示出了在使用多个不同且叠覆的层进行制造期间该策略的使用。
例如，在第一层中，可以控制头部28以在左下角(例如，邻近下支撑表面34和左支具36的内部交接点)开始排出和固化一个或多个连续的树脂涂覆纤维，并且在向上行进到相邻的左上角期间继续排出和固化相同的树脂涂覆纤维。然后，头部28可以朝向部件32的大致中心对角地向内移动，然后在到达中心之前折回以沿着大致平行的轨迹朝向左上角移动。在该折回机动期间，头部28可以与其原始轨迹间隔开一定距离(例如，更多地朝向部件32的右侧间隔开)，使得沿着部件32的对角线存在空的空间，并且在对角线平行径迹的内端形成盒状。然后，头部28可以向右移动到部件32的右上角，然后在到达部件32的内部边缘时向下旋转大约90°。可以在于左上角处制作的部件32的右下角处重复相同的总体图案，使得创建跨越虚拟对角线分割线的镜像。然后，头部28可以向左移动并且停止在其起始点之外，之后头部28可以顺时针转动大约45°并且完全跨越部件32对角地行进到右上角。然后，头部28可以沿着间隔开的平行径迹朝向左下角折回，使得头部28靠近其起始点(例如，相比于起始点径向向外并且略低)。在该折回机动期间，头部28可以与其原始轨迹间隔开一定距离(例如，更多地朝向部件32的左侧间隔开)，使得沿着部件32的对角线存在空的空间。当头部28朝向右上角移动时，其可以在转向点处偏离其轨迹并且进入拐角，使得在平行径迹的内端部处形成箭头形状。箭头形状可以粘合到先前在该角落处设置的硬化纤维。对角铺设的一个或多个纤维可以粘合到先前在部件32的中心处设置的盒形。整个过程可以重复任何次数，以将相应数量的材料径迹添加到第一层，从而增加第一层的横截面积。在重复期间，部件32可以向外生长，并且可以填充上面描述的位于平行径迹之间的空的空间。应当注意，在形成任何一层期间，从头部28排出的纤维可以不与其他纤维叠覆，使得所有纤维都设置在同一平面内。当头部28到达特定层的端点时，可以从头部28切割一个或多个纤维，使得头部28可以重新定位以开始新层。
第二层可以直接形成在第一层的顶部上，例如通过将第一层的图案旋转所需的角度(例如，约90°)。通过将图案旋转大约90°，在第二层中完全对角地延伸跨越部件32的纤维可以与部件32在第一层中的中心处折回的纤维叠覆。重复图案的不同部分的这种叠覆可以有助于增加部件32的强度。可以预期，如果需要，可以在任何位置沉积任何数量的纤维并且任何数量的纤维通常垂直于叠覆层(例如，如图5中所示的那些纤维Fn)定向以互锁这些层。附加地或替代地，可以将先前层的排出但未固化的部分包裹在随后形成的层上，然后固化以提高互锁强度。
可以以交替定向和/或以增量旋转角度定向(例如，当角度不是90°的倍数时)在前两个层的顶部上形成任何数量的额外层。这可以持续直到实现部件32的期望厚度。在一个示例中，可以这种方式制造整个机身12和/或翼14。例如，当使用中间出离方法时，可以在部件32上同时制造表皮18。特别地，通过仅形成支撑件34和/或支具36的外部部分，可以在机身12和/或翼14内部以及相邻部件32之间形成空的空间。
图9示出了用于制造翼14的骨架16和/或表皮18的可替代方法。在该实施例中，代替使用图8的中间出离策略，可以以交替和叠覆的方式使用不同的蛇形图案层。例如，当制造翼14的骨架16时，可控制头部28(参见图7)在肋横截面的最右端或尾端开始排出和固化一个或多个连续的树脂涂覆纤维，并且在向上且向左的弧形行进期间继续排出和固化相同的树脂涂覆纤维。头部28可以完全围绕顶部支撑表面34和肋横截面的前端移动，然后跨越肋横截面的下支撑表面34上以大致笔直的轨迹移回到起始点。一旦制作完肋横截面的完整周边，则头部28可以折回并且在第二圈期间围绕肋的周界遵循反向轨迹。应该注意的是，只要两个圈保持在相同的总体平面内并且彼此紧邻(例如，结合)，则第二圈可以根据需要在第一圈的径向内侧或外侧完成。尽管图9中所示的层-1包括两个完整的材料圈，但是可以预期仅可以使用单圈或多于两圈。在制造层-1的第一圈和/或第二圈期间，头部28可以不穿过肋横截面的中心，使得中心保持没有横梁件和支具。也就是说，层1可以仅形成肋横截面的周界。
在完成层-1之后，可以切断尾随头部28的纤维，并且头部28可以朝向肋横截面的前端移动以制造层-2。可以控制头部28在前端的顶表面34处开始排出和固化一个或多个连续的树脂涂覆纤维，并且在向上且向右(例如，朝向尾端)的弧形行进期间继续排出和固化相同的树脂涂覆纤维。在形成顶部支撑表面34并到达肋横截面的尾端之后，头部28可以沿着下支撑表面34以大致笔直的轨迹朝向前端移回，然后围绕前端弯曲到层-2的第一圈的起始点。在该层-2期间，头部28围绕肋横截面的第一圈的周界可以不穿过肋的中心，使得中心仍然保持没有横梁件和支具。
在层-2的第二圈期间，头部28可以穿过肋横截面的中心，使得在顶部支撑表面34和下部支撑表面34中的相反节点之间的自由空间中形成横梁件38。特别地，在返回第一圈的起始点之后，头部28可以折回并在第一圈内侧的径向位置处围绕弯曲前端遵循相同的总体轨迹。在围绕弯曲前端移动之后，头部28可以远离第一圈移动并且向上且向右(即，朝向尾端)倾斜，从而穿过肋横截面的中心并朝向起始点。在公开的实施例中，横梁件38相对于顶部和/或下部支撑表面34的角度可以是约25-65°。在从头部28排出的材料与第一圈的内侧接合之后，头部28可以大体遵循第一圈轨迹以小段距离，使得材料部段在肋横截面的顶部支撑表面34处设置为与第一圈相邻(例如，位于第一圈内部)。在一个实施例中，该部段是肋横截面长度的约1/3至1/6。此后，头部28可以远离第一圈移动并向下且向右倾斜，再次穿过肋横截面的中心。在从头部28排出的材料再次接合第一圈的内侧之后，头部28可以大体遵循第一圈的轨迹以小段距离，使得另一材料部段在肋横截面的下支撑表面34处设置为与第一圈相邻(例如，位于第一圈的内部)。穿过肋中心和并产生部段的这种蛇形图案可以继续进行直到头部28到达肋横截面的尾端。应该注意的是，在图9的实施例中，肋横截面的任何一层内的横梁件38仅单侧设置。也就是说，穿过肋横截面中心的完整“X”可以仅由两个不同的层产生。
肋横截面的奇数层可以彼此基本相同，同时偶数层也可以彼此相同或迭代复。例如，层-1、3、5、7等可以全部相同。同样，层-2和层-8；层-4层和层-10；以及层-6和层-12可以是相同的对。然而，层-2、4和6可以是彼此不同的迭代。具体地，横梁件38和顶部支撑部段及下部支撑部段的位置可以在偶数层之间交替，使得横梁件38彼此叠覆，从而形成完整的“X”，并且顶部支撑部段和下部支撑部段顺序排列以形成围绕肋横截面的完整周界。应当注意，虽然图9中示出的层-1至层-6形成了在翼14的形成期间可以重复任何次数的完整组，但是任何数量的层可以形成可以重复以形成翼14的组。
在一些实施例中，在形成层-1至层-6之后(和/或在形成这些层中的多个之后)，翼14可以是完整的。也就是说，每层的内圈可以形成骨架16，而外层可以形成表皮18。然而，在其他实施例中，如果需要，在形成层-1至层-6之后，可以在骨架16上设置单独的表皮18。在该实施例中，表皮18可以用手或通过所公开的系统进行设置。如果由所公开的系统进行设置，则可以实施上述第二增材过程(但使用预制材料板代替单根纤维或丝束)。
工业适用性
所公开的骨架16和表皮18的设置和设计可以与任何类型的载具本体10结合使用。例如，骨架16和表皮18可以与飞机本体、无人机本体、汽车本体、船本体或任何其他类型的重量轻、成本低、性能高的载具本体一起使用。由于将表皮18固定到骨架16和/或将载具本体10的部件彼此固定所需的紧固件的数量减少，因此载具本体10可以是轻质且低成本的。此外，由于使用了制造骨架16和表皮18的复合材料，因此载具本体10可以是轻质的。可以以在骨架16和表皮18内使用并设置特定纤维和树脂的独特方式提供高性能。
对于本领域技术人员显而易见的是，可以对所公开的载具本体进行各种修改和变化。考虑到所公开的载具本体的说明书和实践，其他实施例对于本领域技术人员来说是显而易见的。说明书和示例旨在仅被视为示例性的，真实范围由所附权利要求及其等同物指示。

Claims (75)

1.一种载具本体，包括：
包括肋的内部骨架，所述肋具有相反支撑表面、相反支具以及连接所述相反支撑表面和所述相反支具的横梁件，其中，所述相反支撑表面、所述相反支具以及所述横梁件使用中间出离工具路径由至少一个连续纤维形成；以及
形成在所述内部骨架上的表皮，所述表皮包括：
基质材料；
多个连续纤维，其包裹在所述基质材料内并且分层设置成大致平行于所述载具本体的表面。
2.一种载具本体，包括：
内部骨架；以及
形成在所述内部骨架上的表皮，所述表皮包括：
基质材料；以及
包裹在所述基质材料内的多个连续纤维，其中，所述多个连续纤维中的至少一个处于拉伸状态并沿其长度具有不同的拉力水平。
3.如权利要求2所述的载具本体，其中，所述多个连续纤维沿多个不同方向定向。
4.如权利要求3所述的载具本体，其中，所述多个连续纤维中的每个都处于拉伸状态并且沿其长度具有不同的拉力水平。
5.如权利要求4所述的载具本体，其中，所述多个连续纤维具有弯曲轨迹。
6.如权利要求5所述的载具本体，其中，所述多个连续纤维有机地排列在所述表皮内。
7.如权利要求6所述的载具本体，其中：
所述内部骨架形成翼形；以及
所述多个连续纤维从所述翼形的前/后中心附近的基端部朝向所述翼形的前缘和后缘处的尖端延伸。
8.如权利要求7所述的载具本体，其中，所述多个连续纤维的密度沿所述翼形的长度变化。
9.如权利要求8所述的载具本体，其中，所述多个连续纤维在所述基端部处的密度大于在所述尖端处的密度。
10.如权利要求2所述的载具本体，其中，所述基质材料包括沉积在所述表皮中的关键位置处的多种类型树脂。
11.如权利要求10所述的载具本体，其中：
所述内部骨架形成翼形；以及
所述多种类型树脂包括：
位于所述翼形的后缘处的柔性树脂；以及
远离所述后缘使用的丙烯酸树脂。
12.如权利要求10所述的载具本体，其中：
所述内部骨架形成翼形；以及
所述多种类型树脂包括：
位于所述翼形的前缘处的热解树脂；以及
远离所述前缘使用的丙烯酸树脂。
13.一种载具本体，包括：
形成翼形的内部骨架；以及
形成在所述内部骨架上的表皮，所述表皮包括：
基质材料；以及
包裹在所述基质材料内的多个连续纤维，其中，所述多个连续纤维以弯曲轨迹从所述翼形的前/后中心附近的基端部朝向所述翼形的前缘和后缘处的尖端延伸。
14.如权利要求13所述的载具本体，其中，所述多个连续纤维有机地排列在所述表皮内。
15.如权利要求14所述的载具本体，其中：
所述内部骨架形成翼形；以及
所述多个连续纤维从所述翼形的前/后中心附近的基端部朝向所述翼形的前缘和后缘处的尖端延伸。
16.如权利要求15所述的载具本体，其中，所述多个连续纤维的密度沿所述翼形的长度变化。
17.如权利要求16所述的载具本体，其中，所述多个连续纤维在所述基端部处的密度大于在所述尖端处的密度。
18.如权利要求13所述的载具本体，其中，所述基质材料包括沉积在所述表皮中的关键位置处的多种类型树脂。
19.如权利要求18所述的载具本体，其中：
所述内部骨架形成翼形；以及
所述多种类型树脂包括：
位于所述翼形的后缘处的柔性树脂；以及
远离所述后缘使用的丙烯酸树脂。
20.如权利要求18所述的载具本体，其中：
所述内部骨架形成翼形；以及
所述多种类型树脂包括：
位于所述翼形前缘处的热解树脂；以及
远离所述前缘使用的丙烯酸树脂。
21.一种载具本体，包括：
内部骨架；以及
形成在所述内部骨架上的表皮，所述表皮包括：
多种基质材料，所述多种基质材料定位于所述内部骨架的不同位置处，所述多种基质材料包括丙烯酸酯化环氧树脂以及柔性树脂和热解树脂中的至少一种；以及
多个连续纤维，其包裹在所述多种基质材料中。
22.一种载具本体，包括：
通过第一增材制造系统制造的内部骨架；以及
通过与第一增材制造系统不同的第二增材制造系统在所述内部骨架上原位制造的表皮。
23.如权利要求22所述的载具本体，其中，所述内部骨架包括多个相邻的中空管。
24.如权利要求23所述的载具本体，其中：
所述内部骨架和所述表皮一起形成翼形；以及
所述多个相邻的中空管沿所述翼形的长度方向延伸。
25.如权利要求24所述的载具本体，其中，所述多个相邻的中空管由基质材料以及包裹在所述基质材料内的多个连续纤维制成。
26.如权利要求25所述的载具本体，其中，所述表皮由基质材料以及包裹在所述基质材料内的多个连续纤维制成。
27.如权利要求26所述的载具本体，其中，所述内部骨架和所述表皮中的至少一个的所述多个连续纤维处于拉伸状态。
28.如权利要求26所述的载具本体，其中，所述内部骨架和所述表皮中的至少一个的所述多个连续纤维沿多个不同方向定向。
29.如权利要求26所述的载具本体，其中，所述内部骨架和所述表皮中的至少一个的所述多个连续纤维具有在至少两个维度上弯曲的轨迹。
30.如权利要求29所述的载具本体，其中，所述多个连续纤维有机地排列在所述表皮内。
31.如权利要求30所述的载具本体，其中，所述表皮中的所述多个连续纤维从所述翼形的前/后中心附近的基端部朝向所述翼形的前缘和后缘处的尖端延伸。
32.如权利要求31所述的载具本体，其中，所述表皮中的所述多个连续纤维的密度沿着所述翼形的长度变化。
33.如权利要求32所述的载具本体，其中，所述表皮中的所述多个连续纤维在所述基端部处的密度大于在所述尖端处的密度。
34.如权利要求26所述的载具本体，其中，所述内部骨架和所述表皮的所述基质材料包括UV固化树脂。
35.如权利要求26所述的载具本体，其中，所述内部骨架和所述表皮中的至少一个的所述多个连续纤维包括涂敷有绝缘层和强度增强层中的至少一种的导电线、形状记忆纤维或光学纤维中的至少一种。
36.如权利要求26所述的载具本体，其中：
所述内部骨架和所述表皮一起还形成机身形状；以及
所述表皮中的所述多个连续纤维从所述翼形延伸到所述机身形状中。
37.如权利要求26所述的载具本体，其中，所述内部骨架的所述多个连续纤维中的至少一些延伸到所述表皮的一部分中并形成所述表皮的一部分。
38.如权利要求23所述的载具本体，其中，所述多个相邻中空管中的至少一个涂覆为用作燃料箱和燃料通道中的至少一种。
39.一种具有翼和机身的载具本体，包括：
内部骨架，其具有沿所述翼的长度方向延伸的多个相邻的中空管并由涂覆有基质的多个连续纤维形成；以及
表皮，其具有涂覆有基质并设置在所述内部骨架上的多个连续纤维，
其中：
所述内部骨架和所述表皮两者的所述多个连续纤维处于拉伸状态；以及
所述多个相邻的中空管中的至少一个涂覆为用作燃料箱和燃料通道中的至少一种。
40.一种制造载具本体的方法，包括：
实施第一增材制造技术以由涂覆有基质的连续纤维制造内部骨架；以及
实施第二增材制造技术以由涂覆有基质的连续纤维在所述内部骨架上制造表皮。
41.如权利要求40所述的方法，其中，实施所述第一增材制造技术以制造所述内部骨架包括实施所述第一增材制造技术以制造多个相邻的中空管。
42.一种载具本体，包括：
内部骨架；以及
在所述内部骨架上原位制作的表皮，所述表皮包括：
基质材料；以及
包裹在所述基质材料内的多个连续纤维，其中：
所述基质材料包括沉积在所述表皮中的关键位置处的多种树脂；
所述多种树脂包括电绝缘树脂和强度增强层；以及
所述多个连续纤维包括至少一根导电线，所述导电线与所述多个连续纤维中的其它连续纤维交织并构造成用作加热器和应变仪中的至少一种。
43.如权利要求42所述的载具本体，其中，所述多个连续纤维包括至少一个形状记忆纤维，所述形状记忆纤维与所述多个连续纤维中的其他纤维交织并构造成在供能时引起所述载具本体的弯曲。
44.如权利要求42所述的载具本体，其中，所述多个连续纤维包括至少一个光学纤维，所述光学纤维与所述多个连续纤维中的其他连续纤维交织并且构造成在所述载具本体弯曲期间产生光学反馈信号。
45.如权利要求42所述的载具本体，其中：
所述骨架形成翼形；以及
所述多种树脂包括：
位于所述翼形的后缘处的柔性树脂；以及
远离所述后缘的更硬树脂。
46.如权利要求42所述的载具本体，其中：
所述骨架形成翼形；以及
所述多种树脂包括：
位于所述翼形的前缘处的热解树脂；以及
远离所述前缘使用的丙烯酸树脂。
47.如权利要求42所述的载具本体，其中，所述内部骨架的所述多个连续纤维中的至少一些延伸到所述表皮的一部分中并形成所述表皮的一部分。
48.如权利要求42所述的载具本体，其中，所述多个连续纤维包括：
多个第一连续纤维，其分层设置为大致平行于所述载具本体的表面；以及
多个第二连续纤维，其垂直于所述表面延伸以使所述层互锁。
49.如权利要求42所述的载具本体，其中，所述基质材料包括UV固化树脂。
50.一种载具本体，包括：
内部骨架；以及
在所述内部骨架上原位制作的表皮，所述表皮包括：
基质材料；以及
包裹在所述基质材料内的多个连续纤维，其中：
所述内部骨架形成翼形和机身形状；
所述翼形上的表皮中的多个连续纤维延伸到所述机身形状上的表皮中；以及
所述多个连续纤维包括至少一根导电线，所述导电线与所述多个连续纤维中的其它连续纤维交织并构造成用作加热器和应变仪中的至少一种。
51.如权利要求50所述的载具本体，其中，所述多个连续纤维的密度沿所述翼形的长度变化。
52.一种载具本体，包括：
内部骨架；以及
形成在所述内部骨架上的表皮，所述表皮包括：
基质材料；
包裹在所述基质材料内的多个连续结构纤维；以及
与所述多个连续结构纤维交织的导电线、形状记忆纤维和光学纤维中的至少一种，其中：
所述基质材料包括沉积在所述表皮中的关键位置处的多种树脂；
所述骨架形成翼形；以及
所述多种树脂包括：
位于所述翼形的后缘处的柔性树脂；以及
远离所述后缘使用的较硬树脂。
53.如权利要求52所述的载具本体，其中，所述多种树脂包括电绝缘树脂和强度增强层。
54.如权利要求52所述的载具本体，其中，所述多个连续结构纤维包括：
多个第一连续结构纤维，其分层设置为大致平行于所述载具本体的表面；以及
多个第二连续结构纤维，其垂直于所述表面延伸以使所述层互锁。
55.一种制造载具本体的方法，包括：
引导多个连续纤维通过头部，所述多个连续纤维包括结构纤维以及与所述结构纤维交织的导电线、形状记忆纤维和光学纤维中的至少一种；
用基质材料润湿头部中的所述多个连续纤维；以及
从所述头部排出所述多个连续纤维以形成骨架以及位于呈翼形的所述骨架上的表皮。
56.如权利要求55所述的方法，还包括对所述基质材料供能以在从所述头部排出时固化所述表皮。
57.一种载具本体，包括：
形成翼形和机身形状的内部骨架；以及
在所述内部骨架上原位制作的表皮，所述表皮包括：
基质材料；以及
至少部分地涂覆有所述基质材料的多个连续纤维，所述多个连续纤维从所述翼形延伸到所述机身形状上。
58.如权利要求57所述的载具本体，其中：
所述翼形是第一翼形；
所述内部骨架还形成第二翼形；以及
所述第一翼形上的表皮中的所述多个连续纤维延伸至所述机身形状上并且沿伸至所述第二翼形上的表皮中。
59.如权利要求57所述的载具本体，其中：
所述内部骨架包括由所述基质材料以及包裹在所述基质材料内的多个连续纤维制成的肋、翼梁、桁架、纵桁、纵梁以及隔板中的至少一种；以及
肋、翼梁、桁架、纵桁、纵梁以及隔板中的至少一种的所述多个连续纤维中的至少一些延伸到所述表皮的一部分中并形成所述表皮的一部分。
60.如权利要求57所述的载具本体，其中，所述多个连续纤维包括：
多个第一连续结构纤维，其分层设置成大致平行于所述载具本体的外表面；以及
多个第二连续结构纤维，其垂直于所述外表面延伸以使所述层互锁。
61.如权利要求60所述的载具本体，其中，所述多个第二连续纤维在所述多个第二连续纤维的相邻纤维之间正交通过。
62.如权利要求57所述的载具本体，其中，所述多个连续纤维的密度沿所述翼形的长度变化。
63.如权利要求57所述的载具本体，其中，所述基质材料包括沉积在所述表皮中的关键位置处的多种树脂。
64.如权利要求63所述的载具本体，其中，所述多种树脂包括：
位于所述翼形的后缘处的柔性树脂；以及
远离所述后缘的较硬树脂。
65.如权利要求63所述的载具本体，其中，所述多种树脂包括：
位于所述翼形的前缘处的热解树脂；以及
远离所述前缘的丙烯酸树脂。
66.一种载具本体，包括：
具有肋、翼梁、桁架、纵桁、纵梁以及隔板中的至少一种的内部骨架，所述肋、翼梁、桁架、纵桁、纵梁以及隔板由基质材料和至少部分涂覆有所述基质材料的多个连续纤维一起形成机身形状和翼形；以及
在所述内部骨架上原位制作的表皮，
其中，所述多个连续纤维从所述内部骨架延伸到所述表皮中。
67.如权利要求66所述的载具本体，其中，所述多个连续纤维包括：
多个第一连续纤维，其设置成大致平行的层；以及
多个第二连续纤维，其垂直于所述大致平行的层延伸，以使所述大致平行的层互锁。
68.如权利要求67所述的载具本体，其中，所述多个第二连续纤维在所述多个第二连续纤维的相邻纤维之间正交通过。
69.如权利要求66所述的载具本体，其中，所述多个连续纤维的密度沿所述翼形的长度变化。
70.如权利要求66所述的载具本体，其中，所述基质材料包括沉积在所述表皮中的关键位置处的多种树脂。
71.如权利要求70所述的载具本体，其中，所述多种树脂包括：
位于所述翼形的后缘处的柔性树脂；以及
远离所述后缘的较硬树脂。
72.如权利要求70所述的载具本体，其中，所述多种树脂包括：
位于所述翼形的前缘处的热解树脂；以及
远离所述前缘的丙烯酸树脂。
73.一种载具本体，包括：
内部骨架，其包括基质材料以及至少部分涂覆有所述基质材料的多个连续纤维；以及
在所述内部骨架上原位制作的表皮，
其中，所述多个连续纤维包括：
多个第一连续纤维，其设置成大致平行的层；以及
多个第二连续纤维，其垂直于所述大致平行的层延伸，以使所述大致平行的层互锁；以及
所述基质材料包括沉积在所述表皮中的关键位置处的多种树脂；
所述骨架形成翼形；以及
所述多种树脂包括：
位于所述翼形的后缘处的柔性树脂；以及
远离所述后缘使用的丙烯酸树脂。
74.如权利要求73所述的载具本体，其中，所述多个第二连续纤维在所述多个第二连续纤维的相邻纤维之间正交通过。
75.如权利要求73所述的载具本体，其中，所述多个连续纤维的密度沿所述表皮的长度变化。
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