CN110239200B - 一种轻质网格蒙皮蜂窝结构的制备方法 - Google Patents

一种轻质网格蒙皮蜂窝结构的制备方法 Download PDF

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CN110239200B
CN110239200B CN201910675182.5A CN201910675182A CN110239200B CN 110239200 B CN110239200 B CN 110239200B CN 201910675182 A CN201910675182 A CN 201910675182A CN 110239200 B CN110239200 B CN 110239200B
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周秀燕
王梓桥
魏程
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Beijing Mechanical And Electrical Engineering General Design Department
Harbin Glass Steel Research Institute Co Ltd
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Harbin FRP Institute Co Ltd
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Abstract

一种轻质网格蒙皮蜂窝结构的制备方法，它涉及一种蜂窝结构的制备方法。本发明的蜂窝夹层结构网格蒙皮具有可设计性；满足设计刚度要求，优化预埋件胶接稳定的填充方式。网格蒙皮，采用高模量碳纤维缠绕成型，编织角度在[0°～180°)的网格面板，蒙皮交叉点厚度、网格间距可根据设计要求制备。预埋件膨胀胶连接采用爪型分布，经过验证，同等重量下，此时稳定性最强。本发明在满足蜂窝夹层结构件力学性能的基础上，极大限度的降低了蜂窝夹层结构件的重量，对卫星蜂窝夹层结构应用有较强的指导意义。本发明应用于航空航天领域。

Description

一种轻质网格蒙皮蜂窝结构的制备方法
技术领域
本发明涉及一种轻质网格蒙皮蜂窝结构的制备方法。
背景技术
卫星结构设计的特点之一就是尽量减少重量。即在保证规定的刚度和强度的前提下进行结构优化设计，将其质量减少至最小。
铝蜂窝夹层结构是卫星结构中最常见和应用最广的部件，比强度、比刚度高，同时具备抗疲劳性能、减震性能、吸噪吸声、隔热等特点。其组成包括上蒙皮、胶黏剂、蜂窝芯层、埋件以及下蒙皮组成。如图1所示，图1蜂窝夹层结构(由两块高强度的上下蒙皮和中间夹着一层厚而轻的夹心层组成)；其中上、下蒙皮一般包括三种：铝合金、碳纤维复合材料、有机纤维复合材料等。蜂窝芯层材料一般包括：铝合金、芳纶纸等。
蜂窝夹层结构中需存在一定数量的预埋件用于卫星舱体的组装以及安装其他单机组件，而在蜂窝夹层结构成型过程中，预埋件就预装在蜂窝芯中，为了保证预埋件在后期震动、连接等时的强度，需要在预埋件上及邻近蜂窝格子中填充发泡胶进行补强，同产品一起固化。常规的填充方式为预埋件包裹一层或多层发泡胶以及在邻近蜂格内进行多圈填充，根据重量要求以及强度要求决定填充方式。卫星结构中，最优最轻质的成型方式和结构有着极大的实际应用意义。
发明内容
本发明为了保证卫星结构中蜂窝夹层结构的刚度和强度，满足蜂窝夹层结构连接、锁定以及振动要求同时尽量减少重量，提出一种可设计结构形式的网格蒙皮制备方法，同时在该基础上优化预埋件填充方式，保证蜂窝基板的结构稳定性。具有广泛的应用适用性。
本发明的一种轻质网格蒙皮蜂窝结构的制备方法，它包含以下步骤：
一、缠绕网格蒙皮：取工装，使用缠绕机设定缠绕程序，进行缠绕，制得[0°～180°)交叉角的网格蒙皮；
二、网格蒙皮固化：缠绕后的网格经过轴向裁剪，从工装上取下，移至热压罐中抽真空，进行加压固化；
三、蒙皮修整：修整蒙皮边缘；
四、蜂窝芯粘接：利用工装在上、下蒙皮指定位置打孔，并在蒙皮单侧粘接热熔胶膜；依次将下蒙皮、铝蜂窝芯放置在工装上进行粘接；
五、放置预埋件：在蜂窝芯上加工出预埋件孔，将预埋件涂底胶并缠绕一圈发泡胶，利用定位螺钉安置于蜂窝芯预埋件孔内；围绕着预埋件在邻近蜂窝芯网格内放置发泡胶，然后分别沿与预埋件一侧边呈35°、145°和90°角度方向，向蜂窝芯网格内放置发泡胶，且保证发泡胶放置在距预埋件孔中心距离为R80～R160mm范围内的蜂窝芯网格内；
六、粘贴上蒙皮：待埋件位置固定后，利用销钉定位上蒙皮，粘贴；
七、固化处理：将步骤六处理的蜂窝进行抽真空加压固化或金属热合模固化，固化后待蜂窝温度降至室温后进行脱模、修整，即完成所述的轻质网格蒙皮蜂窝结构的制备方法。
本发明的一种轻质网格蒙皮蜂窝结构，所述的蜂窝结构包括网格蒙皮、蜂窝芯、预埋件和热熔胶膜；
所述的网格蒙皮分为上网格蒙皮和下网格蒙皮；上网格蒙皮粘接在蜂窝芯上表面；下网格蒙皮粘接在蜂窝芯下表面；热熔胶膜分别置于上网格蒙皮与蜂窝芯之间，以及下网格蒙皮与蜂窝芯之间；
所述的预埋件置于蜂窝芯开设的预埋件孔内，沿与预埋件一侧边呈35°、-35°和90°角度方向的蜂窝芯网格内设置发泡胶。
本发明的蜂窝夹层结构包括网格蒙皮、胶膜、蜂窝芯，预埋件、填充胶膜等内容。
所述网格蒙皮制备方法利用缠绕机进行螺旋缠绕，可制备[0°～180°)交叉角的高模量网格蒙皮。若设计纤维夹角为40°，可设计缠绕程序缠绕70°，沿缠绕轴向方向为0°方向，缠绕完成后，沿0°剪裁，可得到纤维角度为40°的网格蒙皮。
所述网格蒙皮制备方法利用缠绕机进行螺旋缠绕，可制备不同厚度的栅格形式网格，网格厚度和网格空隙均可控。若设计网格间距为4×4mm，可设计缠绕程序前进量为4mm。对应可制备网格蒙皮交叉点厚度为0.1mm～0.2mm。
所述蜂窝夹层结构预埋件的固定方式，可采用J-145膨胀胶、J-47D胶膜、J-78胶膜对预埋件进行固定，在预埋件周围填充一圈胶膜，固定预埋件位置。
所述蜂窝夹层结构预埋件固定方式，为了提高预埋件的连接强度，对预埋件周围进行补强。补强具体方式，在预埋件周围的蜂窝网格内填胶，然后以预埋件中心为中心点，在半径为R80mm～R160mm范围内设置3条填胶带，填胶带与预埋件边缘的夹角分别为35°， -35°、90°，从而形成爪型的胶结构。在同等重量下，预埋件在此条件下被加强效果最好。
所述网格蒙皮采用高模量碳纤维M40JB-6K、M55JB-6K、M60JB-6K环氧树脂体系为原材料，采用缠绕机进行湿法网格成型，根据设计网格可制备[0°～180°)交叉角的高模量网格蒙皮。采用不同胶接剂对埋件进行加强，验证得出采用爪型填充膨胀胶的方式，在同等重量下，对预埋件强度提高效果最好。
蜂窝夹层结构件经过真空加压固化，固化温度为(125℃～130℃)/(2h～3h)固化，降至常温脱模。
蜂窝夹层结构缩比件外形尺寸为350mm×210mm×22.32mm时，无损探伤合格的蜂窝结构件对比，同等重量填充下，经过爪型填充破坏载荷提高34.3％。
本发明极大的优化了太阳电池阵基板蒙皮结构的可设计性以及埋件固定的方式。
附图说明
图1为本发明的结构示意图；
图2为本发明结构部分剖视图；
图3为蜂窝夹层结构示意图；
图4为实施例1预埋件与填胶后的结构示意图；
图5为实施例1放置预埋件后的蜂窝结构示意图。
具体实施方式
具体实施方式一：本实施方式的一种轻质网格蒙皮蜂窝结构的制备方法，它包含以下步骤：
一、缠绕网格蒙皮：取工装，使用缠绕机设定缠绕程序，进行缠绕，制得[0°～180°)交叉角的网格蒙皮；
二、网格蒙皮固化：缠绕后的网格经过轴向裁剪，从工装上取下，移至热压罐中抽真空，进行加压固化；
三、蒙皮修整：修整蒙皮边缘；
四、蜂窝芯粘接：利用工装在上、下蒙皮指定位置打孔，并在蒙皮单侧粘接热熔胶膜；依次将下蒙皮、铝蜂窝芯放置在工装上进行粘接；
五、放置预埋件：在蜂窝芯上加工出预埋件孔，将预埋件涂底胶并缠绕一圈发泡胶，利用定位螺钉安置于蜂窝芯预埋件孔内；围绕着预埋件在邻近蜂窝芯网格内放置发泡胶，然后分别沿与预埋件一侧边呈35°、145°和90°角度方向，向蜂窝芯网格内放置发泡胶，且保证发泡胶放置在距预埋件孔中心距离为R80～R160mm范围内的蜂窝芯网格内；
六、粘贴上蒙皮：待埋件位置固定后，利用销钉定位上蒙皮，粘贴；
七、固化处理：将步骤六处理的蜂窝进行抽真空加压固化或金属热合模固化，固化后待蜂窝温度降至室温后进行脱模、修整，即完成所述的轻质网格蒙皮蜂窝结构的制备方法。
具体实施方式二：本实施方式与具体实施方式一不同的是：所述的发泡胶沿与预埋件一侧边呈35°、145°和90°角度方向填置于蜂窝芯2的蜂格中，填充区域直径为R80～R160。其它与具体实施方式一相同。
具体实施方式三：本实施方式与具体实施方式一不同的是：步骤一中若网格蒙皮的网格间距为4×4mm，缠绕程序前进量为4mm，得到交叉点厚度为0.1mm～0.2mm的网格蒙皮。其它与具体实施方式一相同。
具体实施方式四：本实施方式与具体实施方式一不同的是：制作网格蒙皮的原料为碳纤维/环氧体系。其它与具体实施方式一相同。
具体实施方式五：本实施方式与具体实施方式一不同的是：碳纤维为M40JB或M55JB 或M60JB。其它与具体实施方式一相同。
具体实施方式六：本实施方式与具体实施方式一不同的是：步骤七中固化温度为120℃～130℃，固化时间为2～3h。其它与具体实施方式一相同。
具体实施方式七：本实施方式与具体实施方式一不同的是：步骤五中涂的底胶为J-47B等胶液，发泡胶胶膜是J-145。其它与具体实施方式一相同。
具体实施方式八：本实施方式与具体实施方式一不同的是：所制备的蜂窝结构包括网格蒙皮1、蜂窝芯2、预埋件3和热熔胶膜4；
所述的网格蒙皮1分为上网格蒙皮1-1和下网格蒙皮1-2；上网格蒙皮1-1粘接在蜂窝芯2上表面；下网格蒙皮1-2粘接在蜂窝芯2下表面；热熔胶膜4分别置于上网格蒙皮 1-1与蜂窝芯2之间，以及下网格蒙皮1-2与蜂窝芯2之间；
所述的预埋件3置于蜂窝芯2开设的预埋件孔5内，沿与预埋件3一侧边呈35°、-35°和90°角度方向的蜂窝芯网格内设置发泡胶6。
其它与具体实施方式一相同。
具体实施方式九：本实施方式与具体实施方式一不同的是：发泡胶6最远端与预埋件孔5中心距离为R80～R160mm。其它与具体实施方式一相同。
本发明内容不仅限于上述各实施方式的内容，其中一个或几个具体实施方式的组合同样也可以实现发明的目的。
通过以下实施例验证本发明的有益效果：
实施例1
本实施例以1000mm×1000mm×23.4mm，面板蒙皮材质为M55JB、夹角为40°、网格间距为3mm×3mm的蜂窝夹层结构为例进行说明。
一、缠绕网格蒙皮：使用直径为320mm空心轴，长度为1200mm作为网格蒙皮制备工装。使用缠绕机设定缠绕程序，因为设计网格蒙皮交叉角度为40°，因此可设定缠绕角度为20°或者70°进行缠绕；设定角度的同时，根据设计要求设定缠绕时网格间距 3mm×3mm。
二、网格蒙皮固化：缠绕后的网格经过轴向裁剪，从工装上取下，移至热压罐中抽真空固化，依据选择的树脂体系进行加压固化。
三、制备上、下蒙皮：依据步骤一和二的步骤制备来另一侧蒙皮。
四、蒙皮修整：修整蒙皮边缘，使之外形尺寸为(1000±0.8)mm×(1000±0.8)mm，注意修整时边缘与纤维夹角为±20°或者±70°方为正确裁定方法。
五、定位预埋件：由于震动工况以及轻质要求，在连接点位置的预埋件进行特殊处理。处理方式为预埋件周围的蜂窝网格内放置发射线发泡胶(J-145膨胀胶)，以预埋件中心为中心点，设置3条填胶带，填胶带与预埋件边缘的夹角分别为35°，-35°、90°，每个填胶带占4个蜂窝网格，形成爪型的填胶结构。
六、蜂窝芯粘接：将蒙皮预埋件位置进行工装打孔定位，将上、下蒙皮粘接面粘贴热破胶膜，按照顺序放置下蒙皮、铝蜂窝、预埋件、填充胶膜，上蒙皮；蜂窝采用规格为5×5，铝厚度为0.05mm的铝蜂窝芯。
七、蜂窝夹层结构成型：覆盖上蒙皮后，产品整体抽真空加压固化(固化温度为125℃，固化时间为3h)，依据J-47体系固化制度进行。固化完成后，待产品温度降至室温后进行脱模、修整。
经过验证，步骤6的填充方式抗压破坏载荷提高34.3％，重量比未进行膨胀胶补强仅增加5.5％。

Claims (8)

1.一种轻质网格蒙皮蜂窝结构的制备方法，其特征在于它包含以下步骤：
一、缠绕网格蒙皮：取工装，使用缠绕机设定缠绕程序，进行缠绕，制得[0°~180°]交叉角的网格蒙皮；
二、网格蒙皮固化：缠绕后的网格经过轴向裁剪，从工装上取下，移至热压罐中抽真空，进行加压固化；
三、蒙皮修整：修整蒙皮边缘；
四、蜂窝芯粘接：利用工装在上、下蒙皮指定位置打孔，并在蒙皮单侧粘接热熔胶膜；依次将下蒙皮、铝蜂窝芯放置在工装上进行粘接；
五、放置预埋件：在蜂窝芯上加工出预埋件孔，将预埋件涂底胶并缠绕一圈发泡胶，利用定位螺钉安置于蜂窝芯预埋件孔内；围绕着预埋件在邻近蜂窝芯网格内放置发泡胶，然后分别沿与预埋件一侧边呈35°、145°和90°角度方向，向蜂窝芯网格内放置发泡胶，且保证发泡胶放置在距预埋件孔中心距离为R80~R160mm范围内的蜂窝芯网格内；
六、粘贴上蒙皮：待埋件位置固定后，利用销钉定位上蒙皮，粘贴；
七、固化处理：将步骤六处理的蜂窝进行抽真空加压固化或金属热合模固化，固化后待蜂窝温度降至室温后进行脱模、修整，即完成所述的轻质网格蒙皮蜂窝结构的制备方法。
2.根据权利要求1所述的一种轻质网格蒙皮蜂窝结构的制备方法，其特征在于步骤一中网格蒙皮的网格间距为4×4mm，缠绕程序前进量为4mm，得到交叉点厚度为0.1mm～0.2mm的网格蒙皮。
3.根据权利要求1所述的一种轻质网格蒙皮蜂窝结构的制备方法，其特征在于制作网格蒙皮的原料为碳纤维/环氧体系。
4.根据权利要求3所述的一种轻质网格蒙皮蜂窝结构的制备方法，其特征在于碳纤维为M40JB或M55JB或M60JB。
5.根据权利要求1所述的一种轻质网格蒙皮蜂窝结构的制备方法，其特征在于步骤七中固化温度为120℃～130℃，固化时间为2～3h。
6.根据权利要求1所述的一种轻质网格蒙皮蜂窝结构的制备方法，其特征在于步骤五中涂的底胶为J-47B胶液，发泡胶胶膜是J-145。
7.根据权利要求1所述的一种轻质网格蒙皮蜂窝结构的制备方法，其特征在于所制备的蜂窝结构包括网格蒙皮（1）、蜂窝芯（2）、预埋件（3）和热熔胶膜（4）；
所述的网格蒙皮（1）分为上网格蒙皮（1-1）和下网格蒙皮（1-2）；上网格蒙皮（1-1）粘接在蜂窝芯（2）上表面；下网格蒙皮（1-2）粘接在蜂窝芯（2）下表面；热熔胶膜（4）分别置于上网格蒙皮（1-1）与蜂窝芯（2）之间，以及下网格蒙皮（1-2）与蜂窝芯（2）之间；
所述的预埋件（3）置于蜂窝芯（2）开设的预埋件孔（5）内，向预埋件孔（5）内涂底胶并贴胶膜，保证胶膜厚度为0.1mm；沿与预埋件（3）一侧边呈35°、145°和90°角度方向的蜂窝芯网格内设置发泡胶（6）；所述的网格蒙皮（1）是通过缠绕机制备得到[0°~180°]交叉角的高模量网格蒙皮，所述的高模量网格是采用蒙皮高模量碳纤维M40JB-6K、M55JB-6K、M60JB-6K环氧树脂体系为原材料，采用缠绕机进行湿法网格成型。
8.根据权利要求7所述的一种轻质网格蒙皮蜂窝结构的制备方法，其特征在于发泡胶（6）最远端与预埋件孔（5）中心距离为R80~R160mm。
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