CN110820169B - 一种t型结构纤维针刺预制体 - Google Patents

一种t型结构纤维针刺预制体 Download PDF

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CN110820169B
CN110820169B CN201911065488.5A CN201911065488A CN110820169B CN 110820169 B CN110820169 B CN 110820169B CN 201911065488 A CN201911065488 A CN 201911065488A CN 110820169 B CN110820169 B CN 110820169B
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缪云良
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Jiangsu Tianniao High Technology Co ltd
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Abstract

本发明涉及复合材料技术领域，尤其涉及一种T型结构纤维针刺预制体，所述预制体的结构包括蒙皮薄层(1)、位于蒙皮薄层(1)上呈对称L形排布的左加强筋(2)和右加强筋(3)；所述预制体采用整体针刺工艺成型。本发明采用模块化的制备方式，将T型结构纤维针刺预制体分成4个模块分别制备，再采用整体针刺将4个模块结合；该方法具有操作简单，模具用量少的特点，同时制备的T型结构纤维针刺预制体尺寸稳定、承载能力强，方便运输。

Description

一种T型结构纤维针刺预制体
技术领域
本发明涉及复合材料技术领域，尤其是涉及一种T型结构纤维针刺预制体及其制备方法。
背景技术
当今空间遥感对地观察技术已成为国家战略能力的重要标志之一，随着空间遥感技术的进步及其分辨率的逐渐提高，空间相机日益向大口径、长焦距、轻量化发展，这对相机支撑结构的性能提出苛刻的要求，不仅质轻、高刚度，而且必须具有极低的热膨胀系数。传统的金属材料已难以满足性能要求，碳纤维复合材料(特别是碳纤维增强碳基、碳化硅基复合材料)支撑结构成为近年来国际研究热点和发展主趋势。
碳纤维复合材料是由碳纤维预制体和基体构成。碳纤维预制体结构决定复合材料制品的性能。为进一步打造“看得清又很轻”的空间相机，让天上卫星“拍到好照片”，需要相机的光学支撑结构大、轻，还要高强度稳定性。因此，支撑结构件存在很多复杂结构，例如加强筋壁板结构件等。根据加筋截面的不同，加筋壁板又分为“T”型加筋壁板、“工”型加筋壁板和混合型加筋壁板等。
目前，大多数T型结构件由复合材料筋条和复合材料蒙皮组成，其成型技术一般是将蒙皮和加筋条分别制备好后，采用紧固件进行机械连接，或采用二次胶接的手段形成加筋壁板结构。由于壁板和加筋单独制作，需要通过机械连接或胶接的方法连接各个部件，从而导致了整体工序较为复杂，增加了生产成本，且机械加工过程中，容易破坏纤维的连续性，造成整体性能和稳定性有所降低。 201710129412.9公开了一种复合材料T型加筋壁板成型工装及成型方法，该方法采用蒙皮成型平板、蒙皮成型盖板、定位销和用于T型筋条铺贴成型的T型筋条成型单元为工装，通过在蒙皮成型盖板上预留筋条定位槽使筋条准确定位，并采用蒙皮盖板使蒙皮区域均匀受压，采用筋条成型盖板使壁板结构加强筋腹板外型面尺寸公差得到有效控制。该方法，提高整体大型壁板结构的刚性和强度，更有效地提高结构整体工艺质量，同时节省了工艺制备周期及成本，但所用工装和模具较多而且复杂，需要精确的定位槽来定位，并固化后才能脱模，不适用于化学气相渗透法制备碳/碳、碳/陶复合材料T型结构件。
发明内容
针对现有技术存在的上述问题，本发明申请人提供了一种T型结构纤维针刺预制体。本发明采用模块化的制备方式，将T型结构纤维针刺预制体分成4个模块分别制备，再采用整体针刺将4个模块结合。该方法具有操作简单，模具用量少的特点，同时制备的T型结构纤维针刺预制体尺寸稳定、承载能力强，方便运输。
本发明的技术方案如下：
一种T型结构纤维针刺预制体，所述预制体的结构包括蒙皮薄层(1)、位于蒙皮薄层(1)上呈对称L形排布的左加强筋(2)和右加强筋(3)；所述预制体采用整体针刺工艺成型。
所述蒙皮薄层(1)通过网胎和纤维布按照一定顺序平铺后针刺制成。
所述蒙皮薄层(1)为由高性能纤维经过纺织工艺制成的面密度为50-600g/cm2的织物；所述高性能纤维为碳纤维、玻璃纤维、石英纤维、芳纶纤维中的一种或多种；所述织物为平纹、缎纹、斜纹、单向织物或网胎；所述蒙皮薄层(1) 由10-100层织物叠层形成，厚度为5-25mm。
所述左加强筋(2)和右加强筋(3)通过网胎和纤维布按一定顺序进行转角折叠铺层针刺形成。
所述左加强筋(2)、右加强筋(3)由高性能纤维经过纺织工艺制成的面密度为50-600g/cm2的织物；所述高性能纤维为碳纤维、玻璃纤维、石英纤维、芳纶纤维中的一种或多种；所述织物为平纹、缎纹、斜纹、单向织物或网胎；所述左加强筋(2)、右加强筋(3)由10-100层织物叠层形成，厚度为5-25mm。
所述左加强筋(2)与右加强筋(3)的L形拐角为60-120°。
所述左加强筋(2)与右加强筋(3)的L形拐角之间留有间隙，所述间隙为类似三角形结构，该类三角结构靠近加强筋一侧带有一定的弧度；所述间隙填充有由碳纤维、玻璃纤维、石英纤维或芳纶纤维通过纺织工艺制成的面密度为 50-600g/cm2的纤维织物；所述纤维织物为平纹、缎纹或斜纹二维织物，还可以为单向织物或网胎。
所述左加强筋(2)和右加强筋(3)还可以呈对称的]形排布。
一种T型结构纤维针刺预制体的制备方法，所述方法包括如下步骤：
(1)将纤维织物按一定顺序平铺并进行针刺形成“一”蒙皮薄层；
(2)将纤维织物按一定顺序在角膜上折叠铺层，再采用针刺工艺制备“┘”型加强筋左侧和“└”型加强筋右侧；
(3)将纤维织物依次裁剪成带状和条状，按照尺寸从大到小依次铺放形成“▲”型，并进行从上到下进行预针刺，形成“▲”折角填充层；或者将纤维织物依次裁剪成带状和条状，采用卷曲的方式形成“”型折角填充层；
(4)将蒙皮薄层置于下层，并依次在蒙皮薄层上置放“┘”加强筋左侧、“▲”或“”型折角填充层和“└”加强筋右侧，从左右两侧进行针刺的同时从上侧进行针刺，随后在转角位置，从“▲”间隙的三个方向进行针刺，获得T型结构件纤维针刺预制体；其中“▲”或“”型折角填充层在针刺过程中发生变形，填充左加强筋(2)与右加强筋(3)的L形拐角之间的间隙。
本发明有益的技术效果在于：
本发明采用模块化的制备方法，方法简单，容易操作，两个简单的角膜完成了T型结构纤维针刺预制体的制备，模具用量少。同时，采用折角填充层对折角位置进行了填充，减少了折角位置的应力集中，提高于T型结构纤维针刺预制体的承载能力。采用整体针刺工艺固定纤维，获得了尺寸稳定的T型结构纤维针刺预制体，该预制体可以脱开角膜进行运输，并进行后续树脂浸渍固化或化学气相沉积工艺。
附图说明
图1为本发明示意图；
图2为本发明示意图；
图中：1、蒙皮薄层；2、左加强筋；3、右加强筋。
具体实施方式
下面结合附图和实施例，对本发明进行具体描述。
实施例1
以制备如图1所示的T型结构件纤维针刺预制体为例，对本发明的制备方法进一步说明。
一种T型结构件纤维针刺预制体的制作方法，具体如下步骤：
(1)根据加强筋的厚度10mm和蒙皮的厚度10mm，先采用10层50g/cm2碳纤维网胎和10层200g/cm2碳纤维平纹布依次交替铺设，形成厚度为5mm的蒙皮薄层，并进行预针刺成型；
(2)采用折角为90°“┘”模具如图1倒置放置后，将10层50g/cm2碳纤维网胎和10层200g/cm2碳纤维平纹布在模具上依次交替铺放，并进行预针刺，制备厚度为5mm的加强筋左侧；
(3)采用折角为90°“└”模具如图1倒置放置后，将10层50g/cm2碳纤维网胎和10层200g/cm2碳纤维平纹布在模具上依次铺放，并进行预针刺，制备厚度为5mm的加强筋右侧；
(4)将10层50g/cm2碳纤维网胎和10层200g/cm2碳纤维平纹布依次裁剪成带状和条状，按照尺寸从大到小依次铺放形成“▲”型，并进行从上到下进行预针刺，形成“▲”折角填充层；
(5)将5mm蒙皮薄层置于下层，并依次在蒙皮薄层上置放“┘”加强筋左侧、“▲”折角填充层和“└”加强筋右侧，从左右两侧进行针刺的同时从上侧进行针刺，随后在转角位置，从“▲”折角填充层的三个方向进行针刺，获得T型结构件纤维针刺预制体。
实施例2
以制备如图1所示的斜T型结构件纤维针刺预制体为例，对本发明的制备方法进一步说明。
一种T型结构件纤维针刺预制体的制作方法，具体如下步骤：
(1)根据加强筋的厚度50mm和蒙皮的厚度50mm，先采用50层200g/cm2玻璃纤维网胎和50层600g/cm2玻璃纤维布依次交替铺设，形成厚度为25mm的蒙皮薄层，并进行预针刺成型；
(2)采用折角为120°“┘”模具如图1倒置放置后，将50层200g/cm2玻璃纤维网胎和50层600g/cm2玻璃纤维平纹布在模具上依次交替铺放，并进行预针刺，制备厚度为25mm的加强筋左侧；
(3)采用折角为60°“└”模具如图1倒置放置后，将50层200g/cm2玻璃纤维网胎和50层600g/cm2玻璃纤维平纹布在模具上依次铺放，并进行预针刺，制备厚度为25mm的加强筋右侧；
(4)将50层200g/cm2玻璃纤维网胎和50层600g/cm2玻璃纤维平纹布裁剪成带状或条状后依次平铺，再采用卷曲的方式形成“”折角填充层；
(5)将25mm蒙皮薄层置于下层，并依次在蒙皮上层置放“┘”加强筋左侧、“”折角填充层和“└”加强筋右侧，从左右两侧进行针刺的同时从上侧进行针刺，随后在转角位置，从“▲”间隙的三个方向进行针刺，获得T型结构件纤维针刺预制体。
实施例3
以制备如图2所示的工型结构件纤维针刺预制体为例，对本发明的制备方法进一步说明。
一种工型结构件纤维针刺预制体的制作方法，具体如下步骤：
(1)根据加强筋的厚度10mm和两侧蒙皮的厚度15mm，先采用40层 200g/cm2芳纶纤维布铺设厚度为10mm的蒙皮薄层，并进行预针刺成型，制备两块厚度10mm的上下蒙皮薄板；
(2)采用90°的“┘”和“└”模具如图2倒置放置后，将25层200g/cm2芳纶纤维布在模具上依次铺放，并进行预针刺，制备厚度为5mm的“]”和“[”加强筋；
(3)将200g/cm2芳纶纤维布裁剪成带状，按照尺寸从大到小依次铺放形成“▲”型，并进行从上到下进行预针刺，制备两块“▲”折角填充层；
(4)将一块10mm上蒙皮薄层置于下层，并依次在壁板上层置放“]”加强筋左侧、“▲”折角填充层和“[”加强筋右侧，从左右两侧高度为加强筋一半的位置进行针刺的同时从上侧进行针刺，随后在转角位置，从“▲”折角填充层的三个方向进行针刺；
(5)将另一块10mm下蒙皮薄层置于下层，随后将另一块“▲”折角填充层放置在下壁板中间位置，并将上述步骤(4)获得的连接上壁板的预制体倒置后放置在下壁板上，以“▲”折角填充层为“]”和“[”加强筋的中心。从左右两侧高度为加强筋一半的位置进行针刺的同时从上侧进行针刺，随后在转角位置，从“▲”折角填充层的三个方向进行针刺。

Claims (6)

1.一种T型结构纤维针刺预制体的制备方法，其特征在于，所述方法包括如下步骤：
(1)将纤维织物按一定顺序平铺并进行针刺形成“一”蒙皮薄层(1)；
(2)将纤维织物按一定顺序在角膜上折叠铺层，再采用针刺工艺制备“┘”型左加强筋(2)和“└”型右加强筋(3)；
(3)将纤维织物依次裁剪成带状和条状，按照尺寸从大到小依次铺放形成“▲”型，并进行从上到下进行预针刺，形成“▲”折角填充层；或者将纤维织物依次裁剪成带状和条状，采用卷曲的方式形成“○”型折角填充层；
(4)将蒙皮薄层置于下层，并依次在蒙皮薄层上置放“┘”左加强筋(2)、“▲”或“○”型折角填充层和“└”右加强筋(3)，从左右两侧进行针刺的同时从上侧进行针刺，随后在转角位置，从“▲”间隙的三个方向进行针刺，获得T型结构件纤维针刺预制体；其中“▲”或“○”型折角填充层在针刺过程中发生变形，填充左加强筋(2)与右加强筋(3)的L形拐角之间的间隙；
所述左加强筋(2)、右加强筋(3)采用的纤维织物为由高性能纤维经过纺织工艺制成的面密度为50-600g/cm2的织物；所述高性能纤维为碳纤维、玻璃纤维、石英纤维、芳纶纤维中的一种或多种；所述织物为平纹、缎纹、斜纹、单向织物或网胎；所述左加强筋(2)、右加强筋(3)由10-100层织物叠层形成，厚度为5-25mm。
2.根据权利要求1所述的制备方法，其特征在于，所述蒙皮薄层(1)采用的纤维织物为由高性能纤维经过纺织工艺制成的面密度为50-600g/cm2的织物；所述高性能纤维为碳纤维、玻璃纤维、石英纤维、芳纶纤维中的一种或多种；所述织物为平纹、缎纹、斜纹、单向织物或网胎；所述蒙皮薄层(1)由10-100层织物叠层形成，厚度为5-25mm。
3.根据权利要求1所述的制备方法，其特征在于，所述左加强筋(2)和右加强筋(3)通过网胎和平纹布按一定顺序进行转角折叠铺层针刺形成。
4.根据权利要求1所述的制备方法，其特征在于，所述左加强筋(2)与右加强筋(3)的L形拐角为60-120°。
5.根据权利要求1所述的制备方法，其特征在于，步骤(3)中，填充层采用的纤维织物为由碳纤维、玻璃纤维、石英纤维或芳纶纤维通过纺织工艺制成的面密度为50-600g/cm2的纤维织物；所述纤维织物为平纹、缎纹或斜纹二维织物，或为单向织物或网胎。
6.根据权利要求1所述的制备方法，其特征在于，所述左加强筋(2)和右加强筋(3)呈对称的]形排布。
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