CN110871614B - 集成表面保护系统及保护复合结构的方法 - Google Patents
集成表面保护系统及保护复合结构的方法 Download PDFInfo
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- CN110871614B CN110871614B CN201910802519.4A CN201910802519A CN110871614B CN 110871614 B CN110871614 B CN 110871614B CN 201910802519 A CN201910802519 A CN 201910802519A CN 110871614 B CN110871614 B CN 110871614B
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Abstract
一种集成表面保护系统(22)及保护复合结构的方法,集成表面保护系统包括单层(24),该单层包括导电网络(26)和纤维增强材料(28)。
Description
技术领域
本说明书涉及适于放置在复合结构或部件(诸如飞机和航空航天复合结构和部件)上的集成多功能表面保护系统。
背景技术
随着碳纤维增强聚合物(CFRP)材料越来越多的使用,飞机结合广泛的雷击保护特征,以确保安全性和合规性。已知系统包括金属箔系统,该金属箔系统包括膨胀网形式的铜或铝箔,该铜或铝箔嵌入聚合物树脂层中,然后层压到复合结构上。
除了雷击保护特征以外,还有多个材料层与复合结构的外侧结合使用,以提供UV保护,从而使用于紧固件安装的钻孔的影响最小化,并为底漆粘合和涂料应用提供光面修整。当前的现有技术针对这些功能中的每一种使用单独的层。
发明内容
在一个实施例中,集成表面保护系统包括单层,该单层包括导电网络和纤维增强材料。
在另一个实施例中,复合结构包括复合基底和复合基底上的单层。单层包括导电网络和纤维增强材料。
在又一实施例中,保护复合结构的方法包括将集成表面保护系统结合到复合结构。集成表面保护系统包括单层,并且该单层包括导电网络和纤维增强材料。
根据以下详细描述、附图和所附权利要求,公开的集成多功能表面保护系统的其他实施例将变得显而易见。
附图说明
图1是飞机的俯视平面图,示出飞机的各种雷击区域。
图2是示出能够保护图1的飞机的复合结构的示例性集成表面保护系统的示意图。
图3是示出能够保护图1的飞机的复合结构的另一示例性集成表面保护系统的示意图。
图4是示出包括图2的集成表面保护系统的示例性复合结构的示意图。
图5是示出包括图3的集成表面保护系统的示例性复合结构的示意图。
图6是示出使用图2和图3的集成表面保护系统保护复合结构的示例性方法的流程图。
具体实施方式
根据本说明书,多层表面保护系统的许多或所有功能都被结合在单个集成表面保护系统中以提供雷击保护,使紧固件安装的钻孔的影响最小化并提供UV保护,和/或为底漆粘合和涂料应用提供光面修整。单个系统中的部件的集成可以减轻设计重量和/或简化加工和制造。单个集成表面保护系统也可以被优化,以确保作为系统的整体设计的稳健性,这可以导致整体系统的改进。
在至少一个示例优化中,应力模拟已经表明,基于由-55℃和70℃之间的温度循环而导致的热应力模拟,在嵌入环氧涂层内的金属膨胀箔上添加玻璃纤维层减少了在没有玻璃纤维层的配置上的热应力。
公开了具有单层的集成表面保护系统,该单层结合了多层表面保护系统的多层的许多或所有功能。集成表面保护系统包括用于防止雷电直接影响的导电网络。集成表面保护系统还包括纤维增强材料,以提供用于处理和自动铺设的结构支撑。纤维增强材料是钻兼容的,并且可以提高关于温度循环的环境耐久性。由于纤维增强材料,可以保持覆盖涂料层的完整性。
公开的集成多功能表面保护系统可以提高效率和/或降低制造成本。公开的集成多功能表面保护系统还可以通过提供雷击保护、减轻钻孔的影响和减少热应力来确保使用的耐久性。
图1是飞机10的俯视平面图,示出飞机10的各个区域11。飞机10的部件13可以位于或形成区域11中的一个或多个。飞机10的此类区域11可以是具有相对高雷击概率的飞机10的位置。区域11可以包括机头区域12、机身区域14、机翼区域16、机尾区域18和翼尖区域20。尽管在此示出并描述了飞机10,但是集成表面保护系统22(在图2和图3中示出)可以用于任何合适的车辆或期望消散或传导电流的其他位置。
图2和图3是示出总体由22表示的示例性集成表面保护系统的示意图。每个图示的集成表面保护系统22包括具有导电网络26和纤维增强材料28的单层24。单层24还可以包括支撑导电网络26和纤维增强材料28的基体材料27。基体材料27可以通过将导电网络26和纤维增强材料28完全封装并结合在一起来支撑导电网络26和纤维增强材料28。通过基体材料27实现的封装可以保护导电网络26和纤维增强材料28免受环境的影响,并且还可以向集成表面保护系统22提供用于底漆粘合和涂料应用的光滑表面。单层24具有第一表面31和与第一表面31相对的第二表面33。基体材料27可以是环氧树脂,其是即使在升高的温度下也相对坚固的热固性树脂,并且很好地粘附到各种纤维增强材料28,诸如碳纤维和玻璃纤维。在不脱离本公开的范围的情况下,附加的部件和特征件可以包括在单层24中。
导电网络26包括赋予集成表面保护系统22导电性(或增强其导电性)的导电材料(或导电材料的组合)。集成表面保护系统22的导电网络26经配置通过集成表面保护系统22传导电流诸如雷电电流,并远离附接点、电子/电气系统和燃料箱。因此,导电网络26可以提供抵挡雷电直接影响的保护。
导电网络26包括由导电材料形成的多个导电元件29。多个导电元件29电连接。在所示的示例中,多个导电元件29物理连接。
例如,如图2所示,导电网络26的导电元件29形成基体材料27内的网或网格。因此,导电元件29物理连接并电连接,从而形成导电网络26。
可替换地,如图3所示,导电网络的导电元件29是分散在整个基体材料27中的颗粒,诸如碎片或片段。基体材料27内的导电元件29(颗粒)的数量具有足够高的浓度,以实现基体材料27内物理的颗粒与颗粒的接触,从而形成导电网络26。
在示例中,导电材料包括金属。金属导电材料可以形成定位在整个单层24中的导电金属元件29的物理连接的网络。具体而言,导电网络26的导电材料可以是物理连接在整个单层24中的金属线段。如图2所示,导电网络26可以采取预制网格或网的形式,其被添加到具有增强材料28的基体材料27中。如图2所示,预制网格或网被示出为三维网络。可替换地,预制网格或网可以是在整个单层24延伸的二维网络。
在一个方面,导电网络26包括铜和铝中的至少一种,铜和铝与各种基体材料27(包括环氧树脂)化学相容,并且是导电的。包括在单层24中的导电材料的量取决于许多因素,诸如导电材料的导电性和导电材料在单层24内的布置。
在另一个示例中,导电网络26包括导电非金属。导电网络26的非金属可以是由导电非金属形成的多个分散段的形式。在这种情况下,导电网络26可以采取足够量的包括在单层24中的多个导电非金属分散段的形式,以实现基体材料27内的物理的段与段的接触,从而变得电连接并形成导电网络26。在一方面,导电非金属段以随机布置方式分布在单层内。在示例中,导电网络26包括石墨烯和碳纳米管中的至少一种,石墨烯和碳纳米管与各种基体材料27(包括环氧树脂)化学相容,并且是高导电的。
存在纤维增强材料28以增加集成表面保护系统22的强度。在组成上,纤维增强材料28可以是单一材料或材料的组合。例如,纤维增强材料28包括具有相对高的强度重量比的玻璃纤维和碳纤维中的至少一种。物理上,纤维增强材料28可以采取多个纤维的形式,诸如分散(例如,随机地)在单层24的基体材料27中的多个纤维。如图所示,纤维增强材料28可以物理分离。可替换地,纤维增强材料28可以物理连接。
集成表面保护系统22的纤维增强材料28可以为处理和自动铺设提供结构支撑,并且可以便于针对紧固件安装的钻孔。通过将纤维增强材料28与导电网络26一起集成到单层24中,与多层结构相比,关于温度循环的环境耐久性得到改善,从而保持覆盖涂料层48的完整性。
如图2和图3所示,集成表面保护系统22可以可选地进一步包括在单层24的第一表面31上或内的紫外线保护层30。如图所示,紫外线保护层30可以是施加在单层24的第一表面31上的独立层。可替换地,紫外线保护层30可以集成到单层24中,使得单层24包括导电网络26、纤维增强材料28和紫外线保护层30。紫外线保护层30可以包括例如具有紫外线保护特性的任何有机聚合物树脂(例如,包含UV稳定剂),以保护下面的材料免受紫外线辐射。
如图2和图3所示,集成表面保护系统22可以可选地进一步包括在单层24的第二表面33上的载体层32。载体层32可以包括用于自动铺设过程的合适纸材,在该过程中单层24被施加到复合基底42。在一种表达方式中,载体层32具有有机硅脱模剂。有机硅脱模剂提供光滑的表面,以便于将载体层32与集成表面保护系统22分离。例如,载体层32的截面厚度在0.1016mm(0.004英寸)至0.2032mm(0.008英寸)的范围内。载体层32可以与集成表面保护系统22分离诸如与单层24分离,并被丢弃。因此,当载体层32与集成表面保护系统22分离时,集成表面保护系统22的表面诸如单层24的第二表面33,附接到复合基底(例如,图4和图5所示的复合基底42)的表面。
图4和图5是示出总体由40表示的示例性复合结构的示意图。复合结构40包括复合基底42和集成表面保护系统22。因此,复合结构40包括复合基底42和单层24,单层24包括导电网络26和纤维增强材料28。如图所示,复合结构40还可以包括如前所述的基体材料27和紫外线保护层30。
如图4和5所示,复合结构40还可以包括定位在集成表面保护系统22上的底漆层46。例如,底漆层46在单层24的至少一个表面上。底漆层46是在涂漆之前施加在复合结构40的单层24上的预备涂层。底漆层46可以确保涂料更好地粘附到复合结构40的单层24。在示例中,底漆层46包括聚氨酯层。在示例中,底漆层46具有0.013mm的厚度。
如图4和图5所示,复合结构40还可以包括在集成表面保护系统22上的涂料层48。涂料层48是作为保护涂层施加到复合结构40的至少一个表面的物质。当复合结构40进一步包括底漆层46时,底漆层46定位在单层24与涂料层48之间。在示例中,涂料层48包括聚氨酯层。在示例中,涂料层48具有0.13mm至0.15mm的厚度。
复合结构40的复合基底42可以是(或可以包括)例如飞机或航空航天结构的任何部件。例如,复合基底42可以是(或可以包括)机头区域12(图1)、机身区域14(图1)、机翼区域16(图1)、机尾区域18(图1)和翼尖区域20(图1)。因此,如图1所示,飞机10的部件13(图1)可以包括复合结构40。
复合结构40的复合基底42可以包括彼此堆叠的多个层片44(例如,碳纤维增强聚合物的片或带)。虽然在图4和图5中示出三个层片44,但是在不脱离本公开的范围的情况下,可以使用少于三个或多于三个的层片44。在一方面,多个层片44中的至少一个层片包括碳纤维增强塑料。
复合结构40可以通过任何适合的工艺形成。在一方面,复合结构40可以通过制造集成表面保护系统22(图2和图3)来形成,该集成表面保护系统22包括例如单层24、紫外线保护层30和载体层32。然后,将集成表面保护系统22结合到复合基底42,之后施加底漆层46和涂料层48。然而,本公开的复合结构40不受该制造过程的限制。
图6是示出根据本说明书实施例的保护复合结构40的示例性方法50的流程图。
方法50包括在框53处,将集成表面保护系统22结合到复合结构40,其中集成表面保护系统22包括单层24,单层24包括导电网络26和纤维增强材料。在示例中,将集成表面保护系统22结合到复合结构40包括将集成表面保护系统22结合到飞机10(图1)的部件13(图1)。复合结构40包括例如飞机或航空航天结构的任何部件,诸如机头区域12、机身区域14、机翼区域16、机尾区域18和翼尖区域20的部件。在一方面,复合结构40包括多个层片(例如,CFRP基底蒙皮层)。
如图所示,方法50还可选地包括在框51处,在结合之前将载体层与集成表面保护系统22分离。该分离允许单层24的第二表面33暴露,以便随后施加到复合结构40。
如图所示,方法50还可选地包括在框52处,通过自动铺设过程(例如,使用拾取和放置机器人)将集成表面保护系统施加到复合结构40。因此,在一方面,集成表面保护系统22被制造为独立部件并结合到复合结构40。
如图所示,方法50还可选地包括在框54处,在结合的集成表面保护系统22上施加底漆层46。施加底漆层46制备复合结构40以用于接收随后的涂料层48,并且增强复合结构40与涂料层48之间的粘合。
如图所示,方法50还可选地包括在框55处,在结合的集成表面保护系统22上施加涂料层48。例如,涂料层48可以施加在底漆层46上。施加涂料层48为复合结构40提供保护涂层。
本公开还包括以下说明性的、非穷尽列举的示例,这些示例可以要求保护也可以不要求保护:
1.一种集成表面保护系统(22),包括:
单层(24),包括导电网络(26)和纤维增强材料(28)。
2.根据示例1所述的集成表面保护系统(22),其中导电网络(26)包括金属。
3.根据示例1或2所述的集成表面保护系统(22),其中导电网络(26)包括铜和铝中的至少一种。
4.根据示例1所述的集成表面保护系统(22),其中导电网络(26)包括导电非金属。
5.根据示例1或4所述的集成表面保护系统(22),其中导电网络(26)包括石墨烯和碳纳米管中的至少一种。
6.根据示例1至5中任一项所述的集成表面保护系统(22),其中纤维增强材料(28)包括玻璃纤维和碳纤维中的至少一种。
7.根据示例1至6中任一项所述的集成表面保护系统(22),其中单层(24)还包括支撑导电网络(26)和纤维增强材料(28)的基体材料(27)。
8.根据示例7所述的集成表面保护系统(22),其中基体材料(27)包括环氧树脂。
9.根据示例1至8中任一项所述的集成表面保护系统(22),还包括在单层(24)的第一表面(31)上或内的紫外线保护层(30)。
10.根据示例1至9中任一项所述的集成表面保护系统(22),还包括在单层(24)的第二表面(33)上的载体层(32)。
11.一种复合结构(40),包括:
复合基底(42);和
示例1的集成表面保护系统(22),施加到复合基底(42)。
12.根据示例11所述的复合结构(40),其中复合基底(42)包括碳纤维增强塑料。
13.根据示例11或12所述的复合结构(40),还包括在集成表面保护系统(22)上的涂料层(48)。
14.根据示例13所述的复合结构(40),还包括定位在集成表面保护系统(22)与涂料层(48)之间的底漆层(46)。
15.一种飞机(10)的部件(13),包括示例11至14中任一项所述的复合结构(40)。
16.一种用于保护复合结构(40)的方法(50),该方法包括以下步骤:
将集成表面保护系统(22)结合到复合结构(40),其中集成表面保护系统(22)包括单层(24),该单层(24)包括导电网络(26)和纤维增强材料(28)。
17.根据示例16所述的方法(50),还包括在结合之前将载体层(32)与集成表面保护系统(22)分离。
18.根据示例16或17所述的方法(50),其中将集成表面保护系统(22)结合到复合结构(40)的步骤包括将集成表面保护系统(22)结合到飞机(10)的部件(13)。
19.根据示例16至18中任一项所述的方法(50),还包括在将集成表面保护系统(22)结合到复合结构(40)的步骤之后,在集成表面保护系统(22)上施加涂料层(48)。
20.根据示例19所述的方法(50),还包括在将集成表面保护系统(22)结合到复合结构(40)的步骤之后,在集成表面保护系统(22)上施加底漆层(46),其中底漆层(46)定位在集成表面保护系统(22)与涂料层(48)之间。
因此,本说明书可以提供用于处理和自动铺设的结构支撑,同时便于钻孔并显著提高关于温度循环的环境耐久性,从而保持覆盖涂料层的完整性。公开的集成多功能表面保护系统和方法可以提高效率并降低制造成本,同时提供免受雷击直接影响的保护并减少热应力。
尽管已经示出和描述了公开的集成多功能表面保护系统的各种实施例,但是本领域技术人员在阅读说明书后可以想到各种修改。本申请包括此类修改,并且仅受权利要求的范围限制。
Claims (16)
1.一种集成表面保护系统(22),包括:
单层(24),所述单层(24)包括:
基体材料(27),
由所述基体材料(27)支撑的导电网络(26),所述导电网络(26)包括金属并且采取三维网络的形式,和
由所述基体材料(27)支撑的纤维增强材料(28);
位于所述单层(24)的第一表面(31)内的紫外线保护层(30);以及
位于所述单层(24)的第二表面(33)上的载体层(32),其中所述载体层(32)与所述单层(24)可分离从而使所述单层(24)的所述第二表面(33)附接到复合基底的表面。
2.根据权利要求1所述的集成表面保护系统(22),其中所述导电网络(26)包括铜和铝中的至少一种。
3.根据权利要求1所述的集成表面保护系统(22),其中所述导电网络(26)包括导电非金属。
4.根据权利要求1或3所述的集成表面保护系统(22),其中所述导电网络(26)包括石墨烯和碳纳米管中的至少一种。
5.根据权利要求1或3所述的集成表面保护系统(22),其中所述纤维增强材料(28)包括玻璃纤维和碳纤维中的至少一种。
6.根据权利要求1所述的集成表面保护系统(22),其中所述基体材料(27)包括环氧树脂。
7.一种用于保护复合结构(40)的方法(50),所述方法包括以下步骤:
将权利要求1-6中任一项所述的集成表面保护系统(22)结合到所述复合结构(40)。
8.根据权利要求7所述的方法(50),所述方法还包括在结合的步骤之前将载体层(32)与所述集成表面保护系统(22)分离。
9.根据权利要求7或8所述的方法(50),其中将所述集成表面保护系统(22)结合到所述复合结构(40)的步骤包括将所述集成表面保护系统(22)结合到飞机(10)的部件(13)。
10.根据权利要求7或8所述的方法(50),所述方法还包括在将所述集成表面保护系统(22)结合到所述复合结构(40)的步骤之后,在所述集成表面保护系统(22)上施加涂料层(48)。
11.根据权利要求10所述的方法(50),所述方法还包括在将所述集成表面保护系统(22)结合到所述复合结构(40)的步骤之后,在所述集成表面保护系统(22)上施加底漆层(46),其中所述底漆层(46)定位在所述集成表面保护系统(22)与所述涂料层(48)之间。
12. 一种复合结构(40),包括:
复合基底(42);以及
根据权利要求1所述的集成表面保护系统(22),施加到所述复合基底(42)。
13.根据权利要求12所述的复合结构(40),其中所述复合基底(42)包括碳纤维增强塑料。
14.根据权利要求12所述的复合结构(40),还包括在所述集成表面保护系统(22)上的涂料层(48)。
15.根据权利要求14所述的复合结构(40),还包括定位在所述集成表面保护系统(22)与所述涂料层(48)之间的底漆层(46)。
16.一种飞机(10)的部件(13),包括根据权利要求12所述的复合结构(40)。
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