CN111361743B - 一种复合材料进气道及其制备方法 - Google Patents
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Abstract
本发明公开了一种复合材料进气道及其制备方法,涉及机载电子吊舱进气道结构设计与制造领域,包括引气分流弯管和整流罩外壳,在所述引气分流弯管与整流罩外壳之间的孔隙填充泡沫结构,该结构形式有利于不同结构特征之间通过共固化工艺形成整体结构,同时可增强进气道整体结构刚度,并提供了一种复合材料进气道及其制备方法,通过合理设计进气道引气分流结构,采用复合材料弯管预埋件配合泡沫芯与外蒙皮共固化成型工艺,使进气道实现轻量化,并具有较高引气效率。
Description
技术领域
本发明涉及机载电子吊舱进气道结构设计与制造领域,尤其涉及一种复合材料进气道及其制备方法。
背景技术
为避免发动机引气带来的一系列改装难题,机载电子吊舱通常采用独立进气道引气,供环控系统制冷或直接用于电子设备冷却。普通进气道一般采用铝或不锈钢钣金件焊接成型,主要存在以下不足:(1)金属材料密度较大,焊缝处需保证一定壁厚且有焊料堆积,不利于减重;(2)传统焊接工艺难以加工复杂三维曲体结构及其交接过渡结构,而简单挤压结构使进气道的引气损失增大;(3)产品成型后有焊疤残留等焊接缺陷,难以保证管道内表面粗糙度,使引气效率降低。因此,采用传统技术手段,无法实现轻量化、引气效率高的复杂引气分流结构。
发明内容
本发明所要解决的技术问题是:提供一种复合材料进气道及其制备方法,通过合理设计进气道引气分流结构,采用复合材料弯管预埋件配合泡沫芯与外蒙皮共固化成型工艺,使进气道实现轻量化,并具有较高引气效率。
本发明提供了一种复合材料进气道,包括:包括引气分流弯管和整流罩外壳,在所述引气分流弯管与整流罩外壳之间的孔隙填充泡沫结构,该结构形式有利于不同结构特征之间通过共固化工艺形成整体结构,同时可增强进气道整体结构刚度。
更进一步的,在所述进气道的迎风断面处设计包边结构,以避免层间剪切受力。
本发明还提供了一种复合材料进气道制备方法,包括
第一步,利用专用模具成型引气分流弯管预埋件;
第二步,将弯管预埋件固定在发泡模具中配合环氧泡沫成型泡沫芯;
第三步,铺覆复合材料织物整流罩以及翻边;
第四步,将复合材料进气道放入成型模具中共固化层压成型;
第五步,机加工孔位。
其中,所述第一步具体包括,
(11)利用预制体成型模具中按照设计铺层铺覆弯管预制体;
(12)合模后加压固化、脱模;
(13)在预制体表面刷J47A胶液贴J47B胶膜,然后铺缠弯管预埋件蒙皮;
(14)预埋件整体真空袋压固化成型。
所述第三步具体包括,
将泡沫芯与弯管预制体整体脱模后刷J47A胶液贴J47B胶膜,再铺覆复合材料织物蒙皮以及翻边。解决了复杂三维曲体结构及其交接过渡结构整体成型的加工难题,进气道引气效率提升5%~10%,分流损失降低30%~60%,相比传统金属材料(铝)减重15%~30%。
通过采用以上的技术方案,本发明的有益效果是:相对于传统的铝材进气道本申请的复合材进气道的重量减轻24.3%,压力恢复系数提高7.9%,分流损失降低51.3%,且无焊接残留,力学性能和防腐蚀能力有所提升。
附图说明
本发明将通过例子并参照附图的方式说明,其中:
图1为本发明的进气道结构外形示意图;
图2为进气道结构组成示意图;
图3为进气道迎风断面包边结构示意图;
图4三口进气道成型工艺流程示意图;
附图标记如下:
1-引气分流弯管,2-整流罩外壳,3-泡沫填充结构,4-迎风断面,5-包边结构,6-泡沫填充结构的局部剖视图。
具体实施方式
本说明书中公开的所有特征,或公开的所有方法或过程中的步骤,除了互相排斥的特征和/或步骤以外,均可以以任何方式组合。
本说明书中公开的任一特征,除非特别叙述,均可被其他等效或具有类似目的的替代特征加以替换。即,除非特别叙述,每个特征只是一系列等效或类似特征中的一个例子而已。
本发明的目的是要提供一种复合材料进气道及其制备方法,通过合理设计进气道引气分流结构,采用复合材料弯管预埋件配合泡沫芯与外蒙皮共固化成型工艺,使进气道实现轻量化,并具有较高引气效率。
如图1-3所示,该进气道由引气分流弯管1、整流罩外壳2以及泡沫填充结构3组成,即在引气分流弯管1与整流罩外壳2之间的孔隙填充泡沫结构3,该结构形式有利于不同结构特征之间通过共固化工艺形成整体结构,同时可增强进气道整体结构刚度,并具有良好的可制造性。
由于进气道迎风断面气动载荷相对集中,而全复合材料成型的进气道采用多层碳布铺缠成型,因此为提高产品的可靠性在进气道的迎风断面4处设计包边结构5,以避免层间剪切受力,图1还示出了完整进气道上的泡沫填充结构的局部剖视图。
此外,本发明还公开了一种复合材料进气道制备方法。该进气道采用全复合材料(碳纤维、泡沫填充剂)加工,采用弯管预埋件配合整流罩分步成型工艺,保证引气分流弯管内表面与整流罩外表面光滑,采用泡沫填充结构配合弯管预埋件与整流罩共固化成型,该方法解决了复杂三维曲体结构及其交接过渡结构整体成型的加工难题,使得进气道引气效率提升5%~10%,分流损失降低30%~60%,相比传统金属材料(铝)减重15%~30%。
其具体步骤如下:
第一步,利用专用模具成型引气分流弯管预埋件;
第二步,将弯管预埋件固定在发泡模具中配合环氧泡沫成型泡沫芯;
第三步,铺覆复合材料织物整流罩以及翻边;
第四步,将复合材料进气道放入成型模具中共固化层压成型;
第五步,机加工孔位。
本发明复合材料进气道制备方法的其主要工艺流程如图4所示,具体为:
第一步,利用预埋件成型模具成型进气道弯管预埋件,为方便精度控制并考虑装模、脱模工序,采用沿纵剖面分割后分别成型分半预制体,然后铺缠外蒙皮共固化的成型工艺,其工艺流程为:(1)利用预制体成型模具中按照设计铺层铺覆弯管预制体;(2)合模后加压固化、脱模;(3)在预制体表面刷J47A胶液贴J47B胶膜,然后铺缠弯管预埋件蒙皮;(4)预埋件整体真空袋压固化成型;
第二步,将弯管预制件固定在发泡模具中配合聚氨酯泡沫成型泡沫芯;
第三步,将泡沫芯与弯管预制体整体脱模后刷J47A胶液贴J47B胶膜,再铺覆复合材料织物蒙皮以及翻边;
第四步,将复合材料三口进气道放入成型模具中共固化层压成型;
第五步,机加工安装孔。
相比传统结构及其焊接成型工艺,本发明中涉及的复合材料进气道优势较明显,如表1所示。
表1复合材料进气道的优势
上述说明示出并描述了本发明的一个优选实施例,但如前所述,应当理解本发明并非局限于本文所披露的形式,不应看作是对其他实施例的排除,而可用于各种其他组合、修改和环境,并能够在本文所述发明构想范围内,通过上述教导或相关领域的技术或知识进行改动。而本领域人员所进行的改动和变化不脱离本发明的精神和范围,则都应在本发明所附权利要求的保护范围内。
Claims (2)
1.一种复合材料进气道制备方法,其特征在于:包括
第一步,利用专用模具成型引气分流弯管预埋件;
第二步,将弯管预埋件固定在发泡模具中配合环氧泡沫成型泡沫芯;
第三步,铺覆复合材料织物整流罩以及翻边;
第四步,将复合材料进气道放入成型模具中共固化层压成型;
第五步,机加工孔位;
所述第一步具体包括:
(11)利用预制体成型模具中按照设计铺层铺覆弯管预制体;
(12)合模后加压固化、脱模;
(13)在预制体表面刷J47A胶液贴J47B胶膜,然后铺缠弯管预埋件蒙皮;
(14)预埋件整体真空袋压固化成型。
2.根据权利要求1所述的复合材料进气道制备方法,其特征在于:所述第三步具体包括:
将泡沫芯与弯管预制体整体脱模后刷J47A胶液贴J47B胶膜,再铺覆复合材料织物蒙皮以及翻边。
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