CN111434488A - 用于生产声阻结构的方法、声阻结构和吸声面板 - Google Patents

用于生产声阻结构的方法、声阻结构和吸声面板 Download PDF

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CN111434488A
CN111434488A CN202010036024.8A CN202010036024A CN111434488A CN 111434488 A CN111434488 A CN 111434488A CN 202010036024 A CN202010036024 A CN 202010036024A CN 111434488 A CN111434488 A CN 111434488A
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layer
resistive structure
resin
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卡尔·西蒙
弗洛里安·拉维斯
丹尼斯·布罗萨尔
弗洛里安·肖塔尔
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Airbus Operations SAS
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Abstract

本发明的一个主题是一种用于生产声阻结构(46)的方法、声阻结构和吸声面板，其特征在于，所述方法包括：产生、固结和切割嵌入在具有第一熔点的第一热塑性树脂中的增强纤维的第一层以获得中间层(54)的步骤；将第二增强纤维层抵靠所述中间层(54)的第一面(64.1)铺设的步骤；使嵌入第二热塑性树脂中的所述第二增强纤维层固结从而获得结合到所述中间层(54)的未穿孔的外层(52)的第二固结步骤，所述第二热塑性树脂的第二固结温度低于所述第一树脂的第一熔点；对所述外层(52)穿孔的步骤；以及在所述中间层(54)的第二面上铺设内层(58)的步骤。本发明的另一主题是一种通过所述方法获得的声阻结构以及一种包括这种声阻结构的吸声面板。

Description

用于生产声阻结构的方法、声阻结构和吸声面板
技术领域
本申请涉及一种用于生产声阻结构的方法、一种由此获得的声阻结构、以及一种包括所述声阻结构的吸声面板。
背景技术
根据图1和图2中可见的一个已知实施例，吸声面板10包括与声波行进穿过的介质M接触的外表面10.1以及与外表面10.1相反的内表面10.2。从外表面10.1朝向内表面10.2，吸声面板10包括声阻结构12、蜂窝结构14和反射层16。声阻结构12包括：穿孔的外层18，该外层具有与外表面10.1相对应的外面18.1和内面18.2；材料条带20，这些材料条带固定到外层18的内面18.2、相互间隔开并且在第一方向上定向；以及长丝22，这些长丝附接到材料条带20、在大致垂直于第一方向的第二方向上相互定向。根据此配置，材料条带20在外层18与长丝22之间界定声学腔体24。为了使声学性能最佳，材料条带20之间的间隔需要是均匀的，并且材料条带20的边缘面20.1、20.2需要是平坦的并且垂直于外层18。
根据一个实施例，外层18和材料条带20由复合材料制成，该复合材料由嵌入PEI(聚醚酰亚胺)类型的热塑性树脂中的碳纤维构成。根据一个过程，将第一碳纤维层26铺设在铺设表面上以获得外层18，然后将材料条带20铺设在第一层26上。第一层26和材料条带20用固结袋覆盖，然后在高压釜中固结。在此固结步骤之后，材料条带20的边缘面20.1、20.2是弯曲的，并且材料条带20的与第一层26相反的表面20.3不是平坦的而是圆顶形的，如图2所展示的。
接下来，对第一层26进行穿孔以获得穿孔的外层18。然后将长丝24固定到材料条带20，以获得声阻结构12。
此实施例并非完全令人满意的，因为材料条带20的边缘面20.1、20.2是弯曲的，并且这扰乱了声学处理。此外，由于材料条带20的面20.3是圆顶形的，因此减少了材料条带20与长丝22之间接触的表面积，并且这可能减损材料条带20与长丝22之间的机械结合强度。
本发明力图克服现有技术的全部或一些缺点。
发明内容
为此，本发明的一个主题是一种产生声阻结构的方法，所述声阻结构包括穿孔的外层、内层和中间层，所述中间层被定位在所述外层与所述内层之间、具有多个相互间隔开的材料条带，其特征在于，所述方法包括：
-产生第一增强纤维层的步骤，
-使嵌入具有第一熔点的第一热塑性树脂中的所述第一增强纤维层固结的第一固结步骤，
-在经固结的所述第一层中切割出开口以便获得呈现交替的开口和材料条带的中间层的步骤，
-将第二增强纤维层抵靠所述中间层的第一面铺设的步骤，
-使嵌入第二热塑性树脂中的所述第二增强纤维层固结从而获得结合到所述中间层的未穿孔的外层的第二固结步骤，所述第二热塑性树脂的第二固结温度低于所述第一树脂的第一熔点，
-对所述外层穿孔以便获得与所述中间层的开口对准地穿过所述外层的孔的步骤，
-将所述内层铺设在所述中间层的第二面上的步骤。
在已经固结的中间层中切割出开口使得可以获得具有平坦边缘面的材料条带并且材料条带之间的间隔均匀，并且这有助于优化声学处理。另外，由于中间层在第二层固结时已经固结并且是刚性的，因此材料条带的内层被定位所抵靠的面是大致平坦的，从而与现有技术相比可以增加材料条带与内层之间接触的表面积。
根据一个实施例，所述第一树脂是PEEK类型的树脂，并且所述第二树脂是PEI类型的树脂。
根据另一特征，在所述第一固结步骤之前，将所述第二树脂的至少一个膜施加到将铺设有所述第二层的所述第一层的第一面和第二面中的至少一个。
根据一个实施例，在所述第一固结步骤之前，将所述第二树脂的第一膜和第二膜施加到所述第一层的第一面和第二面中的每一个。
根据另一特征，包括所述穿孔的外层和所述中间层的若干外壳被组装以获得大致圆柱形的刚性外壳，并且铺设所述内层的所述步骤包括将至少一根长丝缠绕到所述中间层的材料条带上。
根据一个实施例，通过激活所述第二膜将形成所述内层所缠绕的每根长丝结合到所述中间层的材料条带。
本发明的另一主题是一种通过根据本发明的方法获得的声阻结构以及一种包括这种声阻结构的吸声面板。
附图说明
进一步的特征和优点将从本发明的以下描述中变得明显，该描述仅是通过举例方式参照附图给出的，在附图中：
[图1]是展示了现有技术的一个实施例的穿过吸声面板的截面，
[图2]是详细展示了图1中可见的吸声面板的声阻结构的截面，
[图3]是展示了本发明的一个实施例的穿过吸声面板的截面，
[图4]是详细展示了图3中可见的吸声面板的声阻结构的截面，
[图5]是展示了本发明的一个实施例的穿过在第一固结步骤之前的形成声阻结构的中间层的第一层的截面，
[图6]是在第一固结步骤之后的图5中可见的第一层的透视图，
[图7]是展示了本发明的一个实施例的在产生开口的步骤之后的中间层的透视图，
[图8]是展示了本发明的一个实施例的穿过在第二固结步骤之前的声阻结构的外层和中间层的截面，
[图9]是在第二固结步骤之后的在图8中可见的外层和中间层的透视图，
[图10]是展示了本发明的一个实施例的穿过在产生孔的步骤之后的在图9中可见的外层和中间层的截面，
[图11]是包括在图10中可见的外层和中间层的外壳的透视图，
[图12]是外壳组件的透视图，每个外壳由穿孔的外层和中间层通过铺设内层的步骤构成，
[图13]是飞行器的侧向视图，并且
[图14]是穿过图13中可见的飞行器的短舱的进气口的下部部分的截面。
具体实施方式
图13描绘了飞行器30，该飞行器具有机身32、定位在机身32两侧的两个机翼34、以及固定在机翼34下方的推进组件36。每个推进组件36包括短舱38和定位在短舱38内的涡轮机。如图14所展示的，短舱38包括进气口40，该进气口具有用于将空气流朝向涡轮机和风扇引导的管道42。此管道42由至少一个吸声面板44界定。
根据图3和图4中可见的一个实施例，每个吸声面板44具有与声波行进穿过的介质M接触的外表面SE以及作为与外表面SE相反的表面的内表面SI。从外表面SE朝向内表面SI，吸声面板44包括声阻结构46、蜂窝结构48和反射层50。蜂窝结构48和反射层50由于可以与现有技术相同，因此不再进一步描述。
声阻结构46包括：
-外层52，该外层具有外面52.1(对应于外表面SE)和内面52.2；
-中间层54，该中间层与外层52的内面52.2接触、具有相互间隔开并在第一方向上定向的多个材料条带56；以及
-内层58，该内层与中间层54接触、具有牢固地附接到中间层54的长丝(增强纤维的粗纱、增强纤维的带或条带)，这些长丝相互间隔开并且在不同于第一方向的、大致垂直于第一方向的第二方向上定向。
根据此配置，中间层54的材料条带56在外层52与内层58之间界定声学腔体60。
中间层54的每个材料条带56包括在内层52与外层58之间延伸的第一边缘面56.1和第二边缘面56.2、与外层52接触的外表面56.3、以及与内层58接触的内表面56.4。
外层52具有通孔62，这些通孔至少定位在外层52的与声学腔体60对准的那些区域中。
根据一个实施例，中间层54由嵌入在具有第一熔点的第一热塑性树脂的基质中的增强纤维获得。
根据一个实施例，增强纤维是碳纤维。第一树脂是PEEK(聚醚醚酮)类型的树脂，该树脂具有约342℃的第一熔点和约395℃+/-5℃的第一固结温度。
根据图5中可见的一个过程，为了在产生第一层64的步骤期间获得中间层54，将长丝、粗纱、条带或带形式的增强纤维铺设在铺设表面上，该铺设表面可以根据期望的声阻结构的形状而是平坦的或弯曲的。
在此产生步骤之后，第一增强纤维层64在第一固结温度下经受第一固结步骤，以使其变得刚性。为此目的，定位于铺设表面上的第一增强纤维层64用固结袋覆盖并且经受固结周期(温度和压力变化)。增强纤维可以预浸渍有树脂，或者树脂的施加与第一固结步骤同时执行。
在此第一固结步骤结束时，第一层64为刚性外壳的形式，并且包括在一旦各层组装好时分别朝向外层52和内层58定向的第一面64.1和第二面64.2。
在切割步骤期间，切割经固结的第一层64以形成穿其而过的开口68，以便获得具有交替的开口68和材料条带56的中间层54，如图7所展示的。根据一个过程，使用水射流切割、激光切割或任何其他手段切割经固结的第一层64。
根据本发明，第一边缘面56.1和第二边缘面56.2是大致平坦的并且垂直于大致平坦的第一面64.1和第二面64.2。另外，每个材料条带56的宽度L被完美地控制，这意味着材料条带56之间的间隔是均匀的。
如图8所展示的，将对应于外层52的第二增强纤维层70压靠中间层54的第一面64.1。
可以通过将预浸渍有第二树脂的增强纤维的长丝、粗纱、带或条带铺设在第二铺设表面上而获得第二层70。可以与铺设、固结和切割中间层54的步骤并行地完成产生第二层70的此步骤。
根据一个实施例，此第二层70包括预浸渍有第二热塑性树脂的增强纤维，该第二热塑性树脂的第二固结温度低于第一熔点。根据一个实施例，第二树脂是PEI类型的树脂，该树脂具有约210℃的第二熔点和约295℃+/-5℃的第二固结温度。
中间层54和第二层70在第二固结温度下经受第二固结步骤，以使第二层70变得刚性并且将外层52结合到中间层54。为此，中间层54和第二层70用固结袋覆盖并且经受固结周期(温度和压力变化)。如同第一层64，第二层70的增强纤维可以预浸渍有树脂，或者树脂的施加与第二固结步骤同时执行。
在此第二固结步骤中，PEI类型的第二树脂在低于第一树脂的第一熔点的约295℃+/-5℃的第二固结温度下可混溶到PEEK类型的第一树脂的基质中。因为中间层54已经变得刚性，所以此第二固结步骤不会使保持完美平坦的材料条带56的第一边缘面56.1和第二边缘面56.2以及外表面56.4变形。
在第二固结步骤结束时，所获得的是组装在一起的未穿孔的外层52和中间层54，如图9所展示的。
根据图5和图6中可见的一个实施例，为了在产生第一层64的步骤期间促进外层52与中间层54之间的附接，将第二树脂的至少一个膜72施加到将铺设有第二层70的第一层64的第一面64.1和第二面64.2中的至少一个。因此，在第一固结步骤结束时，将铺设有第二层70的第一层64的第一面64.1被第二树脂的膜72覆盖。
根据一个过程，在第一固结步骤之前，将第二树脂的第一膜72和第二膜72’施加到第一层64的第一面64.1和第二面64.2中的每一个。因此，在第一固结步骤结束时，经固结的第一层64包括最终位于其第一面64.1上的第二树脂的第一膜72以及最终位于其第二面64.2上的第二树脂的第二膜72’。第二膜72’促进中间层54与内层58之间的附连。
根据一个实施例，每个树脂膜72、72’的厚度为约25μm。每个树脂膜72、72’覆盖其所施加到的第一面64.1或第二面64.2的整体。
在组装好外层52和中间层54之后，如图10和图11所展示的，在外层52中制成孔62。这些孔可以通过任何适当的手段产生。中间层54的材料条带56可以用作开孔引导件。产生孔62的步骤由于可以与现有技术相同，因此不再进一步描述。
在产生孔62的此步骤结束时，穿孔的外层52和中间层54形成刚性外壳74。这些外壳74中的若干个可以连结在一起以获得大致圆柱形的刚性外壳76，以便形成管道42。
在此组装步骤结束时，通过缠绕至少一根长丝将内层58铺设到中间层54的材料条带56的内表面56.4上。形成内层58所缠绕的长丝通过任何合适的手段(例如通过激活第二膜72’)而结合到中间层54。
在已经施加内层58之后，获得了声阻结构46。接下来，通过任何合适的手段(比如通过使用粘合剂膜78)将配备有反射层50的蜂窝结构48连接到声阻结构46，从而获得大致圆柱形的吸声面板44。
根据另一实施例，将内层58牢固地压靠中间层54并且通过任何合适的手段连接到中间层，从而获得声阻结构46，该声阻结构可以连接到配备有反射层50的蜂窝结构48以形成吸声面板44。
当然，刚才描述的用于生产声阻结构的方法不限于存在于进气管道42处的吸声面板。这样形成的吸声面板可以在飞行器上的其他位置或在其他领域中使用。

Claims (9)

1.一种用于生产声阻结构(46)的方法，所述声阻结构包括穿孔的外层(52)、内层(58)和中间层(54)，所述中间层被定位在所述外层(52)与所述内层(58)之间、具有多个相互间隔开的材料条带(56)，其特征在于，所述方法包括：
-产生第一增强纤维层(64)的步骤，
-使嵌入具有第一熔点的第一热塑性树脂中的所述第一增强纤维层(64)固结的第一固结步骤，
-在经固结的所述第一层(64)中切割出开口(68)以便获得呈现交替的开口(68)和材料条带(56)的中间层(54)的步骤，
-将第二增强纤维层(70)抵靠所述中间层(54)的第一面(64.1)铺设的步骤，
-使嵌入第二热塑性树脂中的所述第二增强纤维层(70)固结从而获得结合到所述中间层(54)的未穿孔的外层(52)的第二固结步骤，所述第二热塑性树脂的第二固结温度低于所述第一树脂的第一熔点，
-对所述外层(52)穿孔以便获得与所述中间层(54)的开口(68)对准地穿过所述外层(52)的孔(62)的步骤，
-将所述内层(58)铺设在所述中间层(54)的第二面(64.2)上的步骤。
2.根据权利要求1所述的用于生产声阻结构(46)的方法，其特征在于，所述第一树脂是PEEK类型的树脂。
3.根据权利要求1所述的用于生产声阻结构(46)的方法，其特征在于，所述第二树脂是PEI类型的树脂。
4.根据前述权利要求之一所述的用于生产声阻结构(46)的方法，其特征在于，在所述第一固结步骤之前，将所述第二树脂的至少一个膜(72，72’)施加到将铺设有所述第二层(70)的所述第一层(64)的第一面和第二面(64.1，64.2)中的至少一个。
5.根据前述权利要求所述的用于生产声阻结构(46)的方法，其特征在于，在所述第一固结步骤之前，将所述第二树脂的第一膜和第二膜(72，72’)施加到所述第一层(64)的第一面和第二面(64.1，64.2)中的每一个。
6.根据前述权利要求之一所述的用于生产声阻结构(46)的方法，其特征在于，包括所述穿孔的外层(52)和所述中间层(54)的若干外壳(74)被组装以获得大致圆柱形的刚性外壳(76)，并且铺设所述内层(58)的所述步骤包括将至少一根长丝缠绕到所述中间层(54)的材料条带(56)上。
7.根据权利要求5和6所述的用于生产声阻结构(46)的方法，其特征在于，通过激活所述第二膜(72’)将形成所述内层(58)所缠绕的每根长丝结合到所述中间层(54)的材料条带(56)。
8.一种通过根据前述权利要求之一所述的方法获得的声阻结构。
9.一种吸声面板，包括根据权利要求8所述的通过根据权利要求1至7之一所述的方法获得的声阻结构。
CN202010036024.8A 2019-01-15 2020-01-14 用于生产声阻结构的方法、声阻结构和吸声面板 Pending CN111434488A (zh)

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