CN113263754A - 用于制造飞行器机翼的由复合材料制成的中央沉箱的方法 - Google Patents
用于制造飞行器机翼的由复合材料制成的中央沉箱的方法 Download PDFInfo
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Abstract
一种用于制造飞行器机翼的中央沉箱的方法,该中央沉箱包括由U形截面的横向构件形成的框架,其中,至少一个横向构件的形成包括:形成堆叠体(34)的步骤,该堆叠体包括施加到干纤维层(24、29)的至少一层树脂膜(28、33);对该堆叠体(34)进行压制的步骤,从而赋予该堆叠体U型截面形状并压紧该堆叠体的各层;以及将堆叠体(34)的树脂预聚合和/或聚合的步骤。在该解决方案的情况下,被处理的纤维层是干纤维层,使得通过自动化的机器对其进行的处理能够以合理的成本及高的生产量进行。由可移除的薄片、即其一个面不具有粘性的薄片所承载的树脂膜的放置同样有助于通过自动装置进行的处理。
Description
技术领域
本发明涉及用于制造飞行器机翼的中央沉箱的方法,该沉箱安装在机身的下部中,以便在飞行器的机身与其机翼之间提供机械连接。
背景技术
飞行器的结构特别地包括两个子组件:一方面是机身,另一方面是两个机翼,机身与各机翼通过被称为中央机翼沉箱的结构件连接。
这种基本上呈平行六面体的套筒的形状的中央结构件在飞行器的机身的中央区域中安装在飞行器的机身的下部中。中央结构件以该中央结构件的侧向开口在机身的两侧上都向外敞开的方式相对于该机身横向地延伸,并且每个开口接纳机翼的端部,使得机翼可以被固定到机身。
这种沉箱包括由复合材料制成的框架,该框架由彼此相邻排列的一排U形截面的横向构件形成,从而大致界定上壁、下壁以及上游壁和下游壁,这些壁相互连接,从而共同界定平行六面体的套筒的形状,同时使其具有很大的刚度。
组件覆盖有外表皮,外表皮本身由复合材料制成,并且例如通过将纤维围绕由平行六面体的心轴承载的横向构件形成的组件卷绕而获得。这些纤维先用树脂浸渍,然后所有浸渍过的纤维被放入聚合高压釜中。
一般而言,横向构件的制造除了必须符合限制的尺寸公差以便使组件能够组装,而且还必须以高生产率实现。在实践中,这些横向构件是通过使用自动装置形成彼此堆叠的预浸纤维层的堆叠体而制成的。然后使该堆叠体聚合以形成横向构件。这些预浸纤维层由可商购的材料制成,通常称为“预浸料坯”或“预浸料”,包括利用热稳定树脂在其整个厚度上预浸的可能的纤维编织层。
尽管如此,用自动装置来形成预浸料坯类型的多层预浸纤维的堆叠体是有问题的,因为这种装置的价格昂贵并且不能实现令人满意的生产率的事实。这是由于下述事实:要被处理的纤维层因用树脂预浸渍而发粘,这将使用自动装置的纤维层的处理显著复杂化。
本发明涉及一种制造这种沉箱所使用的U形截面的横向构件的优化的制造方法,从而可以确保高生产率。
发明内容
为此,本发明涉及一种用于制造飞行器机翼的中央沉箱的方法,该中央沉箱包括由U形截面的横向构件形成的框架,其中,至少一个横向构件的形成包括:
–形成堆叠体的步骤,该堆叠体包括至少一个干纤维层和施加到该干纤维层的一层树脂膜;
–将树脂膜施加到干纤维层上是通过放置包括树脂膜的层而获得的,树脂膜由可移除的薄片承载然后被从可移除的薄片移除;
–使用按压装置对堆叠体进行热压制的步骤,由此赋予堆叠体U型截面的形状且同时压紧堆叠体的各层。
在该解决方案的情况下,被处理的纤维层是干纤维层,使得通过自动化的机器对纤维层进行的处理可以以合理的成本和高的生产量进行。由可移除的薄片——即,其一个面不具有粘性——所承载的树脂膜的放置简化了通过自动装置进行的处理。
本发明还涉及所定义的方法,其包括将存在于所压紧的各层的堆叠体中的树脂预聚合和/或聚合的步骤。
本发明还涉及所定义的方法,其中,预聚合步骤被结合到压制步骤中。
本发明还涉及所定义的方法,其中,至少一个纤维层是由编织纤维制成的织物层。
本发明还涉及所定义的方法,包括以下步骤:将各层的平坦的堆叠体切割成多个带状件,所述多个带状件中的每个带状件对应于一个横向构件。
本发明还涉及所定义的方法,包括将多个横向构件安装到支撑心轴上的步骤、将复合纤维围绕由心轴支承的横向构件卷绕的步骤、以及用树脂浸渍以形成沉箱的外表皮的步骤、以及将表皮和横向构件连结聚合的步骤。
附图说明
图1是包含中央机翼沉箱的飞行器的整体立体图;
图2是单独示出的中央机翼沉箱的整体立体图;
图3是中央机翼沉箱的纵向截面图;
图4是在制造过程中中央机翼沉箱的一部分的纵向截面图;
图5是围绕沉箱框架卷绕纤维以形成其表皮的阶段的整体立体图;
图6是用于形成沉箱框架的横向构件的立体图;
图7是单独示出的平坦纤维层的立体图;
图8是在平坦的纤维层上施加由可移除的薄片承载的树脂膜的立体图;
图9是在移除可移除的薄片之后施加到纤维层上的树脂膜的立体图;
图10是用于制造根据本发明的横向构件的各层的不断堆叠的立体示意图;
图11是为了形成多个横向构件的切割之前的各层的完成的平坦的堆叠体的立体示意图;
图12是用于形成根据本发明的由复合材料制成的U形截面的横向构件的按压装置的截面图;
图13是在根据本发明的横向构件的形成期间按压装置的截面图;
图14是使根据本发明的横向构件的完成成形的按压装置的截面图。
具体实施方式
在图1中,飞行器1包括大体上筒形的机身2,该机身2沿纵向方向AX延伸,并且在其中央区域的下部包括具有附图标记3的中央机翼沉箱。
该中央沉箱3呈基本上为平行六面体的套筒的总体形状,其在垂直于纵向方向AX的、被表示为AT的方向上横向延伸。因此,该套筒状的中央沉箱3包括分别位于其端部4和6处的两个相对的开口,并且所述开口各自在机身的两侧上向外敞开以各自接纳飞行器的一个机翼,用附图标记7和8表示的这些机翼大致沿横向方向AT延伸。
如图2和图3所示,该中央沉箱3包括框架9或骨架,该框架9或骨架由一组U形截面的横向构件11形成,所述横向构件11彼此固定以共同形成平行六面体的套筒形状。这些横向构件11是由例如树脂基体中的碳纤维之类的复合材料制成的元件,并且由这些横向构件11形成的框架9被本身由复合材料制成的表皮12紧密地包围,该表皮12赋予了该组件所需的机械内聚力。
横向构件11的各自的凹部朝向沉箱3的内部定向,使得每一对两个相邻的横向构件11在它们的连接点处界定出加劲肋13,该加劲肋13沿横向方向AT延伸并且朝向沉箱3的内部突出。因此,各个肋13彼此平行地延伸,并且用于增加沉箱的刚度。
如图4和图5所示,该沉箱使用大致平行六面体的心轴14制造,该心轴14在其外表面上包括与肋13相对应的凹槽16,从而构成对于横向构件11的支撑部,该支撑部用于布置横向构件11并将其保持在适当位置以形成框架9并使框架9定形。具体地,每个U形截面的横向构件11固定至心轴14的外表面。
如图6所示,每个U形截面的横向构件11包括呈壁形式的本体17,该壁呈基本平坦的带的形式,两个边缘18、19或分支从该壁侧向延伸,所述两个边缘也呈垂直于本体17的平坦的带的形式且彼此平行。
如图4所示,通过将U形截面的横向构件11的两个边缘18、19中的每个边缘插入到该心轴14的两个相应的凹槽16中而将每个U形截面的横向构件11固定到心轴14上。在心轴14的每个拐角处,安装了拐角横向构件21,该拐角横向构件21具有与横向构件11的截面不同的特定的C形截面。更具体地,每个拐角横向构件21包括非平坦的而是呈角铁形状的底部,即L形截面轮廓,呈平坦的带的形式的两个相对的边缘从该底部延伸。如图4所示,拐角横向构件21用于将框架9的面彼此连接,以构成呈套筒形状的组件。
当所有横向构件11和21都在心轴14上就位时,根据轴线AT竖向延伸所依循的方向将该心轴安装在基部22上,该基部装备有机械装置,该机械装置允许此心轴14及其上安装的横向构件绕其轴线AT旋转且在此操作期间竖向延伸。
在该阶段,如图5所示,碳纤维卷绕在组件上,以形成中央沉箱3的表皮12。该操作是使用可竖向移动的退卷绕头23来实现的,心轴14然后绕其轴线AT旋转。围绕由心轴装载的横向构件卷绕的纤维例如是用树脂浸渍的碳纤维。这些也可以是干燥的碳纤维,随后在卷绕纤维之后施加树脂。
一旦形成表皮,将组件放置在高压釜类型的装置中,以使表皮的树脂与横向构件的树脂聚合,从而形成具有最佳机械内聚力并因此机械强度适用于其预期用途的沉箱。
根据本发明,所使用的复合材料横向构件11是通过下述步骤来制造的:首先形成包含交替排列的碳纤维织物层和树脂膜层的堆叠体,然后热压制该堆叠体以赋予其U形截面形状,同时将这些层彼此压紧,以便也使树脂在织物层的整个厚度上有效地浸渍织物层。
在图7中,有利地使用自动化装置将平坦的干纤维层24放置在平坦的支撑件(未示出)上。在该示例中,这是恒定厚度的碳纤维编织物,有利地是多轴编织物。施加一层干纤维而不是一层用诸如预浸料之类的树脂预浸渍的纤维有助于使用自动化系统进行自动放置,这是因为,与用树脂预浸渍的层不同,干燥层不发粘。
有利地,使用自动化装置将树脂膜层26放置在该层24上。该层26包括可移除薄片27,该可移除薄片27在其下表面上承接预定且恒定厚度的树脂膜28。如图7中示意性示出的,一旦层26在层24上就位,则可移除的薄片27被移除,而树脂膜28在纤维层24的上表面上保持就位,如图9所示。
然后可以在树脂膜28上放置另一层干纤维29,以便在后者上放置另一层31的树脂膜。该层31也包括可移除的薄片32,该薄片32被移除以便将树脂膜33置留在纤维29的层上。
这产生了平坦的、包括一定数量的纤维层的多个层的堆叠体,并且在每对连续的纤维层之间插入树脂膜。纤维层的数量取决于横向构件的机械尺寸,并且层的堆叠以完全自动化的方式或以半自动化的方式完成。
替代性地,树脂以液体的形式供应,而不是以由薄片承载的薄膜的形式供应,这能够适合于自动化装置的某些配置。
在图11中,给定附图标记34的各层的最终堆叠体因此包括交替顺序的干纤维层36和树脂膜37,在该示例中,该堆叠体具有正方形轮廓。然后两个平行的直切口D1和D2产生在该堆叠体34中,以便切割穿过该堆叠体的整个厚度,从而产生三个矩形轮廓的堆叠体,所述堆叠体旨在形成三个横向构件11,所三个带状件被赋予附图标记38、39和41。
然后,带状件38被安装在由按压装置44的下部承载的下腔室43的中央部分42上,如图12示意性示出的。该腔室43包括底部46,中央部分42从底部46突出。该中央部分42从底部46突出,并且具有矩形的总体形状,该矩形总体形状比带状件38窄并且比带状件38长得多。
如图12所示,带状件38以在中央部分42上居中的方式安装,以使该矩形带状件的长边缘在侧向上越过中央部分42延伸,从而与底部46相对。
按压装置44的上部带有与下腔室43在竖向上相对定位的上腔室47,并且还具有与下腔室43的形式相匹配的起伏形式。
一旦组件就位,按压装置44就被致动,以将上腔室47朝向下腔室43降低,如图13和图14所示。这种降低的启动导致带状件38的边缘降低并在侧向上突出超过中央部分42,如图13所示,从而使堆叠的层的带状件具有U形截面形状。
如图14所示,在下降结束时,带状件38的成形完成,并且带状件具有期望的U形截面。然后控制按压装置44,以增加由上腔室47施加在下腔室43上的压力,其结果是能够压紧带状件38的各个组成层,从而构成一个既紧凑又基本上没有气泡的组件。
提供了对腔室43和47进行的加热,以使树脂更加液态以便提高其在织物层内的渗透性、即提高树脂在成形操作期间的注入。该加热还引起树脂的预聚合,以部分固化所获得的横向构件11。
然后,以相同的方式加工带状件39和41,以形成另外两个预制的U形截面的横向构件11。当以此方式制造了必要数量的横向构件时,将这些横向构件安装在心轴14上,以构成待被制造的中央沉箱的框架9。
当所有横向构件11都在心轴14上就位时,心轴被设定为绕竖向轴线AT旋转,从而通过外部卷绕而形成围绕横向构件的纤维表皮。可以通过在线的卷绕期间直接浸渍经卷绕的线、或通过本领域中的任何其他常规技术将树脂直接整合到该表皮中。
当由通过心轴14承载的框架9形成并且由表皮12包围的组件准备就绪时,该组件被安装在高压釜型系统中,以进行横向构件11的树脂和表皮12的树脂的共聚合,以便使这些不同的部件相连结地固化,从而使组件具有适当的机械内聚力,并由此获得令人满意的机械强度。
换句话说,在高压釜中进行横向构件和表皮的连结聚合的事实允许这些元件有效地彼此结合以形成具有高机械强度的总体结构。
在所描述的示例中,本发明被应用于中央机翼沉箱的制造。然而,本发明也可以更普遍地应用于包括呈U形截面的横向构件形式的、覆盖有在高压釜中聚合的表皮的加强件的部件的制造。
一般而言,本发明使得可以以高产量和低成本的方式制造U形截面的、复合材料的横向构件。仅处理干纤维层和由可移除的薄片承载的树脂膜层的事实显著简化了处理这些层所需的自动化手段,因为这些层不发粘。
相比之下,使用预浸料型层——由于它们浸渍了树脂,因此不可避免地会发粘——来制造这些横向构件所需的自动化的处理方法明显更复杂、成本更高且生产率低得多。
Claims (6)
1.一种用于制造飞行器机翼的中央沉箱(3)的方法,所述中央沉箱(3)包括由U形截面的横向构件(11)形成的框架(9),其中,至少一个横向构件的形成包括:
形成堆叠体(34)的步骤,所述堆叠体(34)包括至少一个干纤维层(24、29、36)和施加到所述干纤维层(24、29、36)的一层树脂膜(28、33、37);
将树脂膜(28、33、37)施加到干纤维层(24、29、36)是通过放置包括树脂膜(28、33、37)的层(26、31)而获得的,所述树脂膜(28、33、37)由可移除的薄片(27、32)承载然后被从所述可移除的薄片(27、32)移除;
使用按压装置对所述堆叠体(34)进行热压制的步骤,由此赋予所述堆叠体(34)U型截面的形式且同时压紧所述堆叠体(34)的各层。
2.根据权利要求1所述的方法,包括将存在于经压紧的各层的所述堆叠体(34)中的树脂预聚合和/或聚合的步骤。
3.根据权利要求2所述的方法,其中,所述预聚合的步骤被结合到压制的步骤中。
4.根据权利要求1所述的方法,其中,至少一个纤维层(24、29、36)是由编织纤维制成的织物层。
5.根据权利要求1所述的方法,包括以下步骤:将各层的平坦的所述堆叠体(34)切割(D1、D2)成多个带状件(38、39、41),所述多个带状件(38、39、41)中的每个带状件对应于一个横向构件(11)。
6.根据权利要求1所述的方法,包括将多个横向构件(11)安装到进行支撑的心轴(14)上的步骤、使复合纤维围绕由所述心轴(14)支承的所述横向构件(11)卷绕的步骤、以及用树脂浸渍以形成所述沉箱(3)的外部的表皮(12)的步骤、以及将所述表皮(12)和所述横向构件(11)连结聚合步骤。
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