CN113752644A - 一种冲击自感应的复合材料飞机蒙皮结构及其制备方法 - Google Patents
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Abstract
本发明公开了一种冲击自感应的复合材料飞机蒙皮结构及其制备方法,其中复合材料飞机蒙皮结构,包括:碳纤维承载层,所述碳纤维承载层的一侧设置有碳纳米感应层,所述碳纤维承载层与所述碳纳米感应层之间设置有柔性电路层,所述柔性电路层与所述碳纳米感应层电性连接;所述碳纤维承载层与所述柔性电路层之间设置有玻璃纤维绝缘层;通过将碳纳米材料薄膜作为感应层,通过柔性电路层的连接,与复合材料结构共固化成一体,在满足承载的同时,具有对外物冲击感应的能力,可以解决碳纳米材料感应层与复合材料飞机蒙皮的集成问题,以及复合材料飞机蒙皮遭受外物冲击后,冲击损伤的感应和识别问题。
Description
技术领域
本发明涉及飞机用复合材料领域,特别涉及一种冲击自感应的复合材料飞机蒙皮结构及其制备方法。
背景技术
先进复合材料因具有比刚度大、比强度高、材料性能可设计等一系列优点,被越来越多地应用在各类飞机结构上,以达到减轻机体结构重量,提高机体结构品质的目的。但复合材料结构层间韧性不足,在外物冲击(如冰雹和砂石撞击、工具跌落等)作用下,极易产生层间分层和基体碎裂等内部损伤(表面痕迹很小,较难通过目视检查发现),造成的压缩强度下降可达60%-70%,严重威胁结构安全。如果这些冲击损伤不能够被及时发现,将可能导致灾难性的后果。因此迫切需要发展冲击监测和识别技术,及时发现机身和机翼等大面积蒙皮结构受到的外物冲击,保障飞行安全。
随着材料科学的发展,国内外研究者也在探索将碳纳米材料与复合材料结构结合,形成具有损伤自感应的多功能复合材料结构。早期的研究主要以碳纳米管改性树脂基体为主,通过树脂基体导电性能的变化来反映复合材料结构的变形和损伤。近年来研究者越来越多地关注利用碳纳米材料制备的宏观材料和器件,如碳纳米管纤维、碳纳米管薄膜、石墨烯薄膜等,对复合材料结构进行健康监测。但就目前来说,如何将碳纳米材料与复合材料结构进行较好的集成形成多功能复合材料结构是这项技术向飞机实际应用过程中面临的一个难题。与此同时,在复合材料飞机蒙皮遭受外物冲击后,如何对冲击损伤进行快速的感应和准确的识别也是需要重点解决的一个关键问题。
发明内容
为了解决上述问题,本发明提供一种能解决碳纳米感应层与复合材料飞机蒙皮的集成问题,以及复合材料飞机蒙皮遭受外物冲击后,冲击损伤的感应和识别问题的复合材料飞机蒙皮结构及其制备方法。
为了实现上述目的,本发明一方面提供一种冲击自感应的复合材料飞机蒙皮结构,包括:碳纤维承载层,所述碳纤维承载层的一侧设置有碳纳米感应层,所述碳纤维承载层与所述碳纳米感应层之间设置有柔性电路层,所述柔性电路层与所述碳纳米感应层电性连接;所述碳纤维承载层与所述柔性电路层之间设置有玻璃纤维绝缘层。
作为优选的一种技术方案,所述柔性电路层包括柔性基底,所述柔性基层上设置有电路,电路与电极连接,所述电路还连接有接口。
作为优选的一种技术方案,所述柔性电路是在覆铜聚酰亚胺薄膜上蚀刻而成的。
作为优选的一种技术方案,所述柔性电路层的电极与所述碳纳米感应层的边界电性连接。
作为优选的一种技术方案,所述碳纳米感应层远离所述柔性电路层的一侧设置有玻璃纤维保护层。
作为优选的一种技术方案,所述碳纳米材料感应层由碳纳米材料制备的薄膜制备而成。
作为优选的一种技术方案,所述碳纤维承载层由多层碳纤维材料制备而成。
另一方面,本发明还提供一种冲击自感应的复合材料飞机蒙皮结构的制备方法,包括:
步骤一:根据作用在飞机蒙皮结构上的外载荷要求,确定碳纤维承载层所需的碳纤维预浸料体系、铺层数、铺层角;
步骤二:根据碳纤维选材结果,确定玻璃纤维绝缘层和保护层所需的玻璃纤维预浸料体系;
步骤三:根据飞机蒙皮结构所需监测面积,确定柔性电路层的电极、电路以及接口的布置方案,通过柔性电路制造工艺,在覆铜聚酰亚胺薄膜上蚀刻出所确定的柔性电路层;
步骤四:选定碳纳米感应层所需的薄膜材料,将其覆盖于柔性电路层之上,采用导电介质将柔性电路层的电极与碳纳米感应层边界连接导通;
步骤五:将碳纤维承载层、玻璃纤维绝缘层、柔性电路层、碳纳米感应层以及玻璃纤维保护层依次铺设,由真空袋密封后,送入热压罐固化成型。
本发明相对于现有技术的有益效果是:相对于现有的复合材料结构冲击监测和识别技术,本发明将碳纳米材料薄膜作为感应层,通过柔性电路层的连接,与复合材料结构共固化成一体,在满足承载的同时,具有对外物冲击感应的能力,可以解决碳纳米材料感应层与复合材料飞机蒙皮的集成问题,以及复合材料飞机蒙皮遭受外物冲击后,冲击损伤的感应和识别问题;本发明的制备方法简单,对复合材料飞机蒙皮的原有性能影响小,结合电阻抗成像方法,可以实现对外物冲击造成的损伤进行感应和识别。
附图说明
图1是本发明中冲击自感应的复合材料飞机蒙皮结构的示意图;
图2是本发明中冲击自感应的复合材料飞机蒙皮结构中的柔性电路层的示意图;
图3是本发明中冲击自感应的复合材料飞机蒙皮结构的制备流程图;
图中:1-碳纤维承载层,2-玻璃纤维绝缘层,3-柔性电路层,4-碳纳米感应层,5-玻璃纤维保护层;6-柔性基底,7-电极,8-电路,9-接口。
具体实施方式
下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅是本发明的一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
如本申请和权利要求书中所示,除非上下文明确提示例外情形,“一”、“一个”、“一种”和/或“该”等词并非特指单数,也可包括复数。一般说来,术语“包括”与“包含”仅提示包括已明确标识的步骤和元素,而这些步骤和元素不构成一个排它性的罗列,方法或者设备也可能包含其他的步骤或元素。
除非另外具体说明,否则在这些实施例中阐述的部件和步骤的相对布置、数字表达式和数值不限制本申请的范围。同时,应当明白,为了便于描述,附图中所示出的各个部分的尺寸并不是按照实际的比例关系绘制的。对于相关领域普通技术人员已知的技术、方法和设备可能不作详细讨论,但在适当情况下,所述技术、方法和设备应当被视为授权说明书的一部分。在这里示出和讨论的所有示例中,任何具体值应被解释为仅仅是示例性的,而不是作为限制。因此,示例性实施例的其它示例可以具有不同的值。应注意到:相似的标号和字母在下面的附图中表示类似项,因此,一旦某一项在一个附图中被定义,则在随后的附图中不需要对其进行进一步讨论。
如图1所示,本发明提供一种冲击自感应的复合材料飞机蒙皮结构,包括碳纤维承载层1、玻璃纤维绝缘层2、柔性电路层3、碳纳米感应层4以及玻璃纤维保护层5。碳纳米感应层4设置在碳纤维承载层1的一侧,柔性电路层3设置在碳纤维承载层1与碳纳米感应层4之间设置,柔性电路层3与碳纳米感应层4电性连接;碳纤维承载层1与所述柔性电路层3之间设置有玻璃纤维绝缘层2。
具体的,如图2所示,柔性电路层3包括柔性基底6、电极7、电路8以及接口9;柔性电路层3可由覆铜的聚酰亚胺薄膜蚀刻制备,电路8需绝缘,电极7需裸露以利于与碳纳米感应层4连接;接口9可与电阻抗成像测试系统连接,用于获取碳纳米感应层4边界电压数据。
进一步的,碳纤维承载层1为复合材料飞机蒙皮结构的主要承载部件,承担着蒙皮结构所受的外载荷,其铺层和厚度等设计参数由具体设计方案确定。
进一步的,玻璃纤维绝缘层2位于碳纤维承载层1之上,用于对柔性电路层3和碳纳米感应层4进行电气绝缘,避免与碳纤维承载层1导通短路。
进一步的,碳纳米感应层4铺设于柔性电路层3之上,其是外物冲击的感应元件;当受到冲击后,由于损伤的原因,冲击位置的碳纳米感应层区域会发生电导率变化;碳纳米材料感应层的边界与柔性电路层电极相接触导通;碳纳米材料感应层可由碳纳米材料制备的薄膜构成,优选材料为碳纳米管薄膜。
在此需要说的是,玻璃纤维保护层5位于整个结构最外层,对碳纳米材料感应层起到保护作用。
本实施例提供的复合材料飞机蒙皮结构将碳纳米材料薄膜作为感应层,通过柔性电路层的连接,与复合材料结构共固化成一体,在满足承载的同时,具有对外物冲击感应的能力。可以解决碳纳米材料感应层与复合材料飞机蒙皮的集成问题,以及复合材料飞机蒙皮遭受外物冲击后,冲击损伤的感应和识别问题。
另外,本实施例还提供一种冲击自感应的复合材料飞机蒙皮结构的制备方法,如图3所示,包含如下步骤:
步骤一:根据作用在飞机蒙皮结构上的外载荷要求,选定碳纤维承载层1所需的碳纤维预浸料体系、铺层数、铺层角;本实施例中选用T300碳纤维和QY8911树脂制备的单向带预浸料,单层厚度约0.117mm,共16层,铺层角顺序为[±45/0/90]2S。
步骤二:根据碳纤维选材结果,选定玻璃纤维绝缘层2和玻璃纤维保护层5所需的玻璃纤维预浸料体系;本实施例中选用S级高强玻璃纤维编织布和QY8911树脂制备的预浸料,单层厚度约0.2mm,共1层。
步骤三:根据飞机蒙皮结构所需监测面积,设计柔性电路层3、电极7、电路8和接口9等布置方案,通过柔性电路制造工艺,在覆铜聚酰亚胺薄膜上蚀刻出所设计的柔性电路层3;本实施例中柔性电路层的布置如图2所示,共包含20个电极,电极包围形成的形状为正方形,边长200mm,与碳纳米感应层的形状和尺寸一致,每边均匀分布5个电极;电极为圆形,直径为3mm,通过线宽为0.5mm的电路引出,与接口连接;柔性基底选用聚酰亚胺薄膜,厚度为0.05mm,覆铜层厚度约为0.018mm;将所设计布置方案显影于覆铜层表面,通过湿法蚀刻技术将电极、电路和接口制备出,形成柔性电路层。
步骤四:选定碳纳米感应层4所需的薄膜材料,将其覆盖于柔性电路层3之上,采用导电介质将柔性电路层3的电极7与碳纳米感应层4边界连接导通;本实施例中选择浮动催化化学气相沉积法制备的碳纳米管薄膜作为碳纳米感应层,厚度约0.01mm;将碳纳米管薄膜裁剪成与柔性电路层电极所围成面积一致的形状,并覆盖于柔性电路层之上,采用导电银浆将电极与碳纳米管薄膜边界粘结在一起。
步骤五:将碳纤维承载层1、玻璃纤维绝缘层2、柔性电路层3、碳纳米感应层4以及玻璃纤维保护层5依次铺设,由真空袋密封后,送入热压罐在一定温度和压力下固化成型。本实施例中固化成型所施加的压力为7个大气压,在此压力作用下,首先在30分钟内将温度从室温均匀升至120度,然后保温90分钟,最后在30分钟内将温度从120度降至室温。
所述的复合材料飞机蒙皮结构在固化成型后,将柔性电路层接口与测试系统连接;当外物冲击发生后,碳纳米材料感应层将由于受到冲击损伤而引起冲击部位电导率的变化;采用测试系统依次在电极对中激励微小电流,并测量相应的边界电压,通过电阻抗成像技术重建冲击引起的碳纳米材料感应层电导率变化,实现对外物冲击的感应和识别。
以上所述仅为本发明的实施方式,并非因此限制本发明的专利范围,凡是利用本发明说明书及附图内容所作的等效结构或等效流程变换,或直接或间接运用在其他相关的技术领域,均同理包括在本发明的专利保护范围内。
Claims (8)
1.一种冲击自感应的复合材料飞机蒙皮结构,其特征在于,包括:碳纤维承载层,所述碳纤维承载层的一侧设置有碳纳米感应层,所述碳纤维承载层与所述碳纳米感应层之间设置有柔性电路层,所述柔性电路层与所述碳纳米感应层电性连接;所述碳纤维承载层与所述柔性电路层之间设置有玻璃纤维绝缘层。
2.根据权利要求1所述的复合材料飞机蒙皮结构,其特征在于:所述柔性电路层包括柔性基底,所述柔性基层上设置有电路,电路与电极连接,所述电路还连接有接口。
3.根据权利要求2所述的复合材料飞机蒙皮结构,其特征在于:所述柔性电路是在覆铜聚酰亚胺薄膜上蚀刻而成的。
4.根据权利要求2所述的复合材料飞机蒙皮结构,其特征在于:所述柔性电路层的电极与所述碳纳米感应层的边界电性连接。
5.根据权利要求1所述的复合材料飞机蒙皮结构,其特征在于:所述碳纳米感应层远离所述柔性电路层的一侧设置有玻璃纤维保护层。
6.根据权利要求1所述的复合材料飞机蒙皮结构,其特征在于:所述碳纳米材料感应层由碳纳米材料制备的薄膜制备而成。
7.根据权利要求1所述的复合材料飞机蒙皮结构,其特征在于:所述碳纤维承载层由多层碳纤维材料制备而成。
8.一种冲击自感应的复合材料飞机蒙皮结构的制备方法,其特征在于,包括:
步骤一:根据作用在飞机蒙皮结构上的外载荷要求,确定碳纤维承载层所需的碳纤维预浸料体系、铺层数、铺层角;
步骤二:根据碳纤维选材结果,确定玻璃纤维绝缘层和保护层所需的玻璃纤维预浸料体系;
步骤三:根据飞机蒙皮结构所需监测面积,确定柔性电路层的电极、电路以及接口的布置方案,通过柔性电路制造工艺,在覆铜聚酰亚胺薄膜上蚀刻出所确定的柔性电路层;
步骤四:选定碳纳米感应层所需的薄膜材料,将其覆盖于柔性电路层之上,采用导电介质将柔性电路层的电极与碳纳米感应层边界连接导通;
步骤五:将碳纤维承载层、玻璃纤维绝缘层、柔性电路层、碳纳米感应层以及玻璃纤维保护层依次铺设,由真空袋密封后,送入热压罐固化成型。
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