CN114206722A - 集成拉挤成型复合型材及用于制造其的方法 - Google Patents
集成拉挤成型复合型材及用于制造其的方法 Download PDFInfo
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Abstract
公开了用于电动垂直起降飞行器、轻型直升机、风力涡轮机和其他转子翼应用的集成拉挤成型复合型材、例如转子翼和叶片,以及用于制造其的集成设计和加工方法。本发明提供了用于加固和支撑外蒙皮的多个腹板肋,该外蒙皮可以包括织物层、金属蒙皮或热塑性复合蒙皮。还公开了一种连续拉挤成型具有可变空气动力学扭转的集成复合翼型型材的工艺和方法。还公开了绞合金属丝绳的使用,其使得前缘配重能够在原位连续供给到拉挤成型工艺中并有效地保留在拉挤成型产品中。还公开了用于前缘配重的以载有高密度粉末的基体树脂浸渍的纤维增强结构的使用。
Description
相关申请的交叉引用
本申请根据35 USC第119(e)条要求于2019年6月20日提交的共同未决美国临时专利申请第62/864,250号的优先权,其全部公开内容通过引用并入本文。本申请还根据35USC第119(e)条要求于2019年6月20日提交的共同未决美国临时专利申请第62/864,272号的优先权,其全部公开内容通过引用并入本文。并且,本申请还根据35 USC第119(e)条要求于2019年6月20日提交的共同未决美国临时专利申请第62/864,285号的优先权,其全部公开内容通过引用并入本文。
技术领域
本发明总体上涉及集成拉挤成型复合型材,例如转子翼和叶片,及用于制造其的方法。
背景技术
拉挤成型是一种连续的复合材料制造工艺,其长期以来一直被认为是用于高生产率和低成本的生产产品。将诸如各种形式的玻璃纤维或碳的纤维机械拉过树脂浴槽、成型工具和树脂挤出工具,然后通过加热的钢模具,其将原材料固化成具有用于各种应用的效用的实心型材。例如,玻璃纤维拉挤成型已普遍用于梯子栏杆、化工厂扶手和格栅、工具把手和公路轮廓线等产品。
随着时间的推移,拉挤成型能力已经从制造简单的整体玻璃纤维型材发展为使用各种纤维和树脂的更复杂的形状和应用。拉挤成型空心横截面零件的能力也正在出现。例如,已经有空心翼型形状的小批量演示。实心横截面单向碳拉挤成型正用于风力涡轮机叶片翼梁和大型开发中的飞行器机翼翼梁。
以前,用于直升机和其他转子翼应用的复合转子叶片通常由多种航空级复合材料手工层压并在模具中固化,这将被归类为批处理。这些手工层压批量工艺的示例是预浸料高压釜和烘箱固化、湿法叠层和真空辅助树脂注射。
然而,新兴市场,例如使用电动垂直起降(“eVTOL”)飞行器的城市航空运输需要大批量、先进的复合材料生产。例如,仅服务于几个主要大都市的城市空中交通工具,例如eVTOL,每年需要生产超过2000批次。这种生产需求需要在单班标准工作周的基础上每小时生产一批次。典型的城市空中机动车辆具有多个叶片,因此所需的叶片生产率甚至高于基本机身。这些因素推动用于此类应用的转子叶片设计为用于生产的恒定帘线和恒定横截面设计,并允许大批量制造的工艺。由于所需的模具和制造商的数量,在这些水平上扩展传统的批处理方法以进行非常高的生产是不切实际的。
此外,在许多这些应用中,还需要将金属前缘配重结合到复合翼型结构中。前缘配重通常是圆钢棒料,它要么在通过传统方式层压时粘合到复合翼型形状中,要么在拉挤成型时在原位结合到翼型中。
在工业中将金属前缘配重结合到层压或拉挤成型的翼型截面中的几种选择是常见的,所有这些都具有已知的局限性。
一种选择是在前缘中拉挤成型具有孔的复合型材,用于稍后插入并结合就位的钢棒。这种方法涉及二次组装过程,并且难以确保钢棒在转子叶片的整个长度上有效地粘合就位。
第二种选择是将钢棒在原位插入拉挤成型工艺中,使其成为翼型型材的集成部分。根据金属棒的尺寸和所需的配重,这种方法可能很困难。如果棒的直径很大,那么它通常被接收为20英尺长的棒料。钢棒必须经过喷砂处理并准备插入,以实现与复合翼型的可接受结合。拉挤成型供给工具还必须设计为自动端到端地插入20英尺长的金属棒。而且,必须管理棒对棒接头的位置,因为在其处一根棒与另一根的间隙会有所不同。此外,适航且经过认证的产品在型材的中间跨度的钢棒中不能有接头。
通常,环氧树脂拉挤成型需要二次烘箱后固化以完全交联基体聚合物。很多时候,本领域技术人员会通过拉挤成型工艺影响约百分之八十的产品固化以用于最佳生产线速度且离线后固化产品。当翼型部分在烘箱中进行后固化时,环氧树脂或其他合适的基体树脂会随着固化完成而重新固化。根据所使用的基体树脂,产生的扭转量可能必须大于处理回弹所需的扭转。
因此,需要集成拉挤复合型材及用于制造其的方法,包括拉挤成型复合型材,例如用于eVTOL、轻型直升机、风力涡轮机和其他转子翼应用的转子翼和叶片的翼型型材,其通过连续自动化处理提供大批量、低成本和一致的生产。
此外,需要一种用于将金属前缘配重插入拉挤成型翼型型材中以克服现有技术的限制的解决方案。
此外,因为大多数转子叶片具有沿叶片长度结合的空气动力学扭转以优化性能,所以希望能够生产在叶片连续生产时结合所需空气动力学扭转的叶片。
本发明的一个或多个方面解决了这些和其他需要。
发明内容
出于总结本发明的目的,本文描述了本发明的某些方面、优点和新颖特征。应当理解,根据本发明的任何一个特定实施例,不一定可以获得所有这些优点。因此,本发明可以以实现或优化如本文所教导的一个优点或一组优点而不必实现如本文可教导或建议的其他优点的方式来体现或实施。此外,各个实施例的特征和优点可以在各个方面进行组合。
根据本发明的拉挤成型集成复合型材具有翼梁结构、前缘配重和用于功能性转子翼叶片的其他结构特征。在一个实施例中,前缘配重包括金属前缘配重和碳纤维填充前缘配重。
在一个实施例中,织物层还包封整个集成复合翼型型材并且由蒙皮加强腹板肋支撑。在另一实施例中,外蒙皮包括金属板外蒙皮。在又另一实施例中,热塑性复合蒙皮形成并结合在翼型型材上。
在一个实施例中,集成的复合翼型型材被切割成一定长度并与有助于附接到转子毂组件的根端配件结合。尖端和根部插入肋关闭集成复合翼型型材的开口端。在拉挤成型过程中,前缘配重被集成到集成复合翼型型材中。在一个实施例中,前缘配重可以包括在尖端封闭肋中。在另一实施例中,可以将额外的配重结合到尖端封闭肋中以进一步平衡叶片
在用于飞行动力学的转子叶片应用中需要金属前缘配重。传统的层压转子叶片使用钢棒作为前缘配重,其难以拉挤成型并可靠地保持在叶片中。因此,在另一实施例中,还公开了绞合金属丝绳的使用,其使得前缘配重能够在原位连续地供给到拉挤成型工艺中并且有效地保持在集成复合翼型型材中。丝绳的一个优点是它的长度很长而且很灵活,因此其可以缠绕在卷轴上。因此,在翼型型材中没有需要处理的接头。
在又另一实施例中,将高密度金属粉末或颗粒插入拉挤成型树脂混合物中产生前缘配重,其可以连续在原位供给到拉挤成型工艺中并有效地保留在拉挤成型产品中。
在本发明的各种实施例中,额外的特征和选项可以结合到翼型型材中,例如雷击保护、表面装饰和环境保护、前缘侵蚀保护和额外的根端复板。
在另一实施例中,公开了一种在翼型型材中产生空气动力学扭转的抓具牵拉器和方法。虽然并非对于所有转子翼设计都需要空气动力学扭转,但在许多设计中它是期望的,因为它可以提供飞行性能提高。从根部到尖端,期望的扭转量通常在0到15度之间。因此,还公开了一种连续拉挤成型具有可变空气动力学扭转的翼型型材的方法和牵拉器。
因此,本发明的一个或多个实施例克服了已知现有技术的一个或多个缺点。
例如,在一个实施例中,集成复合翼型型材包括翼梁结构,其包括翼梁腹板和翼梁箱;前缘配重;外蒙皮;多个腹板肋,用于加强和支撑外蒙皮;并且其中前缘配重、翼梁结构和多个腹板肋在拉挤成型期间被集成以形成集成复合翼型型材。
在该实施例中,集成复合翼型型材还可包括金属前缘配重部分和碳纤维填充前缘配重部分;其中,金属前缘配重部分还包括金属绞合丝绳;其中,金属前缘配重部分还包括多个丝棒;其中,外蒙皮包括复合织物层,并且其中复合织物层围绕前缘配重和翼梁结构缠绕;其中织物层包括无纺碳纤维织物;根端配件,用于将集成复合翼型型材连接到飞行器的转子毂,根端配件包括复板加强板和根端短柱;其中,复板加强板包括金属复板加强板;其中,复板加强板包括复合复板加强板;其中,外蒙皮包括金属蒙皮,并且其中金属蒙皮结合到前缘配重和翼梁结构;其中,外蒙皮包括热塑性复合蒙皮,并且其中热塑性复合蒙皮结合到前缘配重和翼梁结构;其中热塑性复合蒙皮还包括外侧和内侧,内侧包括合成遮蔽材料;其中前缘配重包括用基体树脂浸渍的纤维增强结构;进一步包括用于雷击保护的丝网筛;进一步包括外部合成表面遮蔽;进一步包括泡沫插入件以支撑蒙皮加强腹板肋;进一步包括金属前缘箍,其中金属前缘箍结合到前缘配重和翼梁结构。
在另一示例实施例中,一种用于拉挤成型集成复合翼型型材的拉挤成型工具系统包括:前缘加固站;前缘配重模具;第一树脂浸渍站,用于将载有高密度粉末的基体树脂注射到前缘配重模具中;翼型加固站;翼型模具;和第二树脂浸渍站,用于将未载有高密度粉末的基体树脂注射到翼型模具中。
在另一示例实施例中,一种用于在翼型型材中产生空气动力学扭转的抓具牵拉器包括:牵拉器框架;抓具框架,其中抓具框架通过轴承附接至牵拉器框架,并且其中抓具框架相对于牵拉器框架旋转;抓具爪,用于将翼型型材固定在抓具框架中;线性导轨,用于支撑抓具框架和牵拉器框架;牵拉致动器,用于沿线性导轨驱动抓具框架和牵拉器框架;扭转致动器,用于旋转抓具框架;并且其中当牵拉致动器沿着线性轨道驱动抓具框架和牵拉器框架时,扭转致动器使抓具框架旋转,导致翼型型材扭转以在翼型型材中建立空气动力学扭转。
考虑到以下详细描述和附图,本发明的其他目的、特征和优点将变得显而易见。
附图说明
图1示出了根据本发明的示例实施例的被拉挤成型为一个集成复合结构的示例集成复合翼型型材的横截面侧视图。
图2示出了促进集成复合翼型型材以紧固件至飞行器的转子毂组件的连接的示例根端配件的多个视图。
图3示出了备选的集成复合翼型型材的横截面侧视图,其中外蒙皮包括围绕拉挤成型的前缘和翼梁腹板和箱结合以形成集成复合翼型型材的金属蒙皮。
图4示出了另一备选的集成复合翼型型材的横截面侧视图,其中外蒙皮包括热塑性复合蒙皮,其形成并结合在拉挤成型的前缘配重和翼梁腹板和箱上。
图5示出了另一备选的集成复合翼型型材的横截面侧视图,其中前缘配重包括用载有高密度粉末的基体树脂浸渍的纤维增强结构。
图6示出了根据本发明的用于制造集成复合翼型型材的拉挤成型工具系统。
图7示出了可用于将空气动力学扭转构建到翼型型材中的抓具牵拉器的前视图。
图8示出了可用于将空气动力学扭转构建到翼型型材中的抓具牵拉器的后视图。
图9示出了另一实施例的前视图,其中两个抓具牵拉器串联使用以将空气动力学扭转构建到拉挤成型的翼型型材中。
具体实施方式
以下是说明本发明的原理的示例性实施例的详细描述。提供实施例以说明本发明的方面,但本发明不限于任何实施例。本发明的范围包括许多备选、修改和等价物。本发明的范围仅由权利要求书限定。
虽然在以下描述中阐述了许多具体细节以提供对本发明的透彻理解,但是可以根据权利要求书来实践本发明,而无需这些具体细节中的一些或全部。
将参考附图详细描述各种实施例。在可能的情况下,贯穿附图使用相同的附图标记来指代相同或相似的部件。对特定示例和实施方式的引用是出于说明目的,且并不旨在限制权利要求书的范围。
拉挤成型的翼型
图1示出了在没有二次粘合的情况下拉挤成型为一个集成复合组件的集成复合翼型型材100。如图1中所示,集成复合翼型型材100包括翼梁结构105,其包括翼梁腹板110、翼梁箱116、前缘配重120、后缘配重130、蒙皮加强腹板肋140和外蒙皮150。在该实施例中,蒙皮加强腹板肋140支撑外蒙皮150。蒙皮加强肋140在拉挤成型时被构建到集成复合翼型型材100中。因此,集成复合翼型型材100不需要二次复合加工、复合制造或复合粘合,这对于大批量生产很重要。
在一个实施例中,前缘配重120包括金属前缘配重部分122和碳纤维填充前缘配重部分124。在一个实施例中,金属前缘配重122可包括0.375英寸钢丝绳,并且碳纤维填充前缘配重部分124可包括实心24K碳纤维填充物。在另一实施例中,玻璃粗纱或碳丝束纤维用于翼梁箱116,并且碳纤维填充物用于前缘配重部分124和后缘配重130。
在一个实施例中,外蒙皮150包括复合织物层160,其缠绕在翼梁腹板110和翼梁箱116周围,其产生集成复合翼型型材100的中空部分170。在一个实施例中,织物层160封装整个集成复合翼型型材100。可以使用多种复合织物选项用于织物层160,例如机织布或多轴向缝编无纺布。在一个实施例中,3K三轴无纺碳纤维织物用于织物层160。
在又另一实施例中,织物层160中正或负45度的纤维用于处理扭转和弦向载荷。此外,可以在展向方向上添加单向粗纱或丝束以处理弯曲载荷。以正或负45度的纤维还提供拉挤集成复合翼型型材100所需的强度。
在各种其他实施例中,集成复合翼型型材100可以由诸如玻璃纤维、碳纤维或芳族聚酰胺纤维的纤维和诸如环氧树脂、乙烯基酯或聚酯的基体树脂制成。在另一实施方案中,可以使用其他可拉挤成型树脂系统和纤维。
如图1中所示,在一个实施例中,集成复合翼型型材100还具有尺寸1000、1010、1020、1030、1040、1050、1060、1070、1100、1110、1120、1130、1140和1150。在一个实施例中,集成复合翼型型材100具有约12英寸的尺寸1000、约3英寸的尺寸1010、约0.05英寸的尺寸1020、约0.05英寸的尺寸1030、约2英寸的尺寸1040、约3英寸的尺寸1050、约3.37英寸的尺寸1060、约3.37英寸的尺寸1070、约1.22英寸的尺寸1100、约0.4英寸的尺寸1120、约0.187英寸的尺寸1130、约0.05英寸的尺寸1140和约0.05英寸的尺寸1150。
金属前缘配重
在另一实施例中,金属前缘配重部分122可以在生产集成复合翼型型材100时连续插入拉挤成型中。用于拉挤成型转子叶片和其他具有不均匀横截面例如厚横截面前缘配重的空心和实心拉挤型材的拉挤成型方法和拉挤成型工具系统,以及由其制成的产品,在题为“Pultrusion of Profiles Having Non-Uniform Cross Sections”的共同未决的专利申请第16/904,926号中公开,其通过引用并入本文。
在一个实施例中,金属前缘配重部分122包括金属绞合丝绳。钢或不锈钢丝绳可以缠绕,因此它可以像纤维一样被送入拉挤成型机。由于丝绳由绞合股线制成,因此丝绳在外部具有纹理,因此它机械地良好粘附到碳纤维填充前缘配重部分124。换言之,丝绳金属前缘配重部分122的表面不规则与碳纤维填充前缘配重部分124的周围复合结构良好啮合。
丝绳通常以长长度可用,因此不需要接头,并且丝绳可以通过将其从线轴上拉下来连续送入拉挤成型机。一个示例柔性丝绳配置是7x19股,但也可以使用其他丝绳变体。在另一实施例中,丝绳在插入拉挤成型机之前经过蒸汽脱脂以更好地结合。
在备选实施例中,金属前缘配重部分122包括多个小直径丝棒以近似丝绳或股线。所需的小丝棒数量取决于横截面积。所使用的棒的数量应该近似等于单个棒金属前缘配重部分122。
根端配件
图2示出了根端配件200,其有助于以紧固件230将集成复合翼型型材100连接到飞行器的转子毂组件(未示出)。根端配件200由机加工或锻造的根端短柱210组成,具有复板加强板220和紧固件230。
在一个实施例中,复板加强板220可以由复合材料或机加工金属制成,并且可以被层压或结合到集成复合翼型型材100的外部。紧固件230可以为连接通过整个集成复合翼型型材100的贯穿螺栓紧固件或到根部配件200中的螺纹螺栓。湿粘合剂可以与紧固件230结合以填充空隙、增加强度并改善紧固件230的疲劳性能。
根端配件200到集成复合翼型型材100的连接基于三个工程原理,包括插入产生重叠以处理弯曲载荷,紧固件230处理离心和弯曲载荷,并且金属部件和复合材料之间的夹紧力处理弯曲载荷和离心载荷二者并且提供从集成复合翼型型材100到根端配件200的载荷的冗余转移。
如图2中所示,在一个实施例中,集成复合翼型型材100也具有尺寸2000,且根端配件具有尺寸2100和2200。在一个实施例中,集成复合翼型型材100具有约18英尺的尺寸2000,且根端配件具有约1.75英寸的尺寸2100和约9英寸的尺寸2200。
作为备选实施例,复板加强板220可以包括复合根端复板,其可以结合到图2中所示的根端配件200中。复合根端复板比金属复板加强板大以分散应力。复合根端复板可以通过常规复合工艺制造,但必须成形为与集成复合翼型型材100配合。在示例实施例中,复合根端复板在根端配件200组装就位之前结合就位。
备选的拉挤成型翼型实施例
图3示出了备选的集成复合翼型型材300。在集成复合翼型型材300中,外蒙皮150包括金属蒙皮350,该金属蒙皮350随后围绕并结合到集成复合翼型型材300。该备选实施例在例如严重的沙土侵蚀是操作问题的应用中是有用的。金属蒙皮350提供更好的保护以防止严重的沙土侵蚀。
诸如钛板、铝板和不锈钢板料的材料可用于金属蒙皮350。在一个实施例中,金属蒙皮350包括0.040英寸厚的钛金属板。板料形成为U形形状,且然后在拉挤成型的前缘配重120和包括翼梁腹板110和翼梁箱116的翼梁结构105上形成。然后板料用粘合剂膜层380粘合就位。金属蒙皮350可以在后缘配重130处焊接、铆接或粘合结合在一起。
如图3中所示,在一个实施例中,集成复合翼型型材300还具有尺寸3000、3010、3020、3030、3040、3050、3060、3070和3080。在一个实施例中,集成复合翼型型材300具有约12英寸的尺寸3000,约2英寸的尺寸3010,约3英寸的尺寸3020,约4英寸的尺寸3030,约0.5英寸的尺寸3040,约0.05英寸的尺寸3050,约0.187英寸的尺寸3060,约0.4英寸的尺寸3070,以及约0.3英寸的尺寸3080。
图4示出了另一种备选的集成复合翼型型材400,其中外蒙皮150包括热塑性复合蒙皮450,该热塑性复合蒙皮450在拉挤成型的前缘配重120和包括翼梁腹板110和翼梁箱116的翼梁结构105上形成和结合。热塑性复合蒙皮450具有改进的对热固性复合材料的冲击损伤容限。
在一个实施例中,热塑性复合蒙皮450通过压制成型或连续带层压工艺制造。热塑性复合蒙皮450可由玻璃纤维、碳纤维布或其与聚醚醚酮(PEEK)、聚苯硫醚(PPS)或聚醚酰亚胺(PEI)热塑性基体的混合组合制成。热塑性复合蒙皮450还可具有共层压的tedlar(聚氟乙烯)膜,其无需油漆并提供出色的抗紫外线和耐候性。在一个实施例中,热塑性复合蒙皮450包括0.040英寸厚的编织碳布和PPS预固结成型片。
热塑性复合蒙皮450随后被热成型为集成复合翼型型材400的拉挤成型的前缘配重120,从而形成U形形状。U形热塑性复合蒙皮450然后在翼梁腹板110和翼梁箱116周围形成并结合到其上。热塑性复合蒙皮450可以是热塑性的或在后缘配重130处感应焊接以将两侧连接在一起。
虽然热塑性复合蒙皮450可以经过特殊处理以结合到翼梁腹板110和翼梁箱116,但在热塑性复合蒙皮450、翼梁腹板110和翼梁箱体116之间进行有效结合的一个备选实施例是层压合成遮蔽材料到热塑性复合蒙皮450的内侧。合成遮蔽材料在加工时部分嵌入热塑性复合蒙皮450中。当热塑性复合蒙皮450随后缠绕在翼梁腹板110和翼梁箱116周围时,合成遮蔽材料在热塑性复合蒙皮450、翼梁腹板110和翼梁箱116之间形成有效的束缚。
在一个实施例中,集成复合翼型型材400具有与集成复合翼型型材300相同的尺寸。
高密度粉末前缘配重
图5图示了另一备选的集成复合翼型型材500。如图5中所示,集成复合翼型型材500包括翼梁腹板110、翼梁箱116、前缘配重520和外蒙皮150。前缘配重520包括用基体树脂浸渍的纤维增强结构,该基体树脂载有高密度粉末,例如钨或陶瓷。
前缘配重520可以在与集成复合翼型型材100的其余部分相同的模具中固化,或者,如果基体树脂的交叉污染是一个问题,前缘配重520可以如图6中所示在集成复合翼型型材100的其余部分上游的单独模具中固化。因为钨具有约19g/cm3的比重,所以前缘配重520可以具有接近钢的密度的密度。前缘配重520的热膨胀系数(CTE)将几乎与集成复合材料翼型型材100的其余部分相同。此外,不必担心当使用载有高密度粉末的基体树脂时前缘配重520与集成复合翼型型材500的其余部分之间的结合,因为该高密度粉末与光滑的钢棒相比是分散在固化树脂中的颗粒,该光滑的钢棒由于离心力和集成复合翼型型材500的弯曲可以在固化的层压板中滑动。
此外,在用于前缘配重520的拉挤成型工艺中包括高密度金属粉末或颗粒提供比钢棒更大的设计灵活性。例如,翼型横截面可具有前缘配重520,该前缘配重520制成为符合翼型形状的成形元件或具有许多不同几何变化可能的实心块。
用于翼型型材500的拉挤成型工具和工艺
图6示出了拉挤成型工具600,以及用于制造集成复合翼型型材500的相应工艺。本领域已知的典型拉挤成型机可以与拉挤成型工具600一起使用,只要该拉挤成型机具有牵引本领和能力来处理集成复合翼型型材500的期望尺寸
拉挤成型工具600包括前缘加强站610、前缘配重模具620、用于将基体树脂从树脂保持器630注射到前缘配重模具620中的第一树脂浸渍站640、翼型加强件650、翼型模具660和用于将基体树脂从树脂保持器630注射到翼型模具660中的第二树脂浸渍站670。
在一个实施例中,第一树脂浸渍站640中的基体树脂包括载有高密度粉末、例如钨或陶瓷的基体树脂。第二树脂浸渍站670中的基体树脂包括未载有高密度粉末的基体树脂。
图6中所示的拉挤成型工具600系统特别适用于制造集成复合翼型型材500,其中前缘配重520在集成复合翼型型材500的其余部分上游的单独模具中固化,例如,以添加载有高密度粉末的基体树脂到前缘配重520。然而,它可以用于制造任何集成复合翼型型材100、300或400,其中前缘配重120在集成复合翼型型材100、300或400的其余部分上游的单独模具中固化。
空气动力学扭转
转到图7-9,有潜力通过使用抓具牵拉器700沿着集成复合翼型型材100的展向长度将空气动力学扭转构建到集成复合翼型型材100中。此外,虽然这种将空气动力学扭转构建到翼型型材中的潜力此处描述用于集成复合翼型型材100,它也可以用于集成复合翼型型材300、400或500中的任何一个,或用于其他翼型型材。
当集成复合翼型型材100退出拉挤成型模具时,会影响持续引起的空气动力学扭转的可变性的因素可以包括:(1)抓具牵拉器700处的机械滚动量水平加减;(2)抓具牵拉器700与拉挤成型模具的距离;(3)集成复合翼型型材100的固化区在拉挤成型模具中的位置;沿模具长度的拉挤成型模具热量水平和热量分布;(4)拉挤线速度。
在一个实施例中,抓具牵拉器700可用于将空气动力学扭转构建到集成复合翼型型材100中。从拉挤成型机上脱离的集成复合翼型型材100被装载到支撑集成复合翼型型材100的根端180(参见图1)的抓具牵拉器700并且在尖端186处机械地将扭转引入集成复合翼型型材100。
图7和图8示出了包括扭转致动器710、齿轮选择器720、牵拉致动器730、线性导轨740、线性引导件750、抓具爪760、抓具致动器770、轴承810、抓具框架820和牵拉器框架830的抓具牵拉器700的设计的实施例。
抓具牵拉器700由线性引导件750支撑在线性导轨740上,并由牵拉致动器730沿线性导轨740驱动。抓具框架820通过大直径轴承810附接到牵拉器框架830,允许抓具框架820相对于牵拉器框架830旋转。扭转致动器710通过齿轮选择器720驱动抓具框架820的旋转运动。
在使用抓具牵拉器700的牵拉循环开始时,牵拉致动器730完全缩回,抓具框架820旋转以与集成复合翼型型材100对齐,并且抓具爪760夹住集成复合翼型型材100。当牵拉致动器730沿着线性轨道740驱动抓具牵拉器700时,扭转致动器710旋转抓具框架820,导致集成复合翼型型材100扭转以沿集成复合翼型型材100的展向长度将空气动力学扭转构建到集成复合翼型型材100中。
如图9中所示,在另一实施例中,两个抓具牵拉器700可以串联使用以将空气动力学扭转构建到集成复合翼型型材100中。在该实施例中,每个抓具牵拉器700依次牵拉和扭转集成复合翼型型材100,然后返回到其起始位置重复循环。这样,一个抓具牵拉器700总是在牵拉,而另一抓具牵拉器700返回其原始位置。因此,集成复合翼型型材100被连续牵拉通过模具,并且粘在模具中的机会更少。
为新的牵拉循环序列打开以向后行进的抓具牵拉器700必须打开足够宽以清除扭转的集成复合翼型型材100。必须控制另一抓具牵拉器700以使其以与正在关闭的集成复合翼型型材100相同的滚动角关闭。
对于拉挤成型机设计,抓具牵拉器700和拉挤成型模具之间的距离通常是固定的,但在备选实施例中,计算机数控(CNC)机器和软件可以管理距离和其他变量。过程中非破坏性检查(NDI)技术的结合还可用于创建闭环控制系统,用于诱导空气动力学扭转和管理过程以获得可重复的结果。
在另一实施例中,抓具牵拉器700可安装到线性导轨740,但具有在中心线上的滚动轴枢轴。伺服电机控制的滚珠丝杠可以从水平在两个方向上操纵抓具牵拉器滚动。抓具牵拉器700的滚动偏转一直反馈到集成复合翼型型材100,并且随着树脂在拉挤成型模具附近连续胶凝而产生渐进式设定。通常,拉挤成型的拉力载荷线与模具在拉力载荷线的三个轴(例如,轴向、垂直和水平轴)上对齐。拉力载荷线通过往复式抓具牵拉器700与拉挤成型模具对齐来固定。然而,如果相对于拉力线载荷在抓具牵拉器700中包含来自水平的滚动轴线,则它产生在集成复合翼型型材100被拉挤成型时连续地在其中引起扭转的能力。
附加特征和选项
在各种实施例中,附加特征和选项可被并入集成复合翼型型材100。此外,虽然本文针对集成复合翼型型材100描述了这些附加特征和选项,但这些附加特征和选项也可以单独使用或组合用于任何集成复合翼型型材300、400或500。
泡沫插入件190 - 在另一备选实施例中,泡沫插入件190(参见图3和4)可以插入集成复合翼型型材100中以增加集成复合翼型型材100的强度和刚度,同时保持集成复合翼型型材100的后缘部分尽可能轻。泡沫嵌件190可以胶粘就位以支撑蒙皮加强腹板肋140以支撑外蒙皮150。
雷击保护 - 细网(例如200x200)金属丝筛或网已知可提供针对复合材料飞行器和转子翼或叶片结构的雷击保护。在一个实施例中,这样的丝筛可以连续地形成并插入到用于集成复合翼型型材100的拉挤成型工艺中,使得金属丝筛成为集成复合翼型型材100的一部分而无需二次结合操作。
表面装饰和环境保护 - 常规涂料是高速生产的并发症,并引起环境问题。在一个实施例中,印刷和/或着色的合成表面遮蔽被连续供给并插入到拉挤成型工艺中以对集成复合翼型型材100进行着色和环境保护。
在另一实施例中,集成复合翼型型材100的外部被连续涂覆,通过当集成复合翼型型材100退出模具时将“模内”聚合物涂层注射到拉挤成型模具的下游部分。在另一实施例中,第二模具可用作初级拉挤成型模具下游的涂覆模具。
在各种实施例中,初级模具或涂覆模具的涂覆部分应该具有比外壳150稍大的轮廓,并且在一个示例中,约大0.010英寸的数量级,以产生用于模内涂层厚度的空间。
前缘侵蚀保护 - 在另一实施例中,本领域已知的金属前缘箍可以结合到集成复合翼型型材100,以为集成复合翼型型材100提供雨水和沙土或碎屑侵蚀保护。当集成复合翼型型材100围绕转子旋转时,前缘配重120受到会引起侵蚀的因素的影响,因为如果空气中有沙土或碎屑,或者被转子踢起,它会撞击这些颗粒。结果是前缘配重120的纤维和树脂被腐蚀。因此,金属前缘箍可以结合在前缘配重120上以减轻腐蚀。外蒙皮150可以设计成具有凸起或缩进以适应金属前缘箍的厚度而不中断翼型形状和性能。
备选实施例是将具有粘合剂的超高分子量聚合物膜施加到集成复合翼型型材100的前缘配重120以用于腐蚀保护。在一个实施例中,可以使用诸如UHMW PE的聚合物材料。
虽然已经结合其某些特定实施例具体描述了本发明,但是应当理解,这是通过说明而非限制的方式。在不脱离本发明的精神的情况下,在前述公开和附图的范围内可以进行合理的变化和修改。
Claims (19)
1.一种集成复合翼型型材,其包括:
翼梁结构,其包括:
翼梁腹板;和
翼梁箱;
前缘配重;
外蒙皮;
多个腹板肋,用于加强和支撑所述外蒙皮;并且
其中所述前缘配重、所述翼梁结构和所述多个腹板肋在拉挤成型期间被集成以形成所述集成复合翼型型材。
2. 根据权利要求1所述的集成复合翼型型材,其中,所述前缘配重包括:
金属前缘配重部分;和
碳纤维填充前缘配重部分。
3.根据权利要求2所述的集成复合翼型型材,其中,所述金属前缘配重部分还包括金属绞合丝绳。
4.根据权利要求2所述的集成复合翼型型材,其中,所述金属前缘配重部分还包括多个丝棒。
5.根据权利要求1所述的集成复合翼型型材,其中,所述外蒙皮包括复合织物层,其中所述复合织物层围绕所述前缘配重和所述翼梁结构缠绕。
6.根据权利要求5所述的集成复合翼型型材,其中,所述织物层包括无纺碳纤维织物。
7. 根据权利要求1所述的集成复合翼型型材,还包括根端配件,用于将所述集成复合翼型型材校正到飞行器的转子毂,所述根端配件包括:
复板加强板;和
根端短柱。
8.根据权利要求7所述的集成复合翼型型材,其中,所述复板加强板包括金属复板加强板。
9.根据权利要求7所述的集成复合翼型型材,其中,所述复板加强板包括复合复板加强板。
10.根据权利要求1所述的集成复合翼型型材,其中,所述外蒙皮包括金属蒙皮,并且其中所述金属蒙皮结合到所述前缘配重和所述翼梁结构。
11.根据权利要求1所述的集成复合翼型型材,其中,所述外蒙皮包括热塑性复合蒙皮,并且其中所述热塑性复合蒙皮结合到所述前缘配重和所述翼梁结构。
12.根据权利要求11所述的集成复合翼型型材,其中,所述热塑性复合蒙皮还包括外侧和内侧,所述内侧包括合成遮蔽材料。
13.根据权利要求1所述的集成复合翼型型材,其中,所述前缘配重包括用基体树脂浸渍的纤维增强结构。
14.根据权利要求1所述的集成复合翼型型材,还包括用于雷击保护的丝网筛。
15.根据权利要求1所述的集成复合翼型型材,还包括外部合成表面遮蔽。
16.根据权利要求1所述的集成复合翼型型材,还包括泡沫插入件以支撑所述蒙皮加强腹板肋。
17.根据权利要求1所述的集成复合翼型型材,还包括金属前缘箍,并且其中所述金属前缘箍结合到所述前缘配重和所述翼梁结构。
18.一种用于拉挤成型集成复合翼型型材的拉挤成型工具系统,其包括:
前缘加固站;
前缘配重模具;
第一树脂浸渍站,用于将载有高密度粉末的基体树脂注射到所述前缘配重模具中;
翼型加固站;
翼型模具;和
第二树脂浸渍站,用于将未载有高密度粉末的基体树脂注射到所述翼型模具中。
19.一种用于在翼型型材中产生空气动力学扭转的抓具牵拉器,包括:
牵拉器框架;
抓具框架,其中所述抓具框架以轴承附接至所述牵拉器框架,并且其中所述抓具框架相对于所述牵拉器框架旋转;
抓具爪,用于将翼型型材固定在所述抓具框架中;
线性导轨,用于支撑所述抓具框架和所述牵拉器框架;
牵拉致动器,用于沿所述线性导轨驱动所述抓具框架和所述牵拉器框架;
扭转致动器,用于旋转所述抓具框架;并且
其中,当所述牵拉致动器沿着所述线性轨道驱动所述抓具框架和所述牵拉器框架时,所述扭转致动器使所述抓具框架旋转,导致所述翼型型材扭转以将空气动力学扭转构建到所述翼型型材中。
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US201962864272P | 2019-06-20 | 2019-06-20 | |
US201962864285P | 2019-06-20 | 2019-06-20 | |
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US62/864285 | 2019-06-20 | ||
US62/864250 | 2019-06-20 | ||
US62/864272 | 2019-06-20 | ||
PCT/US2020/038413 WO2020257443A1 (en) | 2019-06-20 | 2020-06-18 | Integrated pultruded composite profiles and method for making same |
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US (1) | US20200398968A1 (zh) |
EP (1) | EP3972898A4 (zh) |
JP (1) | JP2022538402A (zh) |
KR (1) | KR20220035104A (zh) |
CN (1) | CN114206722A (zh) |
BR (1) | BR112021025566A2 (zh) |
IL (1) | IL288980A (zh) |
WO (1) | WO2020257443A1 (zh) |
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CN115742383A (zh) * | 2022-11-22 | 2023-03-07 | 中材科技风电叶片股份有限公司 | 拉挤设备、型材的生产方法、扭转板件及风力发电机叶片 |
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WO2020257443A1 (en) | 2020-12-24 |
EP3972898A1 (en) | 2022-03-30 |
US20200398968A1 (en) | 2020-12-24 |
BR112021025566A2 (pt) | 2022-03-03 |
KR20220035104A (ko) | 2022-03-21 |
JP2022538402A (ja) | 2022-09-02 |
IL288980A (en) | 2022-02-01 |
EP3972898A4 (en) | 2023-12-20 |
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