CN1331658C - Three-dimensional knit spacer fabric sandwich composite - Google Patents

Three-dimensional knit spacer fabric sandwich composite Download PDF

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Publication number
CN1331658C
CN1331658C CNB028228367A CN02822836A CN1331658C CN 1331658 C CN1331658 C CN 1331658C CN B028228367 A CNB028228367 A CN B028228367A CN 02822836 A CN02822836 A CN 02822836A CN 1331658 C CN1331658 C CN 1331658C
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China
Prior art keywords
mentioned
woven
fabric
resin
preform
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Expired - Fee Related
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CNB028228367A
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Chinese (zh)
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CN1665676A (en
Inventor
P·E·麦克
M·D·史密斯
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Verdant Technologies Inc
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Verdant Technologies Inc
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Priority claimed from US10/172,053 external-priority patent/US7048985B2/en
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Publication of CN1665676A publication Critical patent/CN1665676A/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • B29C70/443—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding and impregnating by vacuum or injection
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/48—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/546—Measures for feeding or distributing the matrix material in the reinforcing structure
    • B29C70/547—Measures for feeding or distributing the matrix material in the reinforcing structure using channels or porous distribution layers incorporated in or associated with the product
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/04—Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/18—Handling of layers or the laminate
    • B32B38/1866—Handling of layers or the laminate conforming the layers or laminate to a convex or concave profile
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B21/20—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes specially adapted for knitting articles of particular configuration
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/20—All layers being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B32B2260/023—Two or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B32B2262/0269—Aromatic polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/08—Reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/60—In a particular environment
    • B32B2309/68—Vacuum
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2403/00—Details of fabric structure established in the fabric forming process
    • D10B2403/02—Cross-sectional features
    • D10B2403/021—Lofty fabric with equidistantly spaced front and back plies, e.g. spacer fabrics
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00—Industrial
    • D10B2505/02—Reinforcing materials; Prepregs

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)
  • Moulding By Coating Moulds (AREA)

Abstract

The present invention relates generally to the use of a three-dimensional knit spacer fabric component material in the fabrication of a sandwich core interface composite. More specifically it relates to the use of such a spacer fabric as a skin-to-core laminate interface to enhance laminate bonding, and particularly to enhance the interface planarity of monolithic cores grid cut to approximate curvatures in a mold tool and avoid discontinuities in the composite structure.

Description

Three-dimensional knit spacer fabric sandwich composite
Background of invention
Invention field
What the present invention relates generally to a kind of core material novelly uses and uses, and above-mentioned core material provides a kind of resin maceration of improvement, and reaches rigidity and other performance that increases a kind of interlayer composite material.More particularly, it relates to and utilizes three-dimensional knit spacer fabric as a kind of laminated product interface, so that increase the interface plane that laminated product is bonding and especially proofread and correct the monoblock grid core element that cuts and lay, so that attempt to meet the curvature in the desired structure.
The application is the novel application series of the U.S. utility of issue on June 17th, 2002 No.10/172,053 and the preferential provisional application series No.60/307 of July 23 calendar year 2001 issue, 109 part continuation application, the whole disclosure of the two all is included in herein as a reference.The application issues in the U.S. Provisional Application series No.60/322602 of issue on September 17 calendar year 2001, and its whole disclosure is also included within herein as a reference.
The state-of-the art explanation
Fibre reinforced plastics (FRP) composite structure generally is that Zhou Suozhong knows, and takes many shapes and form in some terminal applies, and above-mentioned terminal applies scope arrives airborne vehicle etc. from the seagoing vessel to the bathtub, and scope is from simple to the structure of complexity.Usually the structure of these forms comprises provides a kind of woven or non-woven fortifying fibre structure, that is to say that in the unlimited mould of the desired shape that is added to, the unlimited mould of above-mentioned desired shape generally is called preform.Usually also a kind of core structure is inserted between the internal layer and skin of composite.This dried fibre-reinforced part then must with a kind of curable, generally be heat cured resin, and generally fully soak with artificial coating technique.After soaking, preform allows resin solidification then, so that form the composite of desired shape.The composite structure that produces takes out from mould at last, and after appropriate postprocessing, can use then.
Although these FRP composites demonstrate the many advantages that are better than some alternative materials, the performance of laminated product rigidity (bending resistance) be not it strong point one of them.Although following situation is very general under exception, as utilize the expensive high modulus fibre of price, that is carbon fiber, and/or advanced, that is hot pressing, uneconomic production treatment technology, but when considering a kind of plate bending resistance square ability of predetermined weight, the FRP laminated product is usually not as alternative low density material such as timber.
A kind of plate, especially a kind of rigidity of FRP composite panel, not only with the bending modulus of material, the rigidity size of material is relevant, and generally be plate thickness cube function.Therefore, although the thickness of this plate can realize significantly increasing the rigidity of composite by certain increase relatively in a small amount, this also has in weight and expense pays a price aspect high.
That is to say, a kind of approach that is used to strengthen a kind of FRP plate obviously is to make it thicker, but this may produce shortcoming is a kind of unwanted very double-layer stampings, perhaps, its result is unwanted strength characteristics, with also having a shortcoming is that unwanted price is very expensive, and may have actual manufacturing issue concerning final desirable structure.
Importantly, the problem of Bu Zu intensity, modulus also may often be caused by uniformity not enough in the manufacturing of FRP composite.For example, resinous principle may be to distribute deficiently on whole fibrous matrix, may wherein have the surface discontinuity that causes the intensity variation the space or may reach resin and have brokenly before in fibrous matrix, distributing fully and solidify (such as, arrive a too early gel point).
A kind of optimization technique that increases the FRP panel stiffness is to utilize a kind of sandwich structure.Sandwich structure in the laminated product provides the advantage that can compare with the I-beam structure, but replaces the soffit of girder and the flange of common I-beam, and a kind of sandwich structure utilizes a kind of lightweight core material, and above-mentioned core material is towards the one or both sides on FRP skin next door.The effect of these skins is when plate stands bending load power in composite structure, by resisting compression and the tensile load that is produced in the skin over there, comes the moment of flexure on receiving plate or the beam.
For the skin that can resist moment of flexure, they must keep spaced apart with the central axis (center line) of interlayer rigidly, and prevent to move relative to one another.Selected core material, and the effect of cementing line intensity provides and satisfies these requirements between core and the skin.Concerning the commercial Application of a regulation, irrelevant with selected skin and core material, a kind of globality of sandwich material especially with skin and core element between interfacial adhesion intensity relevant.
A kind of physics of laminated product SMIS and MU also have much relations with the applied manufacturing technology of a kind of regulation structure.Those skilled in the art have recognized that, and are general, in order to reach comprehensive and close contact between each core material and the crust (when with a kind of former, perhaps opposite when the usefulness male tool endothelium), use a kind of vacuum bag technique usually.In vacuum bag technique, with the skin lamination and soak, each core material adds thereon being with or without under the adhesive glue stick situation, and a vacuum bag is added on the assembly.Along with air is discharged from, external environment condition air pressure tends to a core element and is pressed to equably on the skin surface, yet the contact between layer and the core element is limited by the size shape of each core element.Vacuum bag is stayed the appropriate location usually, till crust (such as in former) is when solidifying with core adhered thereto.Preparation (last) internal glass fibers layer is reaching enough uniformly lamination frequent existing problems seldom as a result the time, because present more transparent when soaking the glass layer stampings when preparing, the lamination person can the visualization wicking surface.Yet, there are some serious problems with the FRP skin of contiguous mold tool, each core element blocks or prevents visualization herein.
Can use the vacuum impregnation technology and make each skin simultaneously, and simultaneously atmospheric pressure is added on each core element.Harder at the material that is used for core element, and molded parts so design so that the place of convex or concave surface is provided, core material can be delineated into some less parts, and a kind of scrim can be added on the side in some cases, so that with a kind of more flat X, the Y mode keeps together with each fraction.
Yet the problem that often runs into is, delineation, the radius of curvature of the desired mould used greater than predetermined structure of the lateral dimensions of wherein one or more of each core segment of rectangle normally.This can and cause the space of generation at the interface at superimposed fiber and each core element really.In these cases, the final desirable close contact between skin and the core can only reach by utilizing excessive adhesive or other filler usually, so that occupy the size gap of generation.
It is unpractiaca that these technology are used for vacuum infusion techniques, and general skin and core space all are to fill up with resin.Gap at which kind of situation hypodermis and core is all filled up with a kind of medium, and above-mentioned medium has and is all visibly different machinery of skin or core and strength character, produces a zone of dispersing stress characteristics simultaneously.In addition, when applying vacuum impregnation, may soak by incomplete resin in above-mentioned serious space at the interface and to cause.The interface that produces thereby damage its best desirable performance.As a result, will have discontinuity, the intensity to desirable object has a negative impact simultaneously.
Summary of the invention
Because present intrinsic above-mentioned shortcoming in the FRP core of used known type and the vacuum impregnation application technology in prior art, the invention provides a kind of novel skin and the bonding technology of core, above-mentioned new technique superposes as a kind of adhesive interface by utilizing three-dimensional knit spacer fabric, strengthens bond properties greatly so that reach.
Especially, the inventor's novelty is utilized the bed boundary of a kind of three-dimensional knit spacer fabric as a kind of skin and core, perhaps, increased the interface plane of the monoblock core element graticule mesh of being cut, and broken away from the thought and the design of the routine of prior art as a kind of intermediate layer.When doing like this, a kind of a kind of technology, material and product for providing for the purpose of increasing FRP skin and core cementing line globality is provided for it.
The general objects of the present invention and the result that are described in more detail later provide a kind of new skin and core element adhesive interface, and above-mentioned interface has has increased the advantage that is better than applied up to now composite material interlayer structure.In order to reach this purpose, the present invention generally comprises the space fabric of the three-dimensional knit that utilizes a kind of Z direction fiber with plurality of elastic, and the space fabric of above-mentioned three-dimensional knit is as the one deck in the layer between skin and the core.This technology not only provides a kind of skin of improvement and core bonding, but still a kind of composition of laminated product.
Therefore, an object of the present invention is to provide a kind of three-dimensional knit spacer fabric, above-mentioned three-dimensional knit spacer fabric between skin and the core under the bonding medium situation, will overcome the shortcoming of prior art device in as a kind of interlayer composite material.
Another object of the present invention provides a kind of three-dimensional knit spacer fabric, and above-mentioned three-dimensional knit spacer fabric is as a kind of bonding medium between skin in the interlayer composite material and the core, for using in all processes that are used for the composite manufacturing.
Other purposes of the present invention and advantage are conspicuous to those skilled in the art, and plan these purposes and advantage are all belonged within the scope of the present invention.
On address finishing of relevant purpose, the present invention can implement with form shown in the drawings, however the fact that should note is, each accompanying drawing only is exemplary, and shown in particular configuration in, can carry out various changes.
Brief description
Fig. 1 schematically illustrates according to the described FRP laminated product structure of prior art with cutaway perspective form.
Fig. 2 schematically illustrates according to a kind of FRP laminated product structure of the present invention with cutaway perspective form.
Fig. 3 schematically illustrates used in the present invention a kind of three-dimensional spacer fabric, and above-mentioned three-dimensional spacer fabric is in the state of its uncompressed.
Fig. 4 schematically illustrates used in the present invention a kind of three-dimensional spacer fabric, and above-mentioned three-dimensional spacer fabric is in its state through overcompression.
Fig. 5 is the enlarged diagram of three-dimensional spacer fabric used among the present invention, and above-mentioned three-dimensional spacer fabric is in the state of its uncompressed.
Fig. 6 is the enlarged diagram of three-dimensional spacer fabric used among the present invention, and above-mentioned three-dimensional spacer fabric is in its state through overcompression.
Fig. 7 is the schematic plane of another embodiment of the present invention.
Accompanying drawing and detailed description of the invention
As shown in Figure 1, a kind of woven or non woven fibre strengthens preform layer (12) (last, here, crust) and is added on the mould (10) of a desired shape.In this example, each element (14) with core material is placed between the internal layer (12) and outer (16) of fibre-reinforced part or lamina, so that form the lamina structure.In this example, the sweep of mold shape (10) is like this, so that forms a space (18) between crust (12) and each core element (14).Wish then to be used for some composition of bonding composite with selected resin fill gap (18).
Yet, experience in the prior art is, between each core element and the space (18) between these elements (14) and the lamina (12) often is difficult to fill up fully during manufacture, and wherein produces air gap or space, and the result has a negative impact to the bonding of composite.
As shown in Figure 2, Fig. 2 illustrates a kind of similar modeling tool (20), and a kind of crust lamina (22) shown in it, some core elements (24) and a kind of endothelium lamina (26).In the figure, the present invention uses under the situation that applies additional as shown in the figure space fabric stratiform body (28).
Fig. 3 is another schematic diagram of space fabric structure (30).As can be seen, it comprises two isolated woven and/or skin (32) and (34) sewed up.Extending between that is two-layer and making so that connect this two-layer like that is some transverse fibers (36).These transverse fibers are so made, so that have relative resilient.
Fig. 4 is the schematic diagram of Fig. 3 space fabric, but what illustrate now is to be in a kind of compressive state (40) by applying external pressure.Outer (42) and (44) very well keep their orientation and configurations without overcompression, but each transverse fiber (46) tilting displacement now, the thickness of lamina reduces as a result.Exert pressure and the displacement of transverse fiber (46) still makes elastomer stay a kind of rebounding and the trend of resistance to deformation.Because that yes is soft for the whole isolated fabric,, therefore make the space minimizing between them so it has the performance that meets each core element and the two out-of-shape of die surface itself.
As following that will explain and as illustrated in applicant's patent application, the common applicant of this space fabric is with their brand name " polybeam TM" expression; above-mentioned space fabric has very big advantage and is; during making composite construction, all make in whole fiber/textile liquid resin flow and disperse more convenient, and thereby before the gel point of resin also can in addition filling space between each core material the time.
Mark as Fig. 2 reaches relevant illustration, by being placed on three-dimensional spacer fabric of the present invention (28) between crust (22) and the core element (24), the space is strengthened part by structure FRP (fibre reinforced plastics) and replaces.
For example, three-dimensional knit spacer fabric among Fig. 5 (50) itself is by one first woven fabric layer (52), one second tissue layer (54), form with middle partition adjustable yarn (56), above-mentioned partition adjustable yarn (56) can be a kind of monofilament polyester, glass fibres etc., it interconnects two-layer (52) and (54).The fiber of woven fabric layer (52) and (54) generally extends on X and Y direction, as shown in the figure.Generally the elastomeric yarn (56) that extends in Z direction (even angle is arranged) make two tissue layer keep separating to have a free form, stress-free thickness, what above-mentioned thickness was suitable is about 0.0625 " to 1 " in the scope.Can be in the yarn of interval with large-scale fabric and yarn fiber type, as polyester, glass fibre, Kevlar, carbon and various combination.In addition, traditional material such as fiberglass packing and rove can be sewed up or be adhered on the wherein one or both sides of three-dimensional knit spacer fabric, and it also can be sewed up around other material.As shown in Figure 5, between layer (52) and (54), there is one to be open spaces freely basically.
As shown in Figure 6, core element pressed be close to skin when applying vacuum (that is being lower than atmospheric pressure), resemble among Fig. 2 the time, three-dimensional knit spacer fabric (60) shown in the Z direction on by elastic compression.Though this space fabric thereby flatten a little, it still can meet core-Pi interface, so whole interface obtains a kind of more uniform enhanced structure.
The interface that flattens then can be according to used manufacturing technology, dip bonding agent or resin etc., but the operating period casting resin that is preferably just carrying out.Although be compressed as shown in Figure 6, the very big space of freely opening wide is still arranged, between each skin because wherein fibre density continues little more a lot than the density of outer surface.Although be difficult to measure, calculate at present and show, although may have the free volume of about 88-90% without the space fabric of overcompression, the free volume or the open spaces that still keep about 65-75% through the space fabric of overcompression supply resin to flood.
Fig. 7 illustrates one embodiment of the present of invention with plane, and should be appreciated that, " Tool (instrument) " as shown in plane can represent that has a complicated arc die face.In this case, " Vacuum (vacuum) " code name is represented, pull out in the upper end vacuum of figure, and Resin Input (resin input) illustrates at the place, bottom.Certainly, accurate resin input point can be other place, but general the most suitable be apart from leading to position far away, vavuum pump position.Figure 7 illustrates a part of helical cut pipe, what above-mentioned helical cut pipe was suitable is as a manifold resin access to plant.Laminae (lamina) A as shown in this Fig. 7 and Laminae (lamina) B comprise in each case and isolate fabric between three-dimensional that they are described in more detail in the back.
Employing according to noticeable characteristics of three-dimensional spacer fabric of the present invention is, even applying under the vacuum by compression, but in each element of whole composite construction, the resin of very big open spaces for the dipping uncured arranged still.When liquid resin adds fashionablely by the one or more manifold configuration in the assembly, this especially can be visually observed by the stream cutting edge of a knife or a sword as liquid resin in the sample composites of uncured.Described in applicant's patent application, the movement velocity that can observe this stream cutting edge of a knife or a sword increases nearly 200%-400%.This important feature has many advantages in the present invention.For example, for stand-by resin, it allows to utilize wideer viscosity to change.In addition, always have a bit in this technology " approach ", so that the resin completely of realization fibre preforms floods or soaks before its gel point of resin arrival, this situation causes the parts of manufacturing defective.Realize higher speed by the stream cutting edge of a knife or a sword that resin is formed, then under various environmental conditions and resin/catalyst combination, can be easy to reach and flood completely and soak.
To practical operation of the present invention be described by several examples now, should be appreciated that the present invention is not limited to the illustrational specified conditions of this paper at all.
The invention example
Very generally utilize some light wood core elements in a FRP composite, above-mentioned some light wood core elements are so arranged, so that terminal texture is perpendicular to the plane surface of final structure., make 4 test plate (panel)s herein with terminal texture light wood core element, as shown below.The following describes the laminated product detail list of having stated each test plate (panel).Each test plate (panel) is all used Hetron922 vinyl esters manufacturing, and dipping and curing under the vacuum of 25 inches Hg posts.
2 18 ounces of 3Tex glass of 1 18 ounces of 3Tex glass plates of plate
18 ounces of 3Tex glass of 18 ounces of 3Tex glass
18 ounces of 3Tex glass of 18 ounces of 3Tex glass
3/4”CK-89LamPrep Balsa 3/4”CK-89LamPrep Balsa
Polybeam TM730 1 Polybeam TM703 1
18 ounces of 3Tex glass of 18 ounces of 3Tex glass
18 ounces of 3Tex glass of 18 ounces of 3Tex glass
4 18 ounces of glass of 3 18 ounces of 3Tex glass plates of plate
18 ounces of glass of 18 ounces of 3Tex glass
Polybeam TM703 118 ounces of glass
3/4”CK-89LamPrep Balsa 3/4”CK-89LamPrep Balsa
Polybeam TM703 118 ounces of glass
18 ounces of glass of 18 ounces of 3Tex glass
18 ounces of glass of 18 ounces of 3Tex glass
18 ounces of 3Tex glass
1Annotate: Polybeam TMThe 730th, the trade mark that used space fabric is used in these plates.
Polybeam TMFabric is the knitting space fabric made from a kind of two-seater aircraft of a kind of 3 sley bar Raschel, and above-mentioned two-seater aircraft has following properties:
Stria/rice is 590, and line/rice is 530
(the vertical line of stria=volume seam; The horizontal line of line=volume seam).Yarn is interpreted as 100% monofilament polyester of about 0.2mm diameter.
The overlap joint that is used for this structure is as follows:
Sley bar 1 02,22,20,00,02,66,810,1010,108,88,810,66,
Sley bar 2 (20,46,810,64) * 3
Sley bar 3 66,810,1010,108,88,810,66,20,00,02,22,02,
0-2 is a grilling comb traversing (displacement).The slab gap is 10mm.
Polybeam TMThe 703rd, a kind of knitting space fabric of Raschel that similarly has similar characteristic;
Interior and outer " skin " is a kind of woven glass fiber material of quadrature formula by the 3Tex supply.
After the curing, on each plate, carry out twice test.
Test #1, ASTM C-393 " bending test " is rigidity and an intensity of estimating the sandwich plate sample that stands bending load.
Test #2, ASTM C-297 " straight tension test " is to estimate each structural core perpendicular to tensile strength on the direction of sandwiching surface and modulus.
The interlayer of sandwich plate (edgewise) load can cause the lip-deep warpage of sandwich plate.This outside warpage is the representative of these horizontal stress (flat-wise stress).
The result:
Test ASTMC-297 tensile strength and modulus ASTM C-393 flexible rigidity and modulus
Intensity (psi) Modulus (psi) Rigidity (m*lbf) modulus side/dorsal part Modulus (m*lbf) modulus side/dorsal part Que Xian @100lbs (in) modulus side/dorsal part
Plate 1 1164 30356.3 53642.4/53888.4 20700.2/21049.1 0.045/0.045
Plate 2 1083 27506.1 45069.3/43350.0 19350.9/18681.1 0.054/0.056
Plate 3 877.2 25944.7 51947.5/51592.7 21128.7/20435.9 0.047/0.047
Plate 4 1205.4 28016.2 50772.9/49408.1 22361.4/21922.7 0.046/0.049
These test result proofs are to utilizing Polybeam at interval TMThe composite material strength characteristic of fabric does not have injurious effects, even it has the structure that relative spacing is opened tissue layer, this structure comprises the interior zone that significantly reduces fibre strength with uncompressed with through two kinds of forms of overcompression significantly.
Important observed result of this test is between core (cork wood element) and skin tension failure always to take place.Fracture will not take place on each light wood core element one side, and above-mentioned each light wood core component side becomes to contact bonding with space fabric.In fact because plate 3 has Polybeam on the both sides of core TM703.Fracture of outside 3Tex glass fibre skin and core element fracture, but Polybeam TMInterface to core always remains intact harmless.
Contain Polybeam in order to estimate TMThe mechanical performance of laminated product, make other flat test plate (panel).Various sizes are by the requirement regulation of selected ASTM test.Laminated product is selected so on this basis, so that produce the composite of suitable thickness.Selected lamina detail list is listed as follows (also seeing Fig. 7 for the purpose of the explanation for example).
The tension test of ASTM D 3039 fibre-resin composites
790 3 bending tests of ASTM D
Layer Material The warp thread orientation The layering orientation 1
1 E-LTM2415-7 0° -
2 Polybeam TM730 0° NA
3 E-LTM2415-7 0° -
Table 1 lamina A
3 bending tests of ASTM D790
Layer Material The warp thread orientation The layering orientation
1 E-LTM2415-7 0° -
2 Polybeam TM730 0 ° NA
3 E-LTM2415-7 0° -
4 E-LTM2415-7 0° -
5 Polybeam TM730 0° NA
6 E-LTM2415-7 0° -
Table 2 lamina B
1The 2415th, with 1.5 ounces/foot 2CSM be sewn onto 24 oz/yd on the side 2The rove that twin shaft is sewed up.(-) relates to rove and pasting Polybeam herein TMThe warp-wise spider web.
Lamina A is designed to provide the thickness～.157 by the ASTM standard-required " (4mm) a laminated product, and layer B is designed to provide the thickness～.354 " laminated product (9mm) by the ASTM standard-required.
Strengthen lamina and comprise the loop bonding glass fibre of supplying by Johnson Industries, and have following properties:
Johnson mark: E-LTM2415-7
Fiber type: glass fibre (E)
Structure: 0 °/90 ° twin shafts " LT " series
Dried thickness: 0.066 inch/1.6764mm
Gross weight: 39.08 oz/yd 2/ 1291.41g/m 2
The fibrous structure data
0 °: 12.03 oz/yd 2/ 304.64g/m 2
90 °: 11.95 oz/yd 2/ 405.06g/m 2
Pad/overlay coating: 13.5 oz/yd 2/ 1.5 ounces/foot 2
Manufacture method
In order to adapt to sample requirement as mentioned above, make the plate of 24 " * 24 ".Instrument comprise a kind of through dewaxing treatment cross 48 11* 48 11Flat Formica plate.Lamina A (table 1) is machined, but this lamina is cut into 24 " * 24 " size, and their order in accordance with regulations are placed on the tool surfaces.Finish lamina B (table 2) by lamina towards correct direction repeats lamina A on the A group top of aiming at an edge layering stacking sequence with a kind of 6 " * 24 ".Contiguous lamina B assembling of vacuum port and the helical cut pipe overcoat that will be used for the resin input are assemblied in the opposite side of lamina A, also as shown in Figure 7.Assemble a flexible vacuum bag then, and the surrounding layer stampings fix and seal, resin is soft goes into effective anchor clamps sealing, and vacuumizes.
Vacuum is read with being fixed to a pressure gauge on the normal resin gatherer." during the Hg post, take off anchor clamps from the resin inlet, and inlet tube is put into vinyl ester resin (～230cps (centipoise)) when vacuum reaches 26 subsequently.Note striding across the equal uniform flow cutting edge of a knife or a sword of parts.When the resin cutting edge of a knife or a sword arrives vacuum port, the resin anchor clamps are fixed on the inlet tube again.In this process, keep vacuum (26 " Hg post).In this, the excess resin in the laminated product is pulled out by vacuum, until cross the certain hour resin gel and can not flow again that the time till.Vacuum is remained to this time.After resin is finished its exoergic and cool to room temperature, take off plate and be used for back curing and test.At this test period, observe following condition:
Room temperature :～68 
Resin temperature :～68 
Tool temperature :～68 
Viscosity is defined as 230cps under 77 .
Fiber volume: is 40: 60 to 75: 35 for vacuum-impregnated typical fibers/resin in laminated product (no steeping medium) than scope.These scopes are based on weight, and therefore with resin and the two used composition of fiber much relations are arranged.Therefore should be appreciated that the present invention never is limited to these specific ratios.
Concerning those skilled in the art, obviously,, can pass through with various fiber sizes and fibrous realization by advantage provided by the present invention and practicality.Glass fibre is extensive use of usually, but other fiber such as carbon fiber or Kevlav aromatic polymer fiber also can be used.Thermosetting resin (epoxides, vinyl and other crosslinkable material) also is applicable to this application equally, on a large scale.Utilize three-dimensional spacer fabric to compare with prior art, main find is, they have this special permission faster the enhanced resin add and flow into and pass the ability of composite lay.Surprisingly, even this specific character is applying also maintenance existence under the compression space fabric of vacuum.And, because fiber or Z direction fiber (seeing shown in Fig. 6 and 7) keep elasticity at interval, so have a kind of built-in type to make the tendency of structure resilience, so filling may be unfavorable space and cavity or the similar thing of discontinuity in the final composite that solidifies with method for distinguishing.The lubrication that this resilience is actually by being introduced by the resin dipping helps, and has reduced the interactional fiber of other existence in dry substance and the friction between the fiber simultaneously.So the composite that produces not only structurally, and on its last strength characteristics, all demonstrate the globality and the uniformity of higher degree.In the distinct economic of producing in handling is to utilize another benefit of the present invention, is to realize less loss and substandard product.
Advantages more of the present invention are thought to be implemented the most up hill and dale at present, with at least one made of one piece core element, described core element is arranged between the outmost preform, above-mentioned outmost preform is stacked on the die surface, with utilize a vacuum bag device to produce a negative pressure, and curable resin is communicated with mobile with three-dimensional spacer fabric subsequently.Characteristics of the present invention are, even adjacent fiber fabric layer itself does not have the three-dimensional spacer fabric structure, the curable resin that produces also provides the sufficient side direction of above-mentioned adjacent fiber fabric layer to soak than flowing of fair speed, therefore reaches uniform resin dipping in whole composite laminate.Certainly, the present invention also can use together with many different mold cavities, and is suitable for equally using in aforesaid closed type Tool and Die Technology and open type Tool and Die Technology.
Therefore, the present invention is only limited by the spirit and scope of appended claim.

Claims (6)

1. fiber-reinforced composite laminated product, these goods comprise at least one woven or non-woven fibre-bearing surface;
A relative woven or non-woven fibre-bearing surface;
At least one three-dimensional spacer fabric between described two surfaces, the second woven fabric layer that it has the first woven fabric layer, separate with this first woven fabric layer and with many space fabrics of this first and second woven fabric layer interconnection, described space fabric is compressed, and this space fabric provide one be used to pass above-mentioned first and second tissue layer and between them the basic side direction path freely of resin dipping, above-mentioned whole composite laminate comprises that a kind of cured resin of space fabric usefulness of described compression is saturated fully.
2. fiber-reinforced composite laminated product as claimed in claim 1 wherein, also comprises at least one monoblock core element, its above-mentioned first or at least a portion and above-mentioned space fabric of second surface between.
3. be used to form a kind of method of fiber-reinforced composite laminated product, may further comprise the steps:
At least one first preform is placed on the die surface, and above-mentioned first preform comprises a kind of woven or non-woven fibrous structure, applies a kind of three-dimensional spacer fabric thereon simultaneously, and above-mentioned three-dimensional spacer fabric comprises:
One first woven fabric layer, one the second woven fabric layer that separates with this first woven fabric layer and the many intervals fiber that makes above-mentioned first and second tissue layer interconnection,
Apply one second preform thereon with generation component, above-mentioned second preform comprises a kind of woven or non-woven fibrous structure,
Described assembly is enclosed in the vacuum bag,
Vacuum is added in the above-mentioned vacuum bag,
When applying vacuum, the curable resin synthetic is directed in the described vacuum bag so that described assembly is saturated fully, and
Keep above-mentioned vacuum up to described resin solidification.
4. method as claimed in claim 3, wherein above-mentioned first or at least a portion of second preform and above-mentioned three-dimensional spacer fabric between at least one monoblock core element also is set.
5. method as claimed in claim 4, wherein, described die surface to small part is a spill, and described space fabric is between described first preform and described core element.
6. method as claimed in claim 4, wherein, described die surface to small part is a convex, and described space fabric is between described second preform and described core element.
CNB028228367A 2001-09-17 2002-09-17 Three-dimensional knit spacer fabric sandwich composite Expired - Fee Related CN1331658C (en)

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US10/172,053 US7048985B2 (en) 2001-07-23 2002-06-17 Three-dimensional spacer fabric resin infusion media and reinforcing composite lamina
US10/172,053 2002-06-17
PCT/US2002/029312 WO2003024705A1 (en) 2001-09-17 2002-09-17 Three-dimensional knit spacer fabric sandwich composite

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