CN1394732A - 具有树脂分配网路的大型复合结构 - Google Patents
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Abstract
本发明涉及一种整体的复合结构,它包括:具有外周围表面和设在至少部分外周围表面上的供料槽的芯子;形成在所述芯子外周围表面上并与所述芯子外周围表面上的供料槽连通的槽网路,所述槽各自具有一个比所述供料槽的横截面积小的横截面积;覆盖芯子、供料槽和槽网路的纤维材料;和浸渍纤维材料并基本上充分地填充供料槽和槽网路的固化的树脂。
Description
发明领域
本发明涉及增强纤维树脂复合结构的制造,尤其是涉及大型复合结构的真空加力树脂压铸方法以及该方法中所使用的工具。
发明背景
真空加力树脂压铸法(VA-RTM)一直被用来制造许多大型的纤维增强复合结构比如船体等,其中包括多孔材料和软木芯子。芯子的外侧用纤维增强树脂覆盖。在VA-RTM方法中,将增强纤维,可以是纤维或织物,在干燥状态下在面模上排布在最终产品形状所需的芯子的材料上。然后,将敷设层封装在真空袋中,在真空状态下,用树脂浸渍,再使树脂固化。
各种不同的方法被用来实施和增强树脂的分布。这些方法包括在纤维层外面放置易于处理的分布媒介,和设置穿透芯子的孔和/或槽,以使树脂可由增强纤维层的外面流进里面。例如,可参阅美国专利No.5,316,462和No,4,560,523。在封闭模树脂注射方法中,在多孔材料芯子上使用了供料槽,以助于树脂的流动,这一点可参阅美国专利No.5,096,651。
发明简述
本发明涉及一种在用真空加力树脂压铸法(VA-TRM)制造大型复合结构时的分配树脂的方法,以及用这种方法制造的复合结构。复合结构是用纤维增强树脂包裹内芯制成的。在本发明的一个实施例中,树脂直接输送到与若干在内芯表面上形成的较小的微槽相连的主供料槽网路。树脂从供料槽和微槽向外流动,由芯子穿过增强纤维。在本发明的第二实施例中,在内芯和增强纤维之间设有单独的分配媒介。树脂直接输送到芯子表面上的一个或多个主供料槽,通过分配媒介穿过增强纤维。另外,主供料槽可环绕芯子形成供料环,可以浸渍横向结构部分。
在另一个实施例中,用带有表面结构的金属板制成了一体化的真空袋和模子。表面结构为在板的一面加工出的距离很近的凸起部分,而在板的另一面则有对应的凹入部分。在距离很近的凸起部分之间形成的凹槽就成为树脂分配网络。在板上直接加工出主供料槽。带有表面结构的板子也可用作模板,该模板可用来制做其他工具。
利用这个方法,需用多个芯子的大型复合结构能够在通常的乙烯基酯或聚酯树脂的胶凝时刻之前迅速成型,并可将树脂用量降到最低。将树脂通过真空袋直接输送至供料槽,供料就不仅局限在构件边缘或工具的入口处。相邻的芯子可通过一个树脂入口供料。树脂分配网络可保留在成品件上,省去了对分布材料的处理。这样,微槽在固化后充满了树脂,因而增加了层间剪切强度和剥离强度。特殊结构,如抗剪带、承压腹板、梁等,可在压铸过程中直接与复合结构件制成一体。
附图的简要说明
下面结合附图对本发明进行详细叙述,以使本发明更易于完全理解,附图包括:
图1为相应于本发明第一实施例的复合结构的芯子的透视图;
图2为相应于本发明第一实施例的制造中的复合结构的断面示意图;
图3为相应于本发明的制造中的另一复合结构的透视图;
图4为相应于本发明的制造中的复合结构的透视图;
图5为相应于本发明的复合结构的另一芯子的透视图;
图6为相应于本发明第二实施例的复合结构的芯子的透视图;
图7为相应于本发明第二实施例的制造中的复合结构的断面示意图;
图8为使用一体化模子和真空结构的制造中的复合结构的断面示意图;
图9为用于制造复合结构的刚性模和挠性盖的断面示意图;
图10为带有多个主供料槽的复合结构的芯子的透视图;
图11为相应于本发明另一实施例的用于制造复合结构的一体化模子和真空袋的断面示意图;
图12为制做如图11所示的一体化模子和真空袋的带有表面结构的板的一个表面的透视图;和
图13为图12中带有表面结构的板的另一面的透视图。
对本发明的详细描述
根据本发明制造的大型复合构件包括芯子12,如图1所示。芯子由能承受真空压力的材料制成。常用的材料包括多孔材料,如聚氨酯、聚氯乙烯或软木。芯子可以是实体的或空心的,如多孔聚乙烯。也可以使用混凝土。图示的芯子呈矩形块状,也可以是其它形状,后面将做深入讨论。
在芯子的表面16上设有一个或多个主供料槽或通道14。主供料槽可环绕整个芯子形成一个环。在芯子的表面上还设有由横截面积比主供料槽更小的通道组成的与主供料槽相连通的树脂分配网路。
在本发明的第一实施例中,树脂分配网路由若干在芯子12的表面16上加工出的微槽18组成,如图1所示。微槽18基本上与主供料槽14呈横向排布。某些微槽环绕整个芯子形成了起止端与主供料槽相通的树脂流动环。微槽与主供料槽的实际比例关系取决于芯子的几何形状和树脂浸渍的最佳条件,后面将做进一步讨论。
带有槽网路14的芯子12用一层或多层纤维材料20覆盖,如图2所示。纤维材料可以是由玻璃纤维、碳纤维或其他合适材料制成的织物或编织物。根据最终产品的结构要求,芯子可以用纤维材料完全包裹起来,或留下一个或几个面不用纤维覆盖。纤维材料可以是大片的,用来包裹芯子,纤维材料也可以是单独的小片,用在所需的芯子面上。纤维材料也可以是筒状的,套在芯子上。
若干个用纤维缠绕的芯子排列成所需的最终成品。尽管图2中只示出了两个芯子,芯子的实际数量和排布方式要根据所需的最终产品来确定。可在若干个芯子外用一层或多层纤维材料缠绕形成外层22,如图2所示。纤维材料层的数量、型式、及排布方式取决于所需的最终产品,这些可由本领域的一般技术人员很方便地确定。一般还要设置由外纤维层到真空出口25之间的片23状的泄放层。在现有技术的真空工艺中,通常需要剥离层,而在本发明的方法中,一般不需要剥离层。
芯子周围的和在各芯子之间的纤维材料24形成了诸如抗剪带、承压腹板以及梁等结构要素。例如,在图4中,一组三角形芯子40用来制造平台板。在邻近三角形芯子之间的纤维材料形成了承受压力和剪力的斜构件41。
在缠绕过程中,在主供料槽14中要放置适当的接头26,例如塑料或铜制的T型管,以便随后插入树脂输送管28。在每个供料槽中可放置一个或多个接头,以获得所需树脂流。将缠绕完的结构放在模子29上,将真空袋30覆盖在缠绕完的结构,包括塑料接头,之上,并且以本技术领域常用的方式与模子密封,如图2所示。然后,在真空袋上穿孔,将输送管28通过真空袋直接插入至对应的接头26。输送管与真空袋间要密封,以保证真空度。这样,输送管穿透外真空袋直接插入主供料槽,以将树脂直接输送到主供料槽。
参见图8,真空袋与模子也可以制成一体化的结构80,它既具有足够的刚性以保持作为模的形状,又有足够的挠性以在抽真空时压紧在构件上。例如,一体化结构80可由0.64cm或更薄的标准厚度钢板制成,如前所述,芯子82及纤维材料84、86封装在钢板中。在钢板上钻出通孔以与接头连接。按照前面所述进行树脂浸渍。一体化结构也可用其它材料制造,如橡胶或硅酮或是塑料包覆金属类的薄的复合板材。
图9示出了另一个模子的实施例,其中刚性模90用钢或塑料制成的挠性盖92密封。包括前面所述的芯子和纤维材料的构件放入刚性模的凹槽94中。真空槽96环绕着构件。在盖子或模上设有通孔,以便与接头连接,从而进行前面所述的树脂浸渍。在真空状态下浸渍树脂时,盖子在真空槽的边缘处发生挠曲,以将构件压实。
树脂材料,如聚酯、乙烯基酯、环氧树脂、酚醛、聚丙烯或双顺丁烯二酰亚胺,通过主供料槽14很快地进入微槽18。树脂再由微槽浸透纤维材料20、22。树脂浸渍过程从芯子表面16开始,再向外流入构件的外部。相邻芯子表面间的纤维材料可由一个相邻芯子上的主供料槽来浸渍,如图3和4所示。
主供料槽的横截面积、及微槽的横截面积和微槽之间的间距应优化选择,以保证在固化之前有适当的时间使树脂能浸渍所有的纤维材料,而不出现未浸渍区。典型的主供料槽的尺寸为深1.27cm,宽1.27cm,截面积为1.635cm2。典型的微槽尺寸为深0.32cm,宽0.32cm,截面积大约为0.102cm2。微槽的间距可以为2.54cm。这些尺寸可以改变,以适应不同类别和/或厚度的增强纤维材料。如果构件特别大,为能将树脂迅速分配到构件的所有部位,可以增大主供料槽的截面积。类似地,也可在芯子12上设置多个主供料槽14,如图10所示。
另外,可以减小主供料槽或微槽的横截面积,以限制树脂流动,增加树脂在某一特定区域内的停留时间,还可以在供料槽中放置可暂时阻断树脂流的树脂“熔断器”,来增加树脂停遛时间。熔断器在与树脂接触一段已知的时间后便会被溶解,这段时间的长短可由熔断器的长度来设定。例如,对于乙烯基酯树脂,已成功地使用了泡沫聚苯乙烯熔断器。也可以终止供料槽,以改变树脂的流向。
主供料槽14可使树脂由一个芯子流向相邻的另一芯子。可以在芯子上做出通孔,以使不同的主供料槽相连。可以同时向每一主供料槽输送树脂,以形成并行的回路,或是按规定的顺序向每一主供料槽输送树脂,以形成串联的回路,这要取决于待浸渍构件的几何形状和尺寸。另外,主供料槽可以彼此间互相独立,形成单独的回路。
浸渍后,留出足够的时间使树脂固化。在固化后,微槽18中充满了固体树脂。这些树脂起到了横向的锁定连接作用,它可以提高纤维增强复合材料与芯子间连接的层间剪切强度。留在槽网路中的树脂也可增大纤维增强表层与芯子间的剥离强度。
芯子的实际排列方式、形状及数量要视所需的最终产品而定。例如,图3所示的为三角形芯子。三角形芯子可在至少两个面上设置主供料槽42。中间的三角形芯子可在三个面上设主供料槽。微槽按前面所述的方式设在表面上。一组三角形芯子可排成一列,以形成平台板。在这个例子中,通过管子46输送的树脂,由中间的芯子开始浸渍,顺序地向两边缘扩展,如图4中阴影部分48所示。
图5示出了拱形的芯子50。拱形芯子50在一个面上有主供料槽52和由供料槽辐射出去环绕芯子的微槽网路54。拱形芯子可用来制造带曲面的结构,如船身或拱门。
如图6和图7所示,在本发明的另一个实施例中,芯子60带有如前所述的主供料槽62。分配媒介64贴近芯子表面。媒介由可在真空状态下保持通路畅通的结构构成的网络通路组成。例如,媒介可以由细丝交叉排布,在每个交叉点处设有柱状件,将细丝与芯子表面隔开一定距离,或是条带排列成的格栅状结构,或是稀树织物纤维。例如在美国专利NO.4,902,215和5,025,906中论及了适宜的分配媒介,这里引为参考。然后,如同前面的叙述,将纤维材料66绕在分配媒介之外,将若干芯子排成所需最终品的形状,再将真空袋68置于芯子和纤维材料之上,如前所述。将与树脂源相连的树脂输送管70穿透真空袋68和纤维材料66插入主供料槽62的接头72中。输送管70与真空袋间以本领域中常用的方式进行密封。通过输送管将树脂输送至主供料槽。树脂通过主供料槽较迅速地流进分配媒介。树脂由分配媒介渗透纤维材料。应留有适当的时间间隔使树脂固化。
同微槽相比,树脂分配媒介可使树脂流动状态更加均匀。因而,对较复杂的构件,更倾向于使用树脂分配媒介,但是,要想节省树脂,微槽则更好一些,因为流过微槽的树脂量较少。
在图11至13所示的另一个实施例中,用带有表面结构的金属板104,如薄钢板,将真空袋与模子做成一体化的单一工具102。板材应有足够的刚性以保持作为模子的形状,同时又要有足够的挠性,以便在浸渍树脂时在真空状态下可压紧构件,这一点后面还要深入讨论。实践证明,板厚为0.64cm或更薄比较合适。也可以用塑料或复合材料,如金属和塑料叠层板,制成的带表面结构的板材。
表面结构最好是在板104的一面加工出相距很近的凸起部分108,在板的另一面则有对应的凹入部分106。相距很近的凸起部分108之间形成的凹槽110则成为树脂分配网路。例如,凸起部分可以是六边形。其最大尺寸在0.95cm至1.1cm之间。凹槽深度为0.076cm被证明比较合适。带这种表面结构的板材很容易制造,New Jersey州的Ardmore Textured Metal ofEdison有产品可供。如果需要,也可以只在板的一侧做出表面结构,即:凸起部分的背面没有对应的凹入部分。
板104根据模子112所需的形状成形,模子112的与待浸渍构件相对的模腔118的内壁由带板的带有凸起的部分制成。主供料槽114在板104上的所需位置处直接成形,而不是如前所述设在芯子上。主供料槽的尺寸可如前所述。真空出口通道环绕着工具的周围。
在制做复合构件时,纤维缠绕层放置在模腔118中的靠近工具的带有表面结构的表面上,工具用胶带或其它在本技术领域中常用的密封方法密封。如果不需将表面结构保留在构件上,可以使用剥离层。若需要将表面结构保留在构件表面上,就无需使用剥离层。在构件上形成的表面结构可使构件的强度增大,并且,从美观的角度看,有时也是需要的。纤维缠绕层也包括前面论及的用纤维材料包覆的芯子。在工具的内部抽真空,带表面结构的板被吸并贴近纤维缠绕层,凸起部分的顶部与纤维缠绕层接触,凹槽保持畅通,从而形成了树脂可在其中流过的窄小的互相连接的网路通路。在真空状态下,树脂首先被抽吸进入主供料槽,然后再进入凹槽。树脂可由凹槽完全浸渍纤维材料,最后流到环绕构件的真空出口通道。留出足够的时间使树脂固化。固化后,将构件从工具中取出。
在另一个实施例中,带表面结构的板可作为盖子与常规模子一起使用。纤维缠绕层放置在模子的表面上。带表面结构的板置于纤维缠绕层上,可以任何适宜的方式与模子密封。在靠近常规模子的表面处,也可使用辅助的树脂分配媒介。树脂浸渍过程与前面所述的过程相同。
带表面结构的板还可用做母模,该母模用于由其它材料,如陶瓷,来制造工具。然后,该工具用做树脂浸渍的模子。这时,板构成工具的负像,即:板带有凹入的一面,以用来制造工具。制出的工具具有这样的形状,即:由凹槽分隔开许多凸起部分,这就形成了前面所述的树脂分配媒介。在真空状态下,陶瓷模子基本不会挠性变形,以压紧在构件上。这时单独的真空袋要同模子一起使用,如同在已有技术中人们所熟悉的那样。
本发明并不仅局限于所述的特定实施例,而仅受到所附权利要求的限定。
Claims (13)
1、一种整体的复合结构,包括:
具有外周围表面和设在至少部分外周围表面上的供料槽的芯子;
形成在所述芯子外周围表面上并与所述芯子外周围表面上的供料槽连通的槽网路,所述槽各自具有一个比所述供料槽的横截面积小的横截面积;
覆盖芯子、供料槽和槽网路的纤维材料;和
浸渍纤维材料并基本上充分地填充供料槽和槽网路的固化的树脂。
2、根据权利要求1所述的结构,其特征在于,槽相对于供料槽横向排布。
3、根据权利要求1所述的结构,其特征在于,至少部分槽环绕芯子形成起止于供料槽的环。
4、根据权利要求1所述的结构,其特征在于,树脂分配网路是放置在靠近芯子表面的树脂分配媒介。
5、根据权利要求4所述的结构,其特征在于,树脂分配媒介可以是交叉排布的细丝、条带排列成的格栅状结构或稀松织物纤维;若是细丝,则在细丝交叉点处设有柱状零件,以将细丝与芯子表面隔开一定距离。
6、根据权利要求1所述的结构,其特征在于,还包括若干个芯子,每个芯子带有外周围表面和在表面上贯通芯子长度的供料槽,这些芯子彼此靠近排列。
7、根据权利要求6所述的结构,其特征在于,芯子彼此靠近排列,并使各供料槽基本对正。
8、根据权利要求1所述的结构,其特征在于,芯子是泡沫材料。
9、根据权利要求1所述的结构,其特征在于,芯子是软木。
10、根据权利要求1所述的结构,其特征在于,芯子是混凝土。
11、根据权利要求1所述的结构,其特征在于,芯子是矩形断的块体。
12、根据权利要求1所述的结构,其特征在于,芯子是三角形断面的块体。
13、根据权利要求1所述的结构,其特征在于,芯子是带有曲面的块体。
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US08/612,251 US6773655B1 (en) | 1995-06-07 | 1996-03-07 | Large composite structures and a method for production of large composite structures incorporating a resin distribution network |
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NZ (1) | NZ311277A (zh) |
PT (1) | PT831987E (zh) |
WO (1) | WO1996040488A1 (zh) |
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- 1995-06-07 US US08/475,849 patent/US5958325A/en not_active Expired - Lifetime
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1996
- 1996-03-07 US US08/612,251 patent/US6773655B1/en not_active Expired - Fee Related
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- 1996-06-04 KR KR1019970709122A patent/KR19990022681A/ko active IP Right Grant
- 1996-06-04 PT PT96921312T patent/PT831987E/pt unknown
- 1996-06-04 EP EP96921312A patent/EP0831987B1/en not_active Revoked
- 1996-06-04 DE DE69626645T patent/DE69626645T2/de not_active Expired - Lifetime
- 1996-06-04 ES ES96921312T patent/ES2198489T3/es not_active Expired - Lifetime
- 1996-06-04 AT AT03075169T patent/ATE265311T1/de not_active IP Right Cessation
- 1996-06-04 AT AT96921312T patent/ATE234193T1/de not_active IP Right Cessation
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- 1996-06-04 DE DE69632358T patent/DE69632358T3/de not_active Expired - Lifetime
- 1996-08-02 US US08/691,269 patent/US5721034A/en not_active Expired - Lifetime
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1999
- 1999-02-03 HK HK99100463A patent/HK1015317A1/xx not_active IP Right Cessation
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- 2000-10-11 CN CN00129914A patent/CN1127403C/zh not_active Expired - Lifetime
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Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
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CN103878994A (zh) * | 2014-04-14 | 2014-06-25 | 北京建筑大学 | Frp加气混凝土复合板及其制备方法 |
CN106132674A (zh) * | 2014-07-08 | 2016-11-16 | 宝马股份公司 | 具有优化树脂流动的压制模具 |
CN106132674B (zh) * | 2014-07-08 | 2018-10-26 | 宝马股份公司 | 具有优化树脂流动的压制模具 |
CN114311745A (zh) * | 2021-12-23 | 2022-04-12 | 大连理工大学 | 一种复合材料夹芯结构的成型系统和制备方法 |
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