JP2019048459A - 複合構造及び方法 - Google Patents

複合構造及び方法 Download PDF

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Publication number
JP2019048459A
JP2019048459A JP2018186851A JP2018186851A JP2019048459A JP 2019048459 A JP2019048459 A JP 2019048459A JP 2018186851 A JP2018186851 A JP 2018186851A JP 2018186851 A JP2018186851 A JP 2018186851A JP 2019048459 A JP2019048459 A JP 2019048459A
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Prior art keywords
fillet
composite
composite part
vacuum
inflatable
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JP2018186851A
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JP6670357B2 (ja
Inventor
スタンリー ダブリュ. ストースキー,
W Stawski Stanley
スタンリー ダブリュ. ストースキー,
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Boeing Co
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Boeing Co
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16BDEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B11/00Connecting constructional elements or machine parts by sticking or pressing them together, e.g. cold pressure welding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/40Shaping or impregnating by compression not applied
    • B29C70/42Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/44Shaping 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
    • B29C70/446Moulding structures having an axis of symmetry or at least one channel, e.g. tubular structures, frames
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/54Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/544Details of vacuum bags, e.g. materials or shape
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B29C65/48Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
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    • B29C66/13Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/131Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/40General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/47Joining single elements to sheets, plates or other substantially flat surfaces
    • B29C66/474Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially non-flat
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/40General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/49Internally supporting the, e.g. tubular, article during joining
    • B29C66/494Internally supporting the, e.g. tubular, article during joining using an inflatable core
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/50General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/52Joining tubular articles, bars or profiled elements
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/50General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53Joining single elements to tubular articles, hollow articles or bars
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/50General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/50General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/50General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/737General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
    • B29C66/7375General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured
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    • B29C66/80General aspects of machine operations or constructions and parts thereof
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Abstract

【課題】複合部品を形成する方法の提供。
【解決手段】第1構造要素310Aと第2要素310Bを接合して該第1構造要素と該第2要素の共通部分にフィレット330Aを形成すること、該フィレット内に可膨張性R部充填物を配置すること、複合部品を真空容器300内に配置すること、該可膨張性R部充填物を該真空容器の外の環境に対し大気にすること、該真空容器内に真空を生ぜしめること、及び、該複合部品を硬化させることを含む。
【選択図】図3A

Description

本書に記載されている主題は、製造技術、より具体的には、通常ならばR部充填物が入るであろう区域内に空隙を含む、T型又はI型の複合構造を形成する技術に関する。
複合構造は、様々な製造及び工事の作業において使用される。例としては、航空機の様々な構造部品が、複合材料から形成されることがある。T型又はI型の断面、例えば横梁部あるいはフランジを形成する構造に取り入れられた複合材料は、一般的に、構造の共通部分にフィレットを形成する。従来型の製造技術では、これらのフィレットは、通常R部充填物と呼ばれる合成物によって充填される。ある状況においては、R部充填物の使用によって、完成部品に構造的な問題が生ずる。
従って、複合構造及び複合構造を作成する方法は、例えば、航空機や船舶のような輸送手段の構造において、用途を見出しうる。
1つの実施例では、複合部品を形成する方法は、第1構造要素と第2要素を接合して第1構造要素と第2要素の共通部分にフィレットを形成すること、フィレット内に可膨張性R部充填物を配置すること、複合部品を真空容器内に配置すること、可膨張性R部充填物を真空容器の外の環境に対し大気にすること、真空容器内に真空を生ぜしめること、及び、複合部品を硬化させることを含む。
別の実施例では、複合部品は、複合材料から形成され、共通部分にフィレットを画定するよう共通部分で接合された、第1構造要素及び第2要素、並びにフィレット内に配置された可膨張性R部充填物を備える。
別の実施例では、複合部品は、複合材料から形成され、共通部分にフィレットを画定するよう共通部分で接合された、第1構造要素及び第2要素、並びにフィレット内の空気R部を備える。
本開示の教示による方法及びシステムの実施形態は、以下の図面を参照して、以下に詳細に記述される。
実施形態による、航空機の製造及び保守の方法論のフロー図である。 実施形態による、航空機のブロック図である。 実施形態による、複合構造の側面図である。 実施形態による、空気R部充填物の斜視図である。 実施形態による、バッグキャリアの斜視図である。 実施形態による、フィレットの側面図である。 実施形態による、複合構造の側面図である。 実施形態による、構造にワイヤハーネスを取り付ける方法における作業を示すフロー図である。 実施形態による、航空機の概略図である。
下記の記述では、様々な実施形態を徹底的に理解するため、多数の具体的な詳細事項が記載されている。しかしながら、当業者には、具体的な詳細事項なしで様々な実施形態が実行可能であることが理解されるであろう。他の例では、具体的な実施形態を不明瞭にすることがないよう、よく知られている方法、手順、構成要素及び回路については、詳細に図解または解説していない。
本書に記載されているように、複合構造は組み立てられて、航空機や宇宙飛行体、船舶のような、より大きな構造で使用される構造部品になることがある。例としては、翼部や尾部のような航空機構造は、通常、複合材料から形成される構造部品を含む。本書に記載された実施形態により、複合構造は、R部充填物を使用することなく、組み立てられてT型又はI型の構成要素になることが可能となり、それによって、製造プロセスの効率が高まると共に、軽量で強靭な複合構成要素が実現しうる。
より具体的に図を参照するに、本開示の実施形態は、図1に示す航空機の製造及び保守方法100、並びに図2に示す航空機102に照らして説明されうる。製造前の段階では、例示的な方法100は、航空機102の仕様及び設計104と、材料調達106とを含むことがある。製造段階では、航空機102の構成要素及びサブアセンブリの製造108と、システム統合110が行われる。その後、航空機102は、認可及び納品112を経て運航114に供される。顧客により運航される間に、航空機102は定期的な整備及び保守116(改造、再構成、改修なども含みうる)を受けることが予定される。
方法100の各プロセスは、システムインテグレーター、第三者、及び/又はオペレーター(例えば顧客)によって実施又は実行されうる。本書の目的のために、システムインテグレーターは任意の数の航空機製造者及び主要システムの下請業者を含むことがあるが、それらに限定されず、第三者は、任意の数のベンダー、下請業者及び供給業者を含むことがあるが、それらに限定されず、かつ、オペレーターは、航空会社、リース会社、軍事団体、サービス機関などである可能性がある。図2に示されるように、例示的方法100によって製造された航空機102は、複数のシステム120及び内装122を有する機体118を含むことがある。高レベルのシステム120の例には、推進システム124、電気システム126、油圧システム128、及び環境システム130のうち一又は複数が含まれる。任意の数の他のシステムが含まれることもある。航空宇宙産業の例を示したが、本発明の原理は、自動車産業など、他の産業にも適用しうる。
本書に具現化された装置と方法は、製造及び保守方法100の一又は複数の任意の段階で採用することができる。例えば、製造プロセス108に対応する構成要素又はサブアセンブリは、航空機102の運航中に製造される構成要素又はサブアセンブリに類似の方法で作製又は製造される。また、一又は複数の装置の実施形態、方法の実施形態、あるいはそれらの組み合わせは、例えば、航空機102の組立てを実質的に効率化するか、又は航空機102のコストを削減することにより、製造段階108及び110で利用することができる。同様に、一又は複数の装置の実施形態、方法の実施形態、あるいはそれらの組み合わせを、航空機102の運航中に、例えば整備及び保守116だがそれだけに限定されない用途に、利用することができる。
図3A〜3Dは、実施形態による、複合部品300の概略図である。図3A〜3Dに示すように、いくつかの実施形態では、複合部品300は、まとめて参照番号310と呼ばれうる第1構造要素310A及び310B、並びに、まとめて参照番号320と呼ばれうる第2構造要素320A及び320Bを備える。
第1構造要素310及び第2構造要素320は、ファイバーグラス、カーボン繊維、ケブラー、又はエポキシ樹脂などのような樹脂によって接着された類似の物質といった、繊維強化複合材料などから形成されることがある。第1構造要素310及び第2構造要素320は、例えばアルミニウム、チタン、又は鉄といった、一又は複数の補強金属の層を含む可能性がある。
図3Aに図示された実施形態では、第1構造要素310及び第2構造要素320は、まとめて参照番号330と呼ばれうるフィレット330A及び330Bを共通部分に画定するよう、共通部分で接合される。第1構造要素310は、C型の断面を有し、フィレット330が大体三角形になるように、対向する向きに配置される。フィレット330Aは、第1側面332A、第2側面334A、及び第3側面336Aを有する。同様に、フィレット330Bは、第1側面332B、第2側面334B、及び第3側面336Bを有する。当業者は、フィレット330の形は、第1構造要素310の形次第であることを認識するであろう。側面壁332、334、336は、第1構造要素の形に応じて、真っ直ぐであるか、あるいは湾曲していることがある。例としては、図に図示された実施形態では、フィレットはおよそ45度‐45度‐90度の角度になる角部を有する三角形である。当業者は、別の角度も有用となりうることを認識するであろう。更に、複合部品300は、I型の断面を生ぜしめる2つの第2構造要素320を有するが、当業者は、いくつかの実施形態では、第1構造要素310が単一の第2構造要素に固定されて、T型の断面を生ぜしめる可能性があることを認識するであろう。
様々な実施形態で、複合部品300は、航空機の構造部品となりうる。かかる構成要素の実施例には、主翼ボックス、操縦翼面、翼部、外板、機体、扉などが含まれる。
上述のように、従来使用されてきたフィレット330は、当業においては通常R部充填物と呼ばれる構造材料で満たされていた。ある状況においては、R部充填物をフィレット330内に配置することなく複合部品300を製造することが、有利なこともある。R部充填物なく複合部品300を製造する技術を、図3A〜3C及び図4を参照して説明する。
図4は、実施形態による、R部充填物なく複合部品300を製造する方法における作業を示すフロー図である。図4を参照するに、作業410では、第1構造要素310が横梁部を画定し、第2構造要素が横梁部によって支持される板部を画定するように、図3Aに示される形のような形を画定するよう、構造部品が接合される。実際には、複合部品300は、多数の横梁部を有する可能性がある。構造要素310、320に接着樹脂が塗布されることがある。更に、構造要素310、320を固定するために、一又は複数のクランプが適用されることがある。
作業415では、可膨張性R部充填物350が、フィレット内に配置される。図3Bは、実施形態による、可膨張性R部充填物の概略図である。図3Bを参照するに、いくつかの実施形態では、可膨張性R部充填物350は、ナイロンのような適当なポリマー材料から形成された真空バッグ354を備えることがある。真空バッグ354は、フィレット330の側面332、334、336に合った形になるよう膨張可能であることがある。真空バッグ354は、真空バッグ354を外部環境に対し大気にすることを可能にする、通気孔352を更に備えることがある。
いくつかの実施形態では、真空バッグ354内に少なくとも1つのバッグキャリアが配置される。バッグキャリア360の1例が、図3Cに図示されている。図3Cを参照するに、いくつかの実施形態では、バッグキャリア360は、バッグキャリア360がフィレット330の側面332、334のうち少なくとも2つの一部に沿うように、V型の断面を有する金属製ブラケットとして実施可能である。使用に当たっては、バッグキャリア360は、真空バッグ354内に配置されうる。いくつかの実施形態では、バッグキャリア360は、バッグキャリア内に配置される前に、フィレット330の角部により多くのR部を付与するために布地に覆われることがあり、それによって、フィレット330の角部で薄板に亀裂や割れが生じる可能性が低減する。
代替的な実施形態では、可膨張性R部充填物350は、変形可能材料、例えば適当なポリマー又はゴムから形成されたチューブとして実装されうる。チューブは、図3Bに図示されるように、円筒形である可能性があり、又は、チューブがフィレット330の三角の断面図に対応する三角形になるよう形成されることがある。
作業420では、複合部品300は、真空容器内に配置される。例としては、いくつかの実施形態で、真空容器は、組み立てられた構造部品全体を保持するのに十分な大きさの、第2の真空バッグとして実施されることがある。真空容器(300)は、一体化した真空バッグを有する加圧装置(autoclave)を更に備えることがある。
作業425では、可膨張性R部充填物350を、外部環境に対し大気にする。例としては、いくつかの実施形態で、例えばチューブを通気孔352と結合することや、チューブを周囲環境まで延伸させることによって、可膨張性R部充填物350の通気孔352が周囲環境と流体連通するように配置することがある。
作業430では、真空容器内に真空が生じる。本書で使用される真空という語句は、真空容器内の気体の周囲圧力が、周囲環境の気圧を下回るレベルまで低減されることを意味すると解釈されるべきである。本書で使用されているように、真空という語句は、真空容器内に完全な真空状態が形成されることが必要だと解釈されるべきではない。真空は、真空容器からポンプなどを使用して気体を抜き取ることによって生じうる。
可膨張性R部充填物350は周囲環境に対し大気にされるため、可膨張性R部充填物350は、周囲環境とほぼ一致する内部気圧を保つことになる。したがって、真空容器内に真空が生じる際に、可膨張性R部充填物350は膨張し、フィレット330によって画定された空間を占めることになる。可膨張性R部充填物350がフィレット330内で膨張することで、均一の硬化圧力がフィレット330の側面332、334、336の各々に加わり、それによって、層が変形するリスク及び複合構造310、320の層間の隙間が減少する。
作業435では、複合部品300は、真空容器内で硬化される。いくつかの実施形態では、複合部品300を硬化することは、複合部品を、樹脂及び/又は複合部品300を形成するために使用される任意の接着剤が硬化する温度まで加熱することを含む可能性がある。加えて、複合部品300には、圧力がかけられることがある。複合部品300に適用される具体的な温度及び圧力は、複合部品を構成する材料次第でありうる。例としては、航空宇宙産業で使用される複合材料は、通常、セ氏30度からセ氏200度の温度範囲まで加熱され、15〜100ポンド/平方インチ絶対圧力の圧力がかけられる。
作業440では、複合材料から形成され、共通部分にフィレットを画定するよう共通部分で接合された、第1構造要素310及び第2要素320、並びにフィレット330内の空気R部を備える、硬化された複合部品300を提供するよう、可膨張性R部充填物350は硬化された複合部品300から除去される。
図3Dに示されるように、いくつかの実施形態では、フィレット330は、フィレット330の壁面332それぞれを互いに結合する補強部材340を使って提供される可能性がある。補強部材340は、硬化プロセス中に壁面332に合わせて布材が硬化するように、エポキシ樹脂を添加されることがある布材から形成されうる。かかる実施形態では、補強部材340は、フィレット330を画定する構造部品にかかる圧力及び負担を吸収するのに役立つ。加えて、樹脂が、フィレット330の角部342、344、346の内部の円弧を緩和する。これらの要素はどちらも、フィレット330の角部342、344、346で複合材料に亀裂又は割れが生じる可能性を低減させる。
限定する訳ではないが例としては、いくつかの実施形態で、真空バッグ354は、複合層材料が硬化される時に補強部材340を形成するように、複合層材料に覆われることがある。補強部材340は、補強部材340を形成する複合層材料が、構造部品310、320の弾性係数とほぼ同じ弾性係数を有するように、構造部品310、320と同一の複合材料から形成されることがある。真空バッグ354を覆うために使用される複合層材料の具体的な層の数は、重要ではない。いくつかの実施形態では、真空バッグ354は、1〜5層の複合層材料に覆われることがある。
したがって、本書に記載されているのは、R部充填物ではなく中空隙間(hollow aperture)を含む、一又は複数のフィレット330を含む複合部品を形成する方法である。いくつかの実施形態では、フィレット330は、完全に中空のままになることがある。他の実施形態では、フィレット330は、一又は複数の層の複合層材料から形成された補強部材340を含む可能性がある。使用に当たっては、フィレット330は、ワイヤ、ケーブル、流体線などが延伸されうる導管として、使用されることがある。フィレット330は限定された空間であるため、ワイヤ、ケーブル、又は流体線を所定の位置に保持するための留め具あるいはハウジングは必要ないことがある。
航空機内で使用される時、複合部品300は、航空機が運航する状況に応じて、異なる時点で、圧力がかかった状態及び圧力がかからない状態で作動する、限定された空間を画定する可能性がある。
図3Eに図示された別の実施例では、構造要素310A、310Bの継ぎ目を補強するために、補強ウェビング370A、370Bが、壁面332、334の共通部分に隣接して、構造要素310A、310Bの周りに巻かれることがある。補強ウェビング370A、370Bは、補強ウェビング370A、370Bを形成する複合層材料が、構造部品310A、310Bの弾性係数とほぼ同じ弾性係数を有するように、構造部品310、320と同一の複合材料から形成されることがある。複合材料310A、310Bに巻くために使用される複合層材料の具体的な層の数は、重要ではない。いくつかの実施形態では、真空バッグ354は、1〜5層の複合層材料に覆われることがある。
図5は、本開示の別の実施形態による、複合部品300のような一又は複数の複合部品を有する、航空機500の側面図である。複合部品は、航空機500の機体、翼部、尾部、胴体部及び壁面を含む多岐にわたる場所で使用可能であることが理解されるであろう。代替的な実施形態では、自動車、航空機、船舶又は宇宙船のような、他の種類の構造体、輸送手段、及びプラットフォーム、あるいは他の適当な用途で、使用されうる。
この実施形態では、航空機500は、翼部組立品504、尾部組立品506、及び着陸組立品508を含む機体502を含む。航空機500は更に、一又は複数の推進ユニット510、制御システム512(図示せず)及び航空機500の適切な運航を可能にする多数の他のシステム及びサブシステムを含む。複合部品は、機体502、翼部組立品504、尾部組立品506などの、航空機500の任意の適当な部分、及び航空機500の他の任意の適当な領域で、使用されうることを理解すべきである。概して、航空機500の各種構成要素及びサブシステムは、既知の構造体である可能性があり、説明を簡潔にするため、本書では詳細に記述しないものとする。
図5に示される航空機500は概して、例えば、イリノイ州シカゴのボーイング社から市販されている737、747、757、767、777、及び787型を含む民間旅客機を表わしているが、本書に開示されている本発明の装置及び方法は、実質的に他の任意の種類の航空機の組立にも使用することができる。さらに具体的には、本開示の教示は、他の旅客機、戦闘機、貨物航空機、回転翼航空機、及び例えば2001年9月にBook Sales Publishersから出版されたEnzo Angelucci氏による図解入り軍用機百科事典(The Illustrated Encyclopedia of Military Aircraft)、及び、その文言が参考のため本書に組み込まれている英国サリー州クロイドンのJane‘s Information Groupが出版したジェーン航空機年鑑(Jane’s All the World‘s Aircraft)に記載されたものを含む、その他の任意の種類の有人又は無人の航空機の製造及び組立てに応用することができる。
本開示の一態様によると、複合材料から形成され、共通部分にフィレットを画定するよう共通部分で接合される、第1構造要素及び第2要素、並びにフィレット内の空気R部を備える複合部品が提供される。有利には、少なくとも2つの構造要素が、T型横梁部又はI型横梁部のうち少なくとも1つを形成するよう接合される。有利には、空気R部は、三角形をなす断面の形を有する。有利には、複合部品は更に、フィレット内に配置された補強部材を備える。
また、本明細書および特許請求の範囲において、「結合された」及び「接続された」という語及びそれらの派生語が使用されうる。具体的な実施形態では、「接続された」は2つ以上の要素が互いに直接、物理的に接触もしくは電気的に接触していることを示すために使用されうる。「結合された」は2つ以上の要素が直接、物理的に接触もしくは電気的に接触していることを意味しうる。しかしながら、「結合された」は2つ以上の要素が互いに直接的に接触していないが、それでも、互いに連携または相互作用しうることも意味することがある。
明細書中での「一実施形態」又は「いくつかの実施形態」という言及は、実施形態に関連して記載されている、具体的な機能、構造、又は特徴が、少なくとも1つの実装に含まれていることを意味する。本明細書のさまざまな箇所に登場する「一実施形態では」という語句は、必ずしも同一の実施形態について言及しているわけではない。
実施形態は、構造的特性及び/又は方法論的行為に特有の言語で説明されているが、特許請求の対象は説明された具体的な特性や行為に必ずしも限定されないことを理解されたい。むしろ、具体的な特性及び行為は、請求の対象を実装する例示的な形式として開示されている。
100 例示的な方法
102 航空機
104 仕様及び設計
106 材料調達
108 構成要素及びサブアセンブリの製造
110 システム統合
112 認可及び納品
114 運航
116 整備及び保守
118 機体
120 システム
122 内装
124 推進システム
126 電気システム
128 油圧システム
130 環境システム
300 真空容器(複合部品)
310A、310B 第1構造要素
320A、320B 第2構造要素
330A、330B フィレット
332 第1側面
334 第2側面
336 第3側面
340 補強部材
342、344、346 角部
350 可膨張性R部充填物
352 通気孔
354 真空バッグ
360 バッグキャリア
370A、370B 補強ウェビング
500 航空機
502 機体
504 翼部組立品
506 尾部組立品
508 着陸組立品
510 推進ユニット
512 制御ユニット512

Claims (14)

  1. 複合部品を形成する方法であって、
    第1構造要素(310A)と第2要素(310B)を接合して、前記第1構造要素と前記第2要素との共通部分にフィレット(330A)を形成すること、
    前記フィレット内に可膨張性R部充填物(350)を配置すること、
    前記複合部品を真空容器(300)内に配置すること、
    前記可膨張性R部充填物(350)を前記真空容器(300)の外の環境に対し大気にすること、
    前記真空容器(300)内に真空を生ぜしめること、及び、
    前記複合部品を硬化することを含む、方法。
  2. 前記可膨張性R部充填物(350)は、変形可能材料から形成されたチューブを備える、請求項1に記載の方法。
  3. 前記真空容器(300)は第2の真空バッグを備え、前記可膨張性R部充填物(350)は第1の真空バッグを備える、請求項1または2に記載の方法。
  4. 少なくとも1つのバッグキャリア(360)を前記第1の真空バッグ内に配置することを更に含み、前記バッグキャリア(360)は、前記フィレット(330A)の少なくとも一部に沿うよう形づくられる、請求項3に記載の方法。
  5. 前記フィレット(330A)は三角形をなす形の断面を有し、かつ、前記バッグキャリア(360)は前記三角形の少なくとも2つの辺に沿う構造部品を備える、請求項4に記載の方法。
  6. 前記フィレット(330A)の少なくとも一部に沿って補強部材(340)で覆うことを更に含む、請求項1から5のいずれか一項に記載の方法。
  7. 前記真空容器(300)内に真空を生ぜしめることにより、前記可膨張性R部充填物(350)を前記フィレット内で膨張させる、請求項1から6のいずれか一項に記載の方法。
  8. 複合部品であって、
    複合材料から形成され、共通部分にフィレット(330A)を画定するよう前記共通部分で接合された、第1構造要素(310A)と第2要素(310B)、及び、
    前記フィレット内に配置された可膨張性R部充填物(350)を備える、複合部品。
  9. 前記第1構造要素(310A)と前記第2要素(310B)が、T型横梁部又はI型横梁部のうち少なくとも1つを形成するよう接合された、請求項8に記載の複合部品。
  10. 前記可膨張性R部充填物(350)は、変形可能材料から形成されたチューブを備える、請求項8及び9に記載の複合部品。
  11. 前記可膨張性R部充填物(350)は真空バッグを備える、請求項8から10のいずれか一項に記載の復合部品
  12. 前記真空バッグ内に配置された少なくとも1つのバッグキャリア(360)を更に備え、前記バッグキャリア(360)は、前記フィレットの少なくとも一部に沿うよう形づくられる、請求項11に記載の複合部品。
  13. 前記第1構造要素(310A)と第2要素(310B)の周りに、前記フィレットに隣接して、少なくとも1つの補強部材(340)を更に備える、請求項8から12のいずれか一項に記載の複合部品。
  14. 前記少なくとも1つのバッグキャリア(360)は布地に覆われ、硬化後に前記布地が前記フィレットの少なくとも一部に沿って補強部材(340)を形成するように、前記布地は樹脂材料を含む、請求項12に記載の複合部品。
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US20160160899A1 (en) 2016-06-09
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