JP5801885B2 - 一体型補剛材を有する複合構造物およびその作製方法 - Google Patents
一体型補剛材を有する複合構造物およびその作製方法 Download PDFInfo
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- JP5801885B2 JP5801885B2 JP2013516576A JP2013516576A JP5801885B2 JP 5801885 B2 JP5801885 B2 JP 5801885B2 JP 2013516576 A JP2013516576 A JP 2013516576A JP 2013516576 A JP2013516576 A JP 2013516576A JP 5801885 B2 JP5801885 B2 JP 5801885B2
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- 239000003351 stiffener Substances 0.000 title claims description 169
- 239000002131 composite material Substances 0.000 title claims description 101
- 238000004519 manufacturing process Methods 0.000 title claims description 26
- 230000002787 reinforcement Effects 0.000 claims description 98
- 239000000835 fiber Substances 0.000 claims description 92
- 229920005989 resin Polymers 0.000 claims description 62
- 239000011347 resin Substances 0.000 claims description 62
- 238000000034 method Methods 0.000 claims description 45
- 239000000758 substrate Substances 0.000 claims description 21
- 229920001187 thermosetting polymer Polymers 0.000 claims description 9
- 239000002952 polymeric resin Substances 0.000 claims description 4
- 229920003002 synthetic resin Polymers 0.000 claims description 4
- 238000005304 joining Methods 0.000 claims description 3
- 239000002184 metal Substances 0.000 claims description 3
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 2
- 239000004917 carbon fiber Substances 0.000 claims description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 2
- 230000000717 retained effect Effects 0.000 claims description 2
- 238000002347 injection Methods 0.000 description 22
- 239000007924 injection Substances 0.000 description 22
- 230000008569 process Effects 0.000 description 13
- 239000010410 layer Substances 0.000 description 10
- 210000001503 joint Anatomy 0.000 description 7
- 238000012423 maintenance Methods 0.000 description 7
- 239000000463 material Substances 0.000 description 7
- 239000012779 reinforcing material Substances 0.000 description 5
- 239000000853 adhesive Substances 0.000 description 4
- 230000001070 adhesive effect Effects 0.000 description 4
- 238000013461 design Methods 0.000 description 4
- 239000000945 filler Substances 0.000 description 4
- 239000012783 reinforcing fiber Substances 0.000 description 4
- 230000008859 change Effects 0.000 description 3
- 238000009826 distribution Methods 0.000 description 3
- 239000004744 fabric Substances 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 239000012790 adhesive layer Substances 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 239000002657 fibrous material Substances 0.000 description 2
- 238000001802 infusion Methods 0.000 description 2
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- 230000007246 mechanism Effects 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 230000001066 destructive effect Effects 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 238000003801 milling Methods 0.000 description 1
- 230000008520 organization Effects 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 229920000307 polymer substrate Polymers 0.000 description 1
- 238000009419 refurbishment Methods 0.000 description 1
- 230000008439 repair process Effects 0.000 description 1
- 239000000565 sealant Substances 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 238000009827 uniform distribution Methods 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D99/00—Subject matter not provided for in other groups of this subclass
- B29D99/001—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
- B29D99/0014—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings provided with ridges or ribs, e.g. joined ribs
- B29D99/0017—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings provided with ridges or ribs, e.g. joined ribs with filled hollow ridges
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- 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
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- B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
- B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General 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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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- 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
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- 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
- B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
- B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
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- 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
- B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
- B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
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- B29C66/01—General aspects dealing with the joint area or with the area to be joined
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General 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
- B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
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- 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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/50—General 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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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
- B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
- B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
- B29C66/8145—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
- B29C66/81455—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps being a fluid inflatable bag or bladder, a diaphragm or a vacuum bag for applying isostatic pressure
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
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Description
基体内に保持されている第1繊維強化材を含む構造部材部分と、
構造部材部分を補剛するための補剛材部分であって、基体内に保持されている第2繊維強化材を含み、外殻および内部コアを含む補剛材部分と、
を含む、一体型補剛複合構造物。
2. 基体が、第1部分および第2部分全体を通じて実質的に連続しており、かつ、均質である、1に記載の補剛複合構造物。
3. 構造部材部分が、
パネル、
外板、
はり、
フランジ、
ウェブ、および、
溝形材
のうちの1つである、1に記載の補剛複合構造物。
4. 各々が、基体内に保持されている第2繊維強化材を含む複数の補剛材部分であって、補剛材部分の各々が外殻および内部コアを含む、複数の補剛材部分
をさらに含む、1に記載の補剛複合構造物。
5. 複数の補剛材部分が、相互接続された格子状に配置されている、4に記載の補剛複合構造物。
6. 格子において補剛材部分同士を接続している複数のノード
をさらに含む、5に記載の補剛複合構造物。
7. ノードの各々が、
金属部材、
予め硬化されている複合部材、および、
樹脂基体内に保持されている第3繊維強化材
のうちの1つを含む、6に記載の補剛複合構造物。
8. 構造部材部分が、内部に開口を含み、かつ、
補剛材部分が、開口を実質的に取り囲んでいる、
1に記載の補剛複合構造物。
9. コアが、補剛材部分を通じて長手方向に延在している強化材繊維を含む、1に記載の補剛複合構造物。
10. コアが、強化繊維が保持されている充填材を含み、かつ、
殻が、少なくとも一層の相互接続されている繊維を含む、
9に記載の補剛複合構造物。
11. 構造部材部分が、湾曲しており、かつ、
補剛材部分が、構造部分の曲率に実質的に一致するような外形とされている、
1に記載の補剛複合構造物。
12. 補剛材部分が、構造部材部分の上を覆い、かつ、これと一体形成されている側方へ延在するフランジを含む、
1に記載の補剛複合構造物。
引っ込ませた補剛材プレフォームの上を覆い、かつ、これらに接触するように工具面上に繊維パネル強化材を配置すること、
工具上のパネル強化材および補剛材プレフォームを真空バッグに入れること、
バッグ内を真空引きすること、
パネル強化材と補剛材プレフォームとに熱硬化性樹脂を混注すること、および、
樹脂を注入したパネル強化材および補剛材プレフォームを硬化させること
を含む、補剛複合パネルを作製する方法。
19. 補剛材プレフォームの各々とパネル強化材との間に接着剤を配置すること
をさらに含む、18に記載の方法。
20. 補剛材プレフォームの内側に強化材を配置すること
をさらに含む、18に記載の方法。
21. 大気圧およびバッグを用いて、混注中に補剛材プレフォームをパネル強化材に対して圧縮すること
をさらに含む、18に記載の方法。
22. 補剛材プレフォーム同士を接続している工具面における接続ノードを引っ込ませること
をさらに含む、18に記載の方法。
23. 工具面において補剛材プレフォームを引っ込ませることが、工具面に溝を形成することを含む、18に記載の方法。
繊維プレフォームを受容し、かつ、繊維強化材に対して引っ込ませるための工具面内の少なくとも一本の溝と、
を含む、1つ以上の一体型補剛材を有する複合構造物を作製するための装置。
25. 繊維強化材および繊維プレフォームが、実質的に乾燥しており、かつ、前記装置が、
繊維強化材と繊維プレフォームとに樹脂を混注するための手段
をさらに含む、24に記載の装置。
26. 混注手段が、
樹脂源と、
繊維強化材および繊維プレフォームの上方に真空チャンバを形成する真空バッグと、
真空チャンバ内を真空引きするため、ならびに、樹脂源から真空バッグを介して繊維強化材および繊維プレフォーム内へ樹脂を吸い込むための手段と、
を含む、24に記載の装置。
27. 工具面が、複数の繊維プレフォームを受容し、かつ、繊維強化材に対して引っ込ませるための複数の溝を内部に含み、かつ、
溝の少なくともいくつかが、補剛材の断面形状と実質的に一致する断面形状を有する、
24に記載の装置。
28. 溝の少なくともいくつかが、格子パターンを形成している、27に記載の装置。
29. 溝の少なくとも一本が、補剛材を接続するためのノード要素を受容するよう構成されている、27に記載の装置。
コアの周囲に相互接続している強化繊維の層を巻き付けることにより殻を形成することを含む、管形状の繊維強化材補剛材プレフォームを作製すること、
自動化配置機械を用いて、工具面の溝内に補剛材プレフォームを自動的に配置すること、
繊維強化材ノードプレフォームを作製すること、
補剛材プレフォーム同士を相互接続する地点における工具面の溝内にノードプレフォームを配置すること、
繊維外板強化材を作製すること、
補剛材プレフォームの上を覆い、かつ、これらに接触するように工具面上に外板強化材を配置すること、
外板強化材の上方に当て板を配置すること、
外板強化材および補剛材プレフォームの上方に真空バッグを配置すること、
バッグを工具に封止することにより、外板強化材および補剛材プレフォームの上方に真空気密筐体を形成すること、
筐体を熱硬化性樹脂源に接続すること、
バッグから空気を排気することにより、筐体内に真空を生成すること、
筐体内の真空を用いて、源から筐体内へ樹脂を引き込むことにより、外板強化材と補剛材プレフォームとノードプレフォームとに実質的に同時に樹脂を注入すること、
バッグおよび大気圧を用いて、樹脂を注入した外板強化材と補剛材プレフォームとノードプレフォームとを圧縮すること、および、
樹脂を注入した外板強化材と補剛材プレフォームとノードプレフォームとを硬化させること
を含む、一体型補剛材を有する一体化複合航空機外板を作製する方法。
基体内に保持されており、かつ、少なくとも1つの曲率を内部に含むパネル形状の第1繊維強化材と、
基体内に保持されており、かつ、交差する格子パターンに配置されている長尺の補剛材形状の複数の第2繊維強化材であって、第2繊維強化材の少なくともいくつかが、第1強化材における曲率と実質的に一致する曲率を含み、かつ、パネルの上を覆う基部キャップおよび側方フランジを有し、第2強化材の各々が、繊維の外殻および強化材が充填された内部コアを含む、複数の第2繊維強化材と、
基体内に保持されている接続ノード形状の複数の第3繊維強化材であって、格子パターンにおける交点で第2強化材同士を接続している第3繊維強化材と、
を含む、一体型補剛材を有する一体化複合航空機外板。
Claims (14)
- 硬化ポリマー樹脂基体と、
基体内に保持されている第1繊維強化材を含む構造部材部分と、
構造部材部分を補剛するための補剛材部分であって、基体内に保持されている第2繊維強化材を含み、外殻および内部コアを含む補剛材部分と、
補剛材部分の構造部材部分への接合を助けるように構成されている複数の厚み方向強化材であって、構造部材部分を介して内部コア内へ延在する厚み方向強化材と、
を含む、一体型補剛複合構造物。 - 基体が、実質的に連続しており、かつ、均質である、請求項1に記載の補剛複合構造物。
- 各々が、基体内に保持されている第2繊維強化材を含む複数の補剛材部分であって、補剛材部分の各々が外殻および内部コアを含む、複数の補剛材部分
をさらに含む、請求項1に記載の補剛複合構造物。 - 複数の補剛材部分が、相互接続された格子状に配置されている、請求項3に記載の補剛複合構造物。
- 格子において補剛材部分同士を接続している複数のノードをさらに含み、かつ、ノードの各々が、
金属部材、
予め硬化されている複合部材、および、
樹脂基体内に保持されている第3繊維強化材
のうちの1つを含む、請求項4に記載の補剛複合構造物。 - 構造部材部分が、内部に開口を含み、かつ、
補剛材部分が、開口を実質的に取り囲んでいる、
請求項1に記載の補剛複合構造物。 - コアが、補剛材部分を通じて長手方向に延在している強化材繊維を含む、請求項1に記載の補剛複合構造物。
- コアが、一方向炭素繊維強化材で充填されていて、かつ、
殻が、少なくとも一層の相互接続されている繊維を含む、
請求項7に記載の補剛複合構造物。 - 構造部材部分が、湾曲しており、かつ、
補剛材部分が、構造部分の曲率に実質的に一致するような外形とされている、
請求項1に記載の補剛複合構造物。 - 補剛材部分が、構造部材部分の上を覆い、かつ、これと一体形成されている側方へ延在するフランジを含む、
請求項1に記載の補剛複合構造物。 - 構造物を補剛するための補剛材の大きさおよび地点と概ね一致する少なくとも1つの凹部を金型工具面に形成すること、
凹部内に繊維プレフォームを配置することであって、一層以上の相互接続された繊維をレイアップすることによりコアの周囲に管状殻を形成することを備える、前記配置すること、
繊維プレフォームの上を覆うように金型工具面上に構造部材繊維強化材を配置すること、
金型工具上の繊維強化材とプレフォームとに熱硬化性樹脂を混注すること、
樹脂を注入した繊維強化材およびプレフォームを硬化させること、および
構造部材繊維強化材を介してコア内へ延在する厚み方向強化材を供給すること
を含む、一体化補剛複合構造物を作製する方法。 - 繊維強化材とプレフォームとに混注することが、
繊維強化材とプレフォームと金型工具との上方に真空バッグを配置すること、
バッグ内に真空を発生させること、および、
バッグ内の真空を用いて、樹脂源からバッグ内、ならびに、繊維強化材およびプレフォーム内へ樹脂を引き込むこと
を含む、請求項11に記載の方法。 - コアの周囲に管状殻を形成することが、凹部内にプレフォームを配置する前に行われる、請求項11に記載の方法。
- 凹部内にプレフォームを配置することが、自動配置機械により自動的に行われる、請求項13に記載の方法。
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US12/823,414 US8628717B2 (en) | 2010-06-25 | 2010-06-25 | Composite structures having integrated stiffeners and method of making the same |
PCT/US2011/036191 WO2011162884A1 (en) | 2010-06-25 | 2011-05-12 | Composite structures having integrated stiffeners and method of making the same |
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EP (1) | EP2585287B1 (ja) |
JP (1) | JP5801885B2 (ja) |
KR (1) | KR101837217B1 (ja) |
AU (1) | AU2011269749B2 (ja) |
ES (1) | ES2513542T3 (ja) |
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2010
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- 2011-05-12 ES ES11721905.5T patent/ES2513542T3/es active Active
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PT2585287E (pt) | 2014-12-09 |
JP2013534478A (ja) | 2013-09-05 |
AU2011269749B2 (en) | 2016-02-25 |
EP2585287B1 (en) | 2014-10-01 |
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