JP6680465B2 - 航空機構造用の複合材料部品を製造する方法 - Google Patents
航空機構造用の複合材料部品を製造する方法 Download PDFInfo
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- JP6680465B2 JP6680465B2 JP2015095668A JP2015095668A JP6680465B2 JP 6680465 B2 JP6680465 B2 JP 6680465B2 JP 2015095668 A JP2015095668 A JP 2015095668A JP 2015095668 A JP2015095668 A JP 2015095668A JP 6680465 B2 JP6680465 B2 JP 6680465B2
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- preform
- reinforcing element
- reinforcing
- resin
- composite material
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- 239000002131 composite material Substances 0.000 title claims description 30
- 238000004519 manufacturing process Methods 0.000 title claims description 15
- 238000000034 method Methods 0.000 claims description 62
- 230000003014 reinforcing effect Effects 0.000 claims description 55
- 239000011347 resin Substances 0.000 claims description 41
- 229920005989 resin Polymers 0.000 claims description 41
- 239000012783 reinforcing fiber Substances 0.000 claims description 28
- 238000006116 polymerization reaction Methods 0.000 claims description 21
- 230000002787 reinforcement Effects 0.000 claims description 12
- 239000000835 fiber Substances 0.000 claims description 5
- 238000005553 drilling Methods 0.000 claims description 2
- 238000001723 curing Methods 0.000 description 12
- 230000015572 biosynthetic process Effects 0.000 description 9
- 238000003754 machining Methods 0.000 description 9
- 238000009730 filament winding Methods 0.000 description 7
- 239000000463 material Substances 0.000 description 5
- 238000005470 impregnation Methods 0.000 description 4
- 239000012779 reinforcing material Substances 0.000 description 4
- 229920000049 Carbon (fiber) Polymers 0.000 description 3
- 239000004917 carbon fiber Substances 0.000 description 3
- 239000004744 fabric Substances 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 239000003351 stiffener Substances 0.000 description 3
- 229920001187 thermosetting polymer Polymers 0.000 description 3
- 230000008901 benefit Effects 0.000 description 2
- 230000000295 complement effect Effects 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 230000032798 delamination Effects 0.000 description 2
- 230000013011 mating Effects 0.000 description 2
- 238000009659 non-destructive testing Methods 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
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- 239000011159 matrix material Substances 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 230000008719 thickening Effects 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
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Description
図1に示されているように、胴体10は、細長い全体形状である多数の構造部品を備える。これらの部品は、例えば、「ストリンガ(stringer)」とも呼称される胴体の縦方向補強材14と、床横材16と、床レール18と、床横材16を胴体の外周フレーム22に連結する「ポスト(post)」とも呼称される床支持部材20とから成る。
これらの様々な部品は、断面が通常C字形、I字形、L字形、Z字形、又は、オメガ字形である、ガーダ(girder)の全体形状を有する。
これらの様々な部品は、最初に金属又は炭素で作られた。
術語「複合材料」によって意味されているものは、硬化樹脂のようなバインダとして機能するマトリックスの中に埋め込まれている強化繊維に基づいている材料である。強化繊維は金属又は有機物であり得る。
上述した部品のような細長い形状の構造部品という特定の場合には、炭素繊維の非常に良好な機械的特性の故に、炭素繊維が使用されることが好ましい。
樹脂は、一般的に、例えばエポキシ樹脂類に属する、熱硬化性樹脂のような熱硬化性樹脂である。
こうした方法は、それぞれに図3の平面A−A、B−B、C−C上の断面の形で補強材30を示す図3a、3b、3cによって示されている、その部品に沿って変化する可能性がある断面を有する部品の形成を可能にする。
一定で不変の断面を有する部品の形成の場合には、これらの部品は、引抜成形を使用しても生産されることが可能である。
こうしたリンクロッドの端部部分28が概して複雑な形状であるので、このようなリンクロッドの製造は、同様に、複雑で且つ高コストである方法を必要とする。
この方法は、
重合可能な樹脂の中に埋め込まれている補強繊維を含む第1の複合材料の引抜成形された予成形物(preform)を形成し、この結果として、この得られた予成形物の樹脂が部分重合状態たらしめるステップと、
得られた補強材料の樹脂が部分重合状態にあるように、重合可能な樹脂の中に埋め込まれている補強繊維を含む第2の重合材料から少なくとも1つの補強要素を形成するステップと、その次に、
補強されなければならない予成形物の区域に対して前記少なくとも1つの補強要素を付加するステップと、その次に、
予成形物と前記少なくとも1つの補強要素とによって形成されているアセンブリに属する樹脂の重合を完了させるステップと、
このようにして、前記少なくとも1つの補強要素によって補強される少なくとも1つの部分を有する航空機構造のための複合材料の部品を得るステップと、
を含んでいる。
これによって理解されるべきことは、予成形物の樹脂の重合と前記少なくとも1つの補強要素の樹脂の重合とが、一緒に完了させられるということである。
特に、予成形物の全体的な湾曲は、引抜成形を使用したこの予成形物の形成のステップの後に変更することができない。
さらに、この接合の品質が、従来の非破壊試験を使用して、特に、超音波を使用するタイプの非破壊試験を使用して、検査することができる。
特には、胴体の縦方向補強材、床の横材、床レール、床支持部材、又は、さらには構造リンクロッドのような、細長い全体形状の部品の製造に関する。
この設備50は、炭素繊維のような補強繊維のリールを支持するための支持ユニット52と、含浸ユニット54と、硬化ユニット56と、牽引ユニット58と、鋸引きユニット(sawing unit)60とを備える。
このプロセス全体を通じて、補強繊維が繰り出されることを可能にするその補強繊維に対する牽引が、牽引ユニット58によって提供される。
最後に、鋸引きユニット60が、予成形物が硬化ユニット56を出て行く時に、所望の長さの予成形物64が切断されることを可能にする。
このように形成された予成形物は、例えば、C字形、I字形、L字形、Z字形、又は、オメガ字形の断面を有する。
例えば、補強要素は、後述の説明でより明瞭になるように、プレート又は円板の形状をとる。
そうするために、約1Bar以上の圧力が、当業者に既知の方法によって、例えば真空バッグ又は真空袋を使用して、予成形物64上に各補強要素を保持するために各補強要素に加えられる。予成形物の表面のすべてが補強要素の各々と接触する時に、真空が発生させられることが好ましい。したがって、層間剥離又は空隙の出現の危険性が可能な限り低減させられることが可能である。
さらに、こうして形成された部品の最終的な幾何学的形状が金型によって提供されることが好ましい。
代替案としては、圧力下での樹脂の重合が、熱間成形プレス(hot forming press)によって完了させられる、これにより、真空バッグ又はオートクレーブに対する依存を回避することを可能にする。
図示されている具体例では、この部品は、実質的に互いに平行であり、且つ、その底部72に対して実質的に直角であるウェブ74によって互いに連結されている、2つの底部72を備える、I字形の断面の床支持部材70である。
したがって、この例では、補強要素と、補強されるべき区域とが、平面状の形状を有する。
穴80の端縁を補強するために必要とされる補強要素74の質量は、実際には、穴80の形成において取り除かれるウェブ74の一部分の質量よりも著しく小さいだろう。
代替的には、補強要素76は、例えば1つ又は複数の締結具(図6には示されていない)を通過させるための、1つ又は複数の穴を後で穿孔することが可能である。
したがって、補強要素76は、特にピーニング力(peening force)に関して、ウェブ74の強度を向上させることを可能にする。
この設備90は、図3の引抜成形設備90に全体的に類似しているが、少なくともフィラメントワインディングユニット92をさらに備えるということにおいて、図3の引抜成形設備90とは異なる。
図示されている例では、フィラメントワインディングユニット92は、プレダイ(pre−die)93と含浸ユニット54との間に配置されている。
例えば、図8aから図12bは、この方法を使用する構造リンクロッド95の製造を図示している。
この方法は、まず第1に、引抜成形設備90を使用する、重合可能な材料の中に埋め込まれている補強繊維を含む第1の複合材料の予成形物96(図8a及び図8b)の製造を含み、及び、この結果として、得られた予成形物の樹脂が部分重合状態である。
その次に、このアセンブリは、補強繊維62、94が中で重合可能樹脂で含浸される含浸ユニット54の中に進入し、
その後、樹脂で含浸された補強繊維が硬化ユニット56を通過して前進を続け、この硬化ユニット56内では、成形型がそのアセンブリを成形するように、且つ、好ましくは硬化ユニット56を出て行く時に10%から50%の間の、好ましくは20%から30%の間の、樹脂の重合度を結果的に生じさせるように、樹脂の部分重合が生じる。
このプロセス全体を通じて、補強繊維62、94が繰り出されることを可能にする補強繊維62、94に対する牽引が、牽引ユニット58によって生じさせられる。
最後に、鋸引きユニット60が、補強繊維が硬化ユニット56から出て行く時に所望の長さの主プロファイル96が切断されることを可能にする。
さらに、この具体例では、補強要素98の数が2つであり、及び、互いに類似しているが、この補強要素の一方だけが図面に示されている。
しかし、この副次的予成形物100が予成形物96の2つの互いに反対側に位置した端部部分102の形に後で一体的に押込み結合されることを可能にするように、この副次的予成形物100は、予成形物96の長さよりも短い長さと、予成形物96の内側断面を実質的に相補する形状の外側断面とを有する。
さらに明確に述べると、この例において、図11a及び図11bに示されているように、この作業は、2つの補強要素98を、予成形物96の2つの互いに反対側に位置した端部部分102のそれぞれ1つの中に押込み結合することにある。
任意には、補強要素98は、予成形物96の中に予成形物98を押込み結合することをより容易にするために、前もってその縦方向にスリットが入れられる。
この圧力は、例えば、真空袋又は真空バッグによって加えられる。
予成形物96が、その予成形物96の外側表面に対して反対圧力が加えられることを可能にする嵌合円筒形形状の形で係合させられることが好ましい。
予成形物のすべての表面と各補強要素のすべての表面とが接触する時に、真空が生じさせられることが好ましい。
このようにして、層間剥離の危険性と空隙の発生の危険性とが可能な限り制限されることが可能である。
代替的には、圧力下での樹脂の重合の完了が、熱間成形プレスによって行われ、真空バッグ及びオートクレーブに対する依存を回避することを可能にするだろう。
図示されている具体例では、各補強要素98の切頭円錐形部分104は、リンクロッド95の内側表面内に不連続性が存在することを回避することを可能にする。
構造リンクロッド95の形成という特定の場合には、この機械加工は、特に、固定ヨーク108を形成するために、その部品の端部に関係する。
これを行うために、2つの縦方向スロット110が、構造リンクロッド95のそれぞれの縦方向端部から機械加工され、及び、その次に、貫通穴が、縦方向スロット110の平面E−Eに対して実質的に直角の方向に、補強要素98によって補強された端部部分102の中を貫通してリンクロッド内に穿孔される。
この代替案の形態では、副次的予成形物100a(図14a及び図14b)は、予成形物96の2つの互いに反対側に位置した端部部分102が後でそれぞれの副次的予成形物100aの中に押込み結合されることを可能にするように、予成形物96(図13a及び図13b)の外側断面を実質的に補完する形状の内側断面を有する。
当業者には公知であるように、こうした織物は、補強繊維62によって画定される縦方向に対して傾斜している幾つかの方向に方向配置されている織物を含む。
Claims (10)
- 航空機構造用の部品(70、95,95a)を複合材料から製造するための方法であって、
重合可能な樹脂の中に埋め込まれている補強繊維(62、94)を含む第1の複合材料を引抜成形して予成形物(64、96)を、該予成形物の樹脂が部分重合状態であるように形成するステップと、
前記予成形物(64、96)の形成とは別に、重合可能な樹脂の中に埋め込まれている補強繊維(62、94)を含む第2の複合材料から少なくとも1つの補強要素(76、78、98、98a)を、該補強要素の樹脂が部分重合状態であるように形成するステップと、
その次に、
補強される前記予成形物(64、96)の区域(74、102)に対して前記少なくとも1つの補強要素を付加するステップであって、重合の完了の前に、補強される前記予成形物の前記区域に前記少なくとも1つの補強要素を保持するために、該補強要素に圧力が加えられる、ステップと、
その次に、
前記予成形物(64、96)と前記少なくとも1つの補強要素(76、78、98、98a)とのアセンブリの前記樹脂の重合を完了することによって、前記少なくとも1つの補強要素(76、78、98、98a)が前記予成形物(64、96)に直接取り付けるステップと、
かくして、
前記少なくとも1つの補強要素によって補強された少なくとも1つの部分を有する、航空機構造用の複合材料の部品(70、95,95a)を得るステップと、を含み、
前記部品は、胴体の縦方向補強材、床の横材、床レール、床支持部材、又は、構造リンクロッドのいずれかである、
ことを特徴とする方法。 - 前記予成形物は、前記部品の固定のために、前記少なくとも1つの補強要素(76、78、98、98a)が付加されて補強される、少なくとも1つの端部部分を有する、
ことを特徴とする請求項1に記載の方法。 - 前記部品の前記補強部分を貫通する少なくとも1つの穴(80)を穿孔する後続のステップを含む、
ことを特徴とする請求項1又は2に記載の方法。 - 前記穴(80)の中をケーブル又はダクト又は締結具を通過させる後続のステップを含む、ことを特徴とする請求項3に記載の方法。
- 前記少なくとも1つの補強要素(76、78)が平面状を成し、かつ、前記予成形物(64)の平面状の部分(74)に付加される、
ことを特徴とする請求項1から4のいずれか一項に記載の方法。 - 前記予成形物(96)は閉じた断面を有し、かつ、前記少なくとも1つの補強要素(98、98a)は、押込み結合によって、前記予成形物(96)の補強される区域(102)に付加される、
ことを特徴とする請求項1から4のいずれか一項に記載の方法。 - 前記予成形物(96)は管状を成し、かつ、前記少なくとも1つの補強要素(98,98a)の少なくとも一部が、前記予成形物に一体に押込み結合されることが可能な管状の形状である、
ことを特徴とする請求項6に記載の方法。 - 前記少なくとも1つの補強要素(98、98a)は、管状形状の2つの補強要素を含み、前記補強要素は、固定用の面を形成する前記予成形物(96)の2つの互いに反対側に位置した端部部分(102)の中、又は、上にそれぞれに押込み結合されている、
ことを特徴とする請求項7に記載の方法。 - 前記予成形物と前記補強要素とのアセンブリの重合を完了させるステップの以前の前記予成形物と前記補強要素との重合度が、10%〜50%である、
ことを特徴とする請求項1から8のいずれか一項に記載の方法。 - 前記少なくとも1つの補強要素(76、78、98,98a)は引抜成形を使用して形成される、ことを特徴とする請求項1から9のいずれか一項に記載の方法。
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- 2015-05-08 CN CN201510232363.2A patent/CN105082575B/zh active Active
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FR3020780B1 (fr) | 2017-01-13 |
CN105082575A (zh) | 2015-11-25 |
US20150321429A1 (en) | 2015-11-12 |
CN105082575B (zh) | 2020-07-31 |
JP2015214151A (ja) | 2015-12-03 |
US9796142B2 (en) | 2017-10-24 |
FR3020780A1 (fr) | 2015-11-13 |
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