TW201707949A - 複合材料三明治結構 - Google Patents

複合材料三明治結構 Download PDF

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Publication number
TW201707949A
TW201707949A TW105118386A TW105118386A TW201707949A TW 201707949 A TW201707949 A TW 201707949A TW 105118386 A TW105118386 A TW 105118386A TW 105118386 A TW105118386 A TW 105118386A TW 201707949 A TW201707949 A TW 201707949A
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TW
Taiwan
Prior art keywords
core
panel
surface layer
particles
assembly apparatus
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Application number
TW105118386A
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English (en)
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TWI730964B (zh
Inventor
亞歷山大Ｄ 弗格森
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弗格森高級複合科技有限公司
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Publication of TW201707949A publication Critical patent/TW201707949A/zh
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    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
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    • B29C70/66—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising fillers only, e.g. particles, powder, beads, flakes, spheres the filler comprising hollow constituents, e.g. syntactic foam
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Abstract

本發明關於一種用於成組裝運設備(Unit Load Device)之複合材料三明治基底面板。此面板包含：包含纖維強化材料之上表面層；包含纖維強化材料之下表面層；以及中央核心區段，其中至少大部分包含多數結合於基質材料中的顆粒。此上表面層及下表面層設置有基質材料以供將該等表面層結合至中央核心區段。

Description

複合材料三明治結構
發明領域
本發明關於一種輕量複合材料三明治基底面板，特別是用於做為成組裝運設備(Unit Load Device)的一部分。
發明背景
航空貨運一般是在貨櫃或托貨板形式之成組裝運設備(Unit Load Device)內或上運輸。對於航空工業的所有層面，減少重量為重要優先的事，因為其等於改良燃料效率及降低操作成本的同義詞。目前大部分的成組裝運設備是由高強度的鋁合金製造，承繼自1960年代首批設計。鋁合金可提供適當的成本、密度及可製造性的組合。然而，其具有二個主要的缺點：剛性(及強度)相對於重量的比例及對塑性變形的敏感性。
複合材料，且尤其是複合材料三明治結構，已知具有高剛性(及強度)相對於重量的比例。
美國專利第3556448號(Dobbs)揭示一種結構面板，其中將丁二烯-苯乙烯樹脂的延伸核心設置於一體編織的三維織物的溝紋或網之間。在此揭示由已熱壓縮至平坦的發泡體核心之玻璃纖維表層組成的托貨板。
美國專利第7854204號(Dacus)揭示一種超輕量成組裝運設備，包含強化四角複合材料結構，具有密封於連續排序之聚合物層板且外邊緣經修整的承載胞室負載的核心，具有利用齊平附接裝置 固定之具有中空、多腔室輪廓的輕量材料，以致於呈現有效負載之容易負載及卸載的平坦表面。
美國專利第8776698號(Pherson)揭示一種由多數夾層產生之具有中心面板的航空貨運托貨板，夾層包括設置在具有樹脂及纖維組合之上表層與具有樹脂及纖維組合之下表層之間的的發泡體核心。此外，中心面板利用延伸通過下表層、發泡體核心及上表層之額外纖維強化。將中間層設置環繞發泡體核心的周圍且結合於上表層及下表層之間，以完成中心面板。接著藉由扣合利用連接到中間層而環繞中心面板周圍之多數軌道以形成托貨板。
上述文獻把目標放在與由鋁合金製成的組裝運設備之基底面板相較，增加成組裝運設備之基底面板的剛性相對於重量之比例。然而，其等遭遇一個不同的問題，使得其等不適於操作。成組裝運設備是經由輥軌及球墊而移動且此類裝置的基底面板在其生命週期期間在負載下可能行進數十公里。如同存在於上述面板中之具有對應低抗壓強度的低密度核心，遭遇局部凹陷損壞，其結果造成面板必須停止使用。這就是目前未發現上述發明應用於成組裝運設備的原因。
發明概要
因此，本發明把目標放在一種成組裝運設備(Unit Load Device)，其具有基底面板，該面板包含：包含纖維強化材料之上表面層；包含纖維強化材料之下表面層；以及中央核心區段，其中至少大部分包含多數結合於基質材料中的顆粒；其中該上表面層及該下表面層設置有基質材料以供將該等表面層結合至該中央核心區段。
成組裝運設備的基底面板可包含複合材料三明治結構。
這樣的配置提供符合與現存輕量複合材料三明治基底 面板相同之設計負載及操作要求的輕量結構，但對於塑性變形及/或損害形成的抗性增高。成組裝運設備之主要操作需求為在滾輪運送機上橫移而無永久變形或斷裂。若上及下表面強化材料及中央核心區段的組合，導致低撓曲剛性，面板將環繞輥尖端過度彎曲，其將造成強化材料的破裂。相反地，若核心的剛性太高，面板將無法充分彎曲，接觸力將集中在較小的區域，結果造成較大的局部應力，且因此造成表現出陷入面板的永久凹陷的核心損壞，此凹陷是由於核心承受的應力增加的結果所造成的核心材料壓碎。因此，整體基底面板的撓曲剛性使任一損壞機制的可能性最小化同時仍維持輕量。本發明藉由在強化材料的上層及下層中應用顆粒及基質材料的組合來處理這個問題。
纖維強化材料可包含來自碳、聚芳族醯胺、玄武岩及/或玻璃纖維的纖維，且其等可由任何梭纖物製成，例如平紋、斜紋、緞紋、展紋(spread-tow)或非捲曲織物(NCF)或單向織物，或其等之任何組合。
較佳地，顆粒主要為微球體。面板的核心包含受基質材料包圍之高強度微球體，以形成複合材料發泡體。此核心結合於上及下纖維強化表面層之間以產生輕量、硬質的結構。依微球體的選擇而定，此核心可導致面板具有稍高於傳統低密度發泡體或蜂巢體之剛性相對於重量的比例，但在垂直面板表面的方向上具有遠大於其等的抗壓強度。無法預期地，當微球體具有特定尺寸範圍時，根據本發明之成組裝運設備的核心呈現的抗壓強度顯著大於微球體或基質材料單獨的個別抗壓強度，為2倍以上。
在三明治結構中使用複合材料發泡體提供額外的優點，例如此種三明治結構即使在高溫處理時，例如攝氏840度的火焰下，對於火或引燃具有高度抗性，成組裝運設備或其三明治面板將為自熄性。再者，即使在這樣的極高溫下，複合材料表面層中的纖維將微球體約束在核心內並防止熔融/燃燒的樹脂滴出面板外。
有利地，微球體的結構是中空的。中空微球體的使用進 一步減少面板的重量。
較佳地，大部分的微球體具有40MPa之最小崩塌強度。此一崩塌強度降低使面板無法使用的塑性變形的風險。
在一實施例中，大部分的微球體的直徑小於40μm，在一配置中，直徑小於30μm，且在一些實施例中，直徑小於20μm。
在特別有利的配置中，基質材料結合上及下表面層中的纖維，基質材料將上及下表面層與核心結合，且基質材料結合中央核心中的顆粒是相同且連續的。如此產生單一基質相結構。單一基質相之單一基質材料的使用降低面板之外層分離的風險且在整個面板內產生強力結合。
在固化配置之前，核心內纖維強化材料及顆粒可一起利用基質材料浸漬。或者，僅有在結合上及下表面層中之纖維的基質材料與結合上及下表面層與核心之基質材料二者之間，基質材料可相同或相連的，或僅有在結合上及下表面層與核心之基質材料與結合中心核心中顆粒之基質材料二者之間，基質材料是相同或相連的。
較佳地，上表面層及/或下表面層的厚度界於0.2mm及3.5mm之間。此一厚度提供輕量且牢固之外表面給面板。
有利地，中央核心區段的密度界於0.5及1.2g/cm3之間。如此產生在使用時具有足夠強度對抗凹陷的輕量面板。
在一配置中，中央核心區段包含胞室結構且較佳地，胞室結構為開放胞室結構，以及其至少部分填充有顆粒。胞室結構可為蜂巢狀結構的形式，其可由鋁合金或利用玻璃或聚芳族醯胺纖維強化之複合材料組成，且配置成任何堆積形狀。當使用胞室結構時達到二個額外結構上益處。第一為面板的耐用性大於無蛒巢結構之複合材料發泡體核心。核心合併胞室結構之面板出乎預期地證實當橫跨滾輪運送機時，具有較高的抗裂痕擴張性。第二，依製程而定，製造之面板具有較平坦的表面，最終具有更均一的厚度分布。纖維強化之複合材料的剛性及強度直接受到纖維排列的影響，所以較平坦的表面導致特 性的變動性較低。如此導致面板上脆弱點較少，增加面板的耐用性。
在一較佳的配置中，在中央核心區段與至少一表面層之間設置障壁層。在中央核心區段與表面層之間應用障壁層降低顆粒由核心區段遷移入外層的風險。障壁層可包含輕量面紗、布料、紙材或任何可讓液體滲透的材料，尤其是可讓基質材料滲透，但無法讓核心的顆粒滲透。
在另一配置中，中央核心區段包含多數不同的顆粒且此等顆粒的不同處可依據一或多個選自於下述組群的特性：尺寸、形狀結構及材料。
可於微球體中混合具有不同尺寸等級的額外顆粒，其可改良核心的整體性能，尤其是材料的斷裂韌性。奈米級顆粒可以實心顆粒方式引入，例如尺寸範圍10-200nm的氧化矽顆粒。或者，或額外地，可將嵌段共聚物溶解於樹脂中，以致於在樹脂固化時，嵌段共聚物終止溶解，所以樹脂溶液分解成離散相，其中嵌段共聚物自組合成顆粒及/或自組合成共連續網絡。
較佳地，顆粒本身可包含界於30體積%至74體積%之間的核心，且更佳地顆粒本身可包含界於50體積%至70體積%之間的核心。較佳地，大部分的核心是由固定在基質材料中的顆粒組成，以致能提供核心強度與重量間的平衡。
在一有利的結構中，核心結構沿著體積變化，以致於至少二部分的核心結構具有不同的結構特徵。藉由使核心結構沿著其體積變化，可局部改變強度及其他結構特徵。此點在例如藉由鉚釘或螺栓接合的方式，欲將其他部件附接或合併入面板時特別有需要。核心結構變化與面板邊緣的距離可約40mm，雖然此距離可能在面板之最大長度的0%至25%之間改變。
有利地，在面板的邊緣，可改變核心結構，以致於顆粒實質由其他材料取代，例如短纖維強化材料。短纖維強化材料可取代至少部分或全部的核心內顆粒，以致於短纖維強化材料本身含量可為 核心的0體積%至40體積%。
在另一實施例中，在面板的邊緣，核心結構可改變，以致於複合材料發泡體由設置在二表面層之間(但可延伸超過面板邊緣)的強化材料取代。強化材料可由實心複合材料層合物、鋁合金、鋼材、其他金屬、合金或塑料所組成。提供強化材料條容許局部調整面板的強度及剛性。
本發明的面板，尤其是設置有強化材料的面板，係用於做為成組裝運設備的基底面板，或其可置換以代替現有基底面板，且藉此機械地固定於現有成組裝運設備。當複合材料三明治結構在抵抗緊固件接合負載上相對弱時，使用中央核心周圍區域，其中改變材料組成及/或幾何形狀，容許面板對於在此等接受施加的力的抗性更高。
為了那個目的，至少部分的面板周圍可凹陷或升高以產生唇部。藉由產生一唇部，外邊緣組件可在預定位置配合並固定至面板，而使用除了埋頭孔形式以外的緊固件。若外邊緣組件放置在面板凹入部的下方，則接合點有利地處於壓縮負載狀態而非在裂縫張開拉伸狀態。
較佳地，本文中描述的成組裝運設備的基底面板為輕量複合材料三明治面板。比同等的AKE型成組裝運設備之鋁合金成組裝運設備基底面板，複合材料發泡體及輕量纖維強化表面層造成面板重量可減少高達60%。根據本發明的成組裝運設備對於高壓縮負載及在操作期限升高之所得接觸應力的抗性更高。
有利地，可使耐磨層附接到至少一表面。聚芳族醯胺、聚醯胺、聚乙烯或類似的高耐磨材料可放置於上及/或下強化材料層的外側。
可在至少部分面板的周圍設置多數邊緣軌道。這些軌道可連接面板到其他的成組裝運設備。面板及/或成組裝運設備的材料及/或幾何形狀可改變以使面板不會掉落。
較佳地，成組裝運設備之邊緣軌道可藉由黏著劑結合。 黏著劑的使用提供邊緣軌道與成組裝運設備之基座間的結合，而無需對面板的外層穿孔。
核心由被環繞於基質材料中之高強度微球體製成的低密度複合材料發泡體組成。周圍區域中材料組成及/或幾何形狀的改變有助於面板結合邊緣組件。
本發明延伸到根據本發明之一種製造成組裝運設備之方法。
本發明可應用下述步驟來製造：在表面上設置下表面層，其中該基底舖疊層包含第一強化材料層；在該基底舖疊層上設置核心層，其中該核心層可包含開放胞室結構，以及使該核心層至少部分填充有未結合的顆粒；在該核心層之上方設置上表面層，其中該頂舖疊層包含第二強化材料層；將前述配置密封於密封型外殼內，其中該外殼設置有至少一管道，以容許與該外殼的內側流體連通；經由壓力差將基質材料引入該配置內；以及固化該基質材料。
管道可定位在該配置之上方或下方且通過該外殼以容許空氣自該外殼排除，以產生壓力差。再者，或可替代地，基質材料可經由一或多個管道進入外殼。添加劑或其他元件可在配置密封於該外殼內之外，增加到該配置中。
1‧‧‧上表面層
2‧‧‧障壁層
3‧‧‧複合材料發泡體核心
4‧‧‧障壁層
5‧‧‧下表面層
6‧‧‧耐磨層
7‧‧‧短纖維強化材料
8‧‧‧實心複合材料層合物
9‧‧‧底表面，邊緣幾何形狀
10‧‧‧緊固件
11‧‧‧外邊緣組件
12‧‧‧六角形胞室結構
現在將以僅為例示說明的方式，並配合後附的圖式，描述本發明的實施例，其中：圖1為根據本發明之面板之垂直截面的圖解說明；圖2A根據本發明之面板之水平截面的圖解說明；圖2B為根據本發明之面板之垂直截面的圖解說明；圖3為顯示二面板之變形的圖； 圖4為根據本發明之第二面板之垂直截面的圖解說明；圖5為根據本發明之第三面板之垂直截面的圖解說明；圖6為根據本發明之第四面板之垂直截面的圖解說明；以及圖7為根據本發明之第五面板之垂直截面的圖解說明。
範例實施例之詳細說明
圖1顯示包含夾置複合材料發泡體核心3之上表面層1及下表面層5的複合材料三明治基底面板。核心之二側皆具有障壁層2及4。接著利用多數外邊緣組件(未顯示)圍繞整個面板。對於邊緣組件將附接到面板的區域，可改變複合材料核心3的局部材料組成，及/或改變周圍區域的局部幾何形狀。耐磨層6可結合至下表面層5。
依所使用的製造方法而定，本發明之部分實施例包括合併入複合材料發泡體3的胞室結構。圖2A為合併入複合材料發泡體核心3之六角形胞室結構12的水平截面，以及圖2B為合併入複合材料發泡體核心3之六角形胞室結構12的垂直截面。同樣地，使用之製造方法可意指不一定需要在核心與頂表面之間的障壁層2，及/或在核心與底表面之間的障壁層4。最後，本發明之部分實施例可省略耐磨層6。
複合材料發泡體核心3是由含有輕量中空玻璃微球體的基質材料製成。大部分的微球體的直徑等於或小於40μm，較佳在9-25μm的範圍內，及/或崩塌強度大於40MPa。複合材料發泡體核心3包含50-70體積%之被環氧樹脂基質材料圍繞的微球體。
本發明可應用碳纖維強化的環氧樹脂，以0°/90°/±45°舖疊層用於表層，雖然也可使用其他舖疊層。清楚地，成角度的舖疊層能與其他材料一起使用。
IATA法規提及應在所有成組裝運設備的基座進行凹陷測試。圖3顯示靜態凹陷測試的結果，比較根據本發明之面板(FCF30)上受到的力以及由傳統高強度發泡體核心(Gurit® M200)建構之面板上受到的力。二個面板皆具有相同的核心厚度、表面層材料及表面層厚 度。負載條件是由球形鋼球反復試驗，此條件在常態下使用於航空貨運地板，藉由Instron® 5585H材料測試機迫使球形鋼球進入面板。測試結果顯示於圖3的圖形中。如圖式所示，在相同負載之外，由傳統發泡體核心製成之面板的最大凹陷，比本發明多出6倍以上，傳統發泡體核心面板將塑性變形且因此難以自飛機卸貨，而根據本發明的面板呈現顯著較低變形且因此較容易卸貨。
如圖4所示，在一實施例中，在面板周圍的複合材料發泡體組成為使微球體減少至0%，並接著由包含高達體積40%之複合材料發泡體的短纖維強化材料7取代。此一實施例使用平均纖維長度為100μm之切碎的碳纖維強化材料，然而，短纖維可為碳、聚芳族醯胺、玄武岩及/或玻璃纖維等纖維。為了有助於由中央面板核心至周圍區域的組成改變，周圍區域可含有胞室蜂巢結構。如此使局部改變之核心材料與中央複合材料發泡體核心的其餘部分分隔。或者，短纖維強化材料可僅取代中央核心部分，或其可同時使用於核心及周圍邊緣區域。
在另一實施例中，如圖5所示，部分的複合材料發泡體核心可部分由不同材料取代。舉例而言，強化材料條可取周圍邊緣區域，使得局部地，結構為實心複合材料層合物8。或者，可使用實心金屬或非金屬材料。強化材料可設置在表面層之間，但可延伸超出面板邊緣。
圖6顯示另一實施例，其中改變面板的邊緣幾何形狀。面板可在頂及/或底表面9形成凹陷，以致於當與地面接觸時，容許面板的中央部分保持平坦，使得可使用突頭緊固件10來取代埋頭形式以連接外邊緣組件11至面板。或者，圖7顯示具有置於面板之凹陷部下方的外邊緣組件之配置。如此有利地使接合點處於壓縮負載狀態而非在裂縫張開拉伸狀態。在此二配置中，環繞面板的邊緣產生「茶盤」狀唇部，其增加面板的有效剛性。改變的邊緣幾何形狀也可與圖1、3及4所示態樣組合，使得核心具有組成改變或由不同材料取代的特徵。
當使用彎曲的邊緣幾何形狀9時，也可顯現使用複合材料發泡體的額外優點。在利用此一幾何形狀的操作負載下，可發展出很大的通過厚度應力，其導致傳統聚合物發泡體之破裂及損壞。利用複合材料發泡體可達到的剛性及強度容許維持如此的負載，其接著使得面板與成組裝運設備之其他部分能有更有效率的接合點。
成組裝運設備之另一實施例應用包含邊緣連接區域而非機械緊固件的面板。黏著劑結合排除在複合材料三明治面板進行任何鑽孔的需要，因此，增加面板的結構完整性。黏著劑可以類似焊接方式應用：沿著面板的周長連續施用或形成分開的點狀物。
在本發明的其他實施例中，包含50%以上之核心的複合材料發泡體，包含微米級微球體，其含量可少量到占核心的30體積%，可多量到最高達74體積%。微球體可為實心或空心，或由玻璃、碳、金屬、聚合物或陶瓷材料製成。
依面板的需求而定，可於基質中使用熱固性或熱塑性樹脂，例如：乙烯酯、丙烯酸酯或PEEK。此外，基質可包括化學添加劑，例如：阻燃劑，增韌劑及/或抗UV劑。
在較佳實施例中，核心的平均厚度可為約2.8mm，以致於總面板厚度為約4mm。然而，依應用而定，核心厚度可界於1mm至8mm之間。
本發明之實施例的一或多個特徵可與本發明之一或多個特徵組合或予以取代。
1‧‧‧上表面層
2‧‧‧障壁層
3‧‧‧複合材料發泡體核心
4‧‧‧障壁層
5‧‧‧下表面層
6‧‧‧耐磨層

Claims (15)

  1. 一種成組裝運設備(Unit Load Device)，其具有基底面板，該設備包含：包含纖維強化材料之上表面層；包含纖維強化材料之下表面層；以及中央核心區段，其中至少大部分包含多數結合於基質材料中的顆粒，其中該上表面層及該下表面層設置有基質材料以供將該等表面層結合至該中央核心區段。
  2. 如請求項1之成組裝運設備，其中該等顆粒主要為微球體。
  3. 如請求項2之成組裝運設備，其中大部分該微球體具有40MPa之最小崩塌強度。
  4. 如請求項2或3之成組裝運設備，其中大部分該微球體具有小於40μm的直徑。
  5. 如請求項1至4中任一項之成組裝運設備，其中在該上及下表面層中的基質材料、結合該上及下表面層的基質材料以及使該等顆粒結合於該中央核心的基質材料，是相同且連續的。
  6. 如請求項1至5中任一項之成組裝運設備，其中該上表面層及/或該下表面層的厚度為界於0.2mm至3.5mm之間。
  7. 如請求項1至6中任一項之成組裝運設備，其中該大部分的核心的密度為界於0.5至1.2g/cm3之間。
  8. 如請求項1至7中任一項之成組裝運設備，其中該核心區段包含至少部分填充有顆粒之胞室結構。
  9. 如請求項1至8中任一項之成組裝運設備，其中該障壁層設置於該核心區段與至少一表面層之間。
  10. 如請求項1至9中任一項之成組裝運設備，其中該核心區段包含多數不同顆粒，其中該等顆粒根據一或多個選自於包含下述特徵之組群的特徵而有不同：尺寸、形狀、結構及材料。
  11. 如請求項1至10中任一項之成組裝運設備，其中50%以上的該中央核心區段結構包含複合材料發泡體，其中微米級顆粒構成該核心的30體積%至74體積%之間。
  12. 如請求項1至11中任一項之成組裝運設備，其中該核心的結構及/或組成沿著體積而改變，以致於至少二部分之該核心結構具有不同的結構特徵。
  13. 如請求項1至12中任一項之成組裝運設備，其中該面板包含設置於該二表面層之間的強化材料條。
  14. 如請求項12之成組裝運設備，其中該面板之該核心的至少一區域包含併入0體積%至40體積%之短纖維強化材料的複合材料。
  15. 如請求項1至14中任一項之成組裝運設備，其中至少部分之面板周圍凹陷或升高以產生唇部。
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