TW202212117A - 具有連續纖維強化元件的強化結構及其製造方法 - Google Patents

具有連續纖維強化元件的強化結構及其製造方法 Download PDF

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TW202212117A
TW202212117A TW110118935A TW110118935A TW202212117A TW 202212117 A TW202212117 A TW 202212117A TW 110118935 A TW110118935 A TW 110118935A TW 110118935 A TW110118935 A TW 110118935A TW 202212117 A TW202212117 A TW 202212117A
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Taiwan
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reinforced
elements
fiber
cross
reinforcement
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TW110118935A
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English (en)
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羅夫 方克
顏斯 榮格
馬丁 威爾許
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美商阿爾巴尼工程組合股份有限公司
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Publication of TW202212117A publication Critical patent/TW202212117A/zh

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Abstract

一種強化結構，由強化元件組成。強化元件具有嵌入在基體材料之中的連續纖維。強化元件係結合在基體材料中，以形成強化結構之所期望形狀。

Description

具有連續纖維強化元件的強化結構及其製造方法
本發明涉及一種熱塑性結構，所述熱塑性結構具有一輪廓（profile），所述輪廓係透過連續纖維強化長絲（filaments）予以強化。
使用高彈性纖維複合材料，例如具有碳纖維、玻璃纖維、醯胺纖維（aramid fibers）、陶瓷纖維或玄武岩纖維（basalt fibers）以及基體，例如自熱固性或熱塑性、彈性體、碳、石墨或陶瓷和相關材料所製得，需要使用適當的結構（constructions）以使傳輸功率適於材料。與材料相關（material-related）是指，就纖維方向上和跨越纖維方向的不同機械性能而言，針對性地使用材料的各向異性（anisotropy）。
由纖維複合材料製成的用於功率傳輸的連桿（connecting rods），係特別用於導向和機械儲存、支撐、斜撐（bracing）或連接。由纖維複合材料製成的連桿已為人所知多年。這種連桿較佳地，但不排他地，用於飛行器或太空飛行器中。飛行器和太空飛行器，例如飛機、旋翼飛機、飛艇、無人航空系統、火箭或衛星的連桿，主要係軸向承載壓縮力和拉伸力。
對重量和成本節約日益增長的需求，導致具有由熱固性纖維複合材料製成的管狀體（tubular bodies）之已知設計的支柱（struts）的之潛力受到限制。
熱塑性結構可被用在連桿或拉壓支柱，其中具有大外部尺寸的支柱可在預定的安裝空間內實現。
在熱固性基體之基礎上使用纖維強化管和輪廓時，通常存在一個基本問題，即維持因衝擊所造成的疊層損壞（laminate damage）盡可能的小。昂貴的堅韌改質樹脂系統通常被用來解決有上述問題的衝擊損壞。相比之下，使用熱塑性基體材料對衝擊行為則有正面的影響。
即便纖維強化輪廓的生產成本非常高，然而輪廓的幾何形狀卻非常有限。由熱固性基體製成的輪廓在製作完成後並無法重新塑形，且相較於熱塑性材料，熱固性材料具有較差的衝擊性能。此外，僅有有限數量的熱固性材料具有火災煙霧和毒性（fire smoke and toxicity, FST）認證且可被用於包括航空方面的特定環境。
本技術可提供一種具有輪廓之熱塑性結構，其中所述輪廓藉由連續纖維強化長絲予以強化。所述輪廓可形成作為拉壓支柱及其他支撐結構的基礎。
本創作之一實施例包括具有橫截面輪廓的強化結構，橫截面輪廓具有連續纖維強化長絲和第一基體材料。連續纖維強化長絲係沿著纖維強化元件的縱軸嵌入在第一基體材料中，以形成連續纖維強化元件。
在一些實施例中，強化結構更包括第二基體材料。所述連續纖維強化元件係嵌入在第二基體材料中，以形成橫截面輪廓。
在一變化例中，第一基體材料和第二基體材料為不同的材料。在另一變化例中，第一基體材料和第二基體材料為相同的材料。
在一方面中，強化結構的橫截面輪廓可具有一形狀，所述形狀係選自由以下組成的群組：三角形、圓形、矩形和T形。在一實施方式中，橫截面輪廓具有圍繞一中空區域的外輪廓（outer contour），中空區域的形狀係選自由以下組成的群組：三角形、圓形和矩形。
在另一方面中，連續纖維強化元件的橫截面輪廓可為一形狀，所述形狀係選自由以下組成的群組：三角形、圓形、矩形、梯形和六邊形。在一特定方面中，連續纖維強化元件具有直徑為 0.4 mm或更大的圓形橫截面形狀。
在又一方面中，強化結構包括具有一外輪廓之連續纖維強化元件，以與其他的連續纖維強化元件互鎖（interlocking）或相互嚙合（intermeshing）。
強化結構可具有至少35%之連續纖維強化元件的纖維體積比例。
在一特定實施例中，所述強化結構具有管狀橫截面輪廓。連續纖維強化元件可具有橫截面形狀，所述橫截面形狀係選自由以下組成的群組：三角形、圓形、矩形、梯形和六邊形。在一實施方式中，連續纖維強化元件具有直徑為0.4 mm或更大的圓形橫截面形狀。在任一管狀強化結構中，連續纖維強化元件的纖維體積比例可為至少35%。
在具有管狀截面積輪廓的所述強化結構之一方面中，所述纖維強化元件可具有橫截面形狀，所述橫截面形狀為具有所述管狀橫截面的一直徑（D）的弧段（arc segment）。纖維強化元件形成強化結構的管狀配置。一單向強化帶的纏繞層可被纏繞在弧段的管狀配置之外表面上。
在具有管狀橫截面輪廓的強化結構之另一方面中，纖維強化元件可具有橫截面形狀，所述橫截面形狀為管狀橫截面的一直徑（D）的弧段。弧段形成強化結構的管狀配置，強化結構具有位在纖維強化元件之邊緣之間的間隙。基體材料可圍繞所述管狀配置的外表面，並填充所述間隙。單向強化熱塑性帶的纏繞層可被纏繞在基體材料的外表面上。
本公開的一實施例是一種形成具有管狀橫截面輪廓之強化結構的方法，所述方法包括形成具有管狀橫截面的一直徑（D）的至少二弧段，以及形成具有至少二弧段之強化結構的管狀配置。此可包括纏繞一層在已形成的管狀配置之外表面上。
在形成強化結構的方法之一方面中，相鄰弧段之邊緣在接觸位置相互接觸並接著。在一特定的實施方式中，弧段為互鎖元件以相互接著。
在形成強化結構的方法之另一方面中，存在一間隙在相鄰弧段的邊緣之間，弧段形成管狀配置且施加基體材料在弧段的一外表面上，基體材料填充所述間隙。
在形成具有管狀配置的強化結構的方法之任何方面中，纏繞在外表面上的所述層可為單向強化熱塑性帶。或者，所述層為單向強化熱固帶。在任一這些方面中，所述方法包括在已定義的纏繞進給寬度（winding feed width）及旋轉之一預張力（pretension）下，纏繞所述纏繞層，以及加熱所述纏繞層，以融化所述帶之基體及管狀配置，以幫助接著。
本創作中的術語「包含（comprising）」和「包含（comprises）」可以表示「包括（including）」、「包括（includes）」或「具有（having）」，或者可以具有美國專利法中通常賦予術語「包含（comprising）」或「包含（comprises）」的含義。若申請專利範圍中使用了「基本上由…組成（consisting essentially of）」或「基本上由…組成（consists essentially of）」之用語，其具有美國專利法所賦予它們的含義。本發明的其他方面係在以下公開內容中所描述者或從以下公開內容中顯而易見者（且在本發明的範圍內者）。
術語「線（threads）」、「纖維（fibers）」、「長絲（filaments）」和「紗線（yarns）」在以下描述中可互換使用。如本文所用，「線」、「纖維」、「長絲」和「紗線」可以指單絲（monofilaments）、複絲紗線（multifilament）、加撚紗線（twisted yarns）、複絲絲束（multifilament tows）、變形紗線（textured yarns）、編織紗線（braided yarns）、塗層紗線（coated yarns）、雙組分紗線（bicomponent yarns）以及本領域具有通常知識者所已知的任何材料。紗線可由碳、玻璃纖維、棉、醯胺、聚醯胺、聚酯、金屬、聚乙烯及/或表現出所需物理、熱、化學或其他特性的其他材料製成。
術語「嵌入（embedded）」和「封裝（encapsulated）」可被交互使用。
根據本創作之纖維強化結構可具有以下特徵，輪廓橫截面係使用連續纖維強化元件來填充，以增強例如強度和剛度之機械性能。在一特定應用中，這種纖維強化結構可提供例如為連桿或拉壓支柱之支撐構件的橫截面輪廓，其中具有最大可能外部尺寸的支柱可在預定的安裝空間內實現。
圖1繪示纖維強化元件100的橫截面輪廓。圖中繪示了圓形橫截面形狀，但其他的橫截面形狀，包括但不限於矩形、三角形、梯形、六邊形等，是可考慮的。連續纖維強化元件可具有至少35%的纖維體積含量。纖維強化元件包括嵌入在基體104中的連續纖維強化長絲（filaments）105，連續纖維強化長絲105在纖維強化元件100的長度上是連續的，且分佈在橫截面輪廓上。連續纖維強化元件100可具有至少0.40 mm的直徑。
纖維強化長絲係包括，但不限於以下材料：紡織品、碳、玻璃、玄武岩、塑料、陶瓷、醯胺、聚酯、尼龍和人造絲。基體材料包括，但不限於：聚丙烯（polypropylene，PP）、聚醯胺（polyamide，PA）、丙烯腈丁二烯苯乙烯（acrylonitrile butadiene styrene，ABS）、聚乙烯亞胺（polyethylene imine，PEI）、聚鄰苯二甲醯胺（polyphthalamide，PPA）、聚苯硫醚（polyphenylene sulfide，PPS）、聚芳醚酮（polyaryletherketone，PAEK）、聚醚酮酮（polyetherketoneketone，PEKK）或聚醚醚酮（polyetheretherketone，PEEK）。紡織品包括單纖維長絲或由玻璃、碳、玄武岩、陶瓷和/或塑料製成的粗紗（rovings），以形成編織纖維（woven fabrics）、編織物（braids）、針織物（knitted fabrics）和無緯織物（laid fabrics）。
熱塑性連續纖維強化元件可例如透過拉擠成型程序（pultrusion）製造而得，其中連續纖維強化長絲係被供給到拉擠成型程序之中。
圖2繪示纖維強化元件200，其以矩形橫截面連續強化全輪廓且具有連續纖維強化的全輪廓，且具有嵌入在基體材料204中的纖維強化長絲205。所述纖維強化元件的尺寸可等於或大於0.5英吋（12.7 mm）的寬度，乘以0.008英吋（0.2 mm）的厚度。
圖3繪示編織纖維增強元件300的橫截面，其包括基體材料304及與纖維310互織的紡織強化長絲307。透過使用半完成的紡織品，可在含有纖維310之元件300之縱軸的橫向上實現額外強化。為方便起見，元件300被繪示為具有矩形的橫截面形狀，因為任何形狀都是可被考慮的。紡織強化長絲307被繪示為具有橢圓形的橫截面形狀，但任何形狀都可被考慮。此外，當受到壓縮力時，紡織強化長絲307的形狀可被改變。
編織纖維強化元件300可以相互組合，以形成具有如本說明書所述任何期望之橫截面輪廓的強化結構。
圖4A至圖4D繪示結構元件之橫截面形狀的非限制性示例，結構元件可包括本說明書上述的纖維強化元件。為方便起見，係以圓形纖維增強元件呈現，然而其他形狀可被考慮。圖4A至圖4C的橫截面形狀為所述形狀的周邊的外輪廓。亦即，結構元件的周邊圍繞著中空區域H。
圖4A繪示圓形結構元件400，圓形結構元件400係包括嵌入在基體材料430中的纖維強化元件410。如同前述，基體材料430與纖維強化元件410中的基體材料可以相同或不同。圖4B繪示矩形結構元件404，矩形結構元件404係包括嵌入在基體材料430中的纖維強化元件410。圖4C繪示三角形結構元件406，三角形結構元件406係包括嵌入在基體材料430中的纖維強化元件410。圖4D繪示T形結構元件408，T形結構元件408係包括嵌入在基體材料430中的纖維強化元件410。圖4A至圖4D示出了可由纖維強化元件形成的結構元件形狀的示例。其他結構元件形狀為可考慮的。
圖5繪示與連續纖維強化長絲510相關的連續纖維強化互鎖元件500的區段。纖維強化長絲可類似於如前圖1之部分所述。纖維強化長絲可沿元件500之長度且單向地放置並嵌入在基體材料540中。
基於其功能性外輪廓502，連續纖維強化元件500可互鎖或相互嚙合。互鎖元件500示出了一種可能的互鎖功能性外輪廓502，外輪廓502具有頭部504和尾部506。頭部504係成形以互鎖或嵌套（nest）在如圖6所示的尾部506中。本領域具有通常知識者已知的其他互鎖功能性外輪廓，在不脫離本創作技術的發明概念下，係可考慮的。
圖6繪示強化結構600的一實施方式，強化結構600包括至少二互鎖纖維強化元件500。纖維強化結構600可具有任何期望的外部形狀，其可藉由基體材料640中的至少二纖維強化元件500的互鎖，以形成期望的外部形狀602。其中基體材料640與纖維強化互鎖元件的所述基體材料540可以相同或不同。
圖7繪示纖維強化元件702之另一實施方式的橫截面，纖維強化元件702包括嵌入在基體材料706中的纖維強化長絲705。纖維強化元件702可為一圓的弧段。元件702的厚度W可為1 mm，但任何期望的厚度也可被形成。
圖8繪示出了強化管狀結構801的橫截面，強化管狀結構801係由纖維強化元件802、804、806、808所形成。各纖維強化元件802、804、806、808可為一圓的弧段，弧段之形成可如圖7之部分所討論。所述元件802、804、806、808形成具有直徑D的圓，所述圓可被纏繞層803包圍並接觸在元件802、804、806、808的外側上。如圖繪示，各纖維強化元件802、804、806、808為四分之一（90度）的弧段。圖8所繪示係為方便解釋，因為可以有兩個或更多的纖維強化元件。此外，這些元件可為任意度數的弧段且不需為相同度數的弧段。
元件802、804、806、808可在接觸位置810組裝，以形成管狀結構。元件802、804、806、808可透過本領域具有通常知識者所知的任何已知機制，在接觸位置810彼此接著。或者，所述弧段可預先固定在心軸（mandrel）上，所述心軸具有接著點以接著或等同接著在所述弧段的內表面上。此外，元件802、804、806、808可作為互鎖元件，以如圖5之部分所討論的方式相互接著。如後將述，可透過纏繞在所述已形成的管狀結構周圍的單向強化熱塑性帶來形成纏繞層803。
圖9繪示強化管狀結構901之橫截面，強化管狀結構901係由纖維強化元件902、904、906、908所形成。各纖維強化元件902、904、906、908可為一圓的弧段，所述弧段之形成可如圖7之部分所討論。元件902、904、906、908形成一圓，且在所述圓的弧段之間具有間隙910。基體材料914可填充間隙910，且還圍繞並接觸在元件的外側上，這可透過共擠出製程（co-extrusion）或其他已知方式來實現。纏繞層903可圍繞並接觸基體材料914的外側上。如後將述，可透過纏繞在已形成的管狀結構周圍的單向強化熱塑性或熱固性帶來形成纏繞層903。圖9所繪示是為方便解釋，因為可以有兩個或更多的纖維強化元件。此外，這些元件可為任意度數的弧段且不需為相同度數的弧段。
圖10A繪示第一製程步驟，其中弧段元件1002，可為弧段元件802、804、806、808，係定位在心軸1007上。
圖10B繪示第二製程步驟，其中位於心軸1007上的弧段元件1002係透過由單向強化熱塑性帶1012製成的纏繞層1003來強化。所示的纏繞層1003係例如透過熱塑性纏繞所產生的環向纏繞（hoop winding），其中熱源1008融化所述帶1012的所述基體，且係在預張力1010下纏繞並伴有一已定義的纏繞進給寬度1011及旋轉1009。透過環向纏繞，弧段元件係固定且強化在管體中。纏繞層也可為交叉纏繞層（cross-wound layers）。透過交叉纏繞層，所述纏繞層偏離約90°之環向纏繞角至弧段的縱軸。例如，帶的交叉纏繞層可以±45°纏繞於弧段的縱軸。其他的纏繞角度也是可考慮的。所述纏繞層可為一層或多於一層。
纏繞過程可為不連續的或連續的。在連續纏繞的情況下，弧段元件可透過共擠出製程來預先固定。或者，管狀結構的弧段可直接地被拉擠（pultruded），而無需製造纖維強化元件的中間步驟。此外，與不連續纏繞相比，纏繞器（winder）會旋轉，而不是部件旋轉。在連續纏繞的情況下，預先固定可足以消除心軸。
其他的實施方式也涵蓋在以下的申請專利範圍內。
100:纖維強化元件 104:基體 105:連續纖維強化長絲 200:纖維強化元件 204:基體材料 205:纖維強化長絲 300:編織纖維強化元件 304:基體材料 307:紡織強化長絲 310:纖維 400:圓形結構元件 404:矩形結構元件 406:三角形結構元件 408:T形結構元件 410:纖維強化元件 430:基體材料 500:連續纖維強化元件（互鎖元件） 502:外輪廓 504:頭部 506:尾部 510:連續纖維強化長絲 540:基體材料 600:強化結構 602:外部形狀 640:基體材料 702:纖維強化元件 705:纖維強化長絲 706:基體材料 801:強化管狀結構 802、804、806、808:纖維強化元件 803:纏繞層 810:接觸位置 901:強化管狀結構 902、904、906、908:纖維強化元件 903:纏繞層 910:間隙 914:基體材料 1002:弧段元件 1003:纏繞層 1007:心軸 1008:熱源 1009:旋轉 1010:預張力 1011:已定義的纏繞進給寬度 1012:單向強化熱塑性帶 H:中空區域 W:厚度
[圖1]繪示具有圓形橫截面的纖維強化元件的橫截面輪廓。 [圖2]繪示具有矩形橫截面的纖維強化元件的橫截面輪廓。 [圖3]繪示編織纖維強化元件的橫截面。 [圖4A至圖4D]繪示包括纖維強化元件的結構元件之橫截面形狀的示例。 [圖5]繪示連續纖維強化互鎖元件的橫截面輪廓。 [圖6]繪示包括圖5的至少二互鎖纖維強化元件的結構管狀元件之橫截面形狀的細節。 [圖7]繪示具有弧段輪廓之纖維強化元件的橫截面。 [圖8]繪示使用圖7之元件的第一強化管狀結構與強化層結合的橫截面輪廓。 [圖9]繪示使用圖7之元件的第二強化管狀結構與強化層結合的橫截面輪廓。 [圖10A至圖10B]繪示用以施加環向層（hoop layer）以固定具有弧段輪廓的若干個纖維強化元件以實現強化管狀結構的機制。
100:纖維強化元件
104:基體材料
105:連續纖維強化長絲

Claims (25)

  1. 一種具有橫截面輪廓（404, 406, 408, 600, 801, 901）的強化結構，包括： 連續纖維強化長絲（105, 205, 307, 510, 705）；以及 一第一基體材料（104, 204, 304, 540, 706）， 其特徵在於，該些連續纖維強化長絲係沿一纖維強化元件的一縱軸嵌入該第一基體材料中，以形成連續纖維強化元件（100、200、300、500、702）。
  2. 如請求項1所述的強化結構，包括： 一第二基體材料（430, 640）， 其中該些連續纖維強化元件係嵌入該第二基體材料中，以形成該橫截面輪廓。
  3. 如請求項2所述的強化結構，其中該第一基體材料和該第二基體材料為不同的材料。
  4. 如請求項2所述的強化結構，其中該第一基體材料和該第二基體材料為相同的材料。
  5. 如請求項1至4中任一項所述的強化結構，其中該橫截面輪廓具有一形狀，該形狀係選自由以下組成的群組：三角形、圓形、矩形和T形。
  6. 如請求項5所述的強化結構，其中該橫截面輪廓具有圍繞一中空區域的一外輪廓，該中空區域的形狀係選自由以下組成的群組：三角形、圓形和矩形。
  7. 如請求項1至6中任一項所述的強化結構，其中該些連續纖維強化元件具有一橫截面形狀，該橫截面形狀係選自由以下組成的群組：三角形、圓形、矩形、梯形和六邊形。
  8. 如請求項1至7中任一項所述的強化結構，其中該些連續纖維強化元件具有一外輪廓，用於與其他連續纖維強化元件互鎖或相互嚙合。
  9. 如請求項1至8中任一項所述的強化結構，其中該些纖維強化元件係彼此互鎖，並嵌入一第二基體材料中。
  10. 如請求項7或9所述的強化結構，其中該些連續纖維強化元件具有直徑為0.4 mm或更大的一圓形橫截面形狀。
  11. 如請求項1至10中任一項所述的強化結構，其中該連續纖維強化元件的纖維體積比例為至少35%。
  12. 如請求項1所述的強化結構，其中該橫截面輪廓為管狀。
  13. 如請求項12所述的強化結構，其中該些連續纖維強化元件具有一橫截面形狀，該橫截面形狀係選自由以下組成的群組：三角形、圓形、矩形、梯形和六邊形。
  14. 如請求項13所述的強化結構，其中該些連續纖維強化元件具有直徑為0.4 mm或更大的一圓形橫截面形狀。
  15. 如請求項12至14中任一項所述的強化結構，其中該連續纖維強化元件的纖維體積比例為至少35%。
  16. 如請求項12至15中任一項所述的強化結構，其中該些纖維強化元件（702, 802, 804, 806, 808, 902, 904, 906, 908）具有一橫截面形狀，該橫截面形狀為具有該管狀橫截面的一直徑（D）的一弧段。
  17. 如請求項16所述的強化結構，包括： 纖維強化元件（802, 804, 806, 808），形成該強化結構之一管狀配置；以及 一單向強化帶的一纏繞層（803），纏繞在該管狀配置的一外表面上。
  18. 如請求項16所述的強化結構，包括： 纖維強化元件（902, 904, 906, 908），形成該強化結構之一管狀配置，該強化結構具有位在該些纖維強化元件之邊緣之間的間隙（910）； 一單向強化熱塑性帶的一纏繞層（903），纏繞在該第二基體材料的一外表面上。
  19. 一種具有如請求項12所述的管狀橫截面輪廓之強化結構的形成方法，包括： 形成具有該管狀橫截面的一直徑（D）的至少二弧段； 形成具有該至少二弧段之該強化結構的一管狀配置；以及 纏繞一層在已形成的該管狀配置之一外表面上。
  20. 如請求項19所述的強化結構的形成方法，其中該些相鄰弧段之邊緣在接觸位置相互接觸並接著。
  21. 如請求項19所述的強化結構的形成方法，其中該些弧段為互鎖元件以相互接著。
  22. 如請求項19所述的強化結構的形成方法， 其中，一間隙位於形成該管狀配置之該些相鄰弧段的邊緣之間，以及 施加一基體材料在該些弧段的一外表面上，該基體材料填充該些間隙。
  23. 如請求項19至22中任一項所述的強化結構的形成方法，其中該纏繞層為單向強化熱塑性帶。
  24. 如請求項19至22中任一項所述的強化結構的形成方法，其中該纏繞層為單向強化熱固性帶。
  25. 如請求項23或24所述的強化結構的形成方法，包括： 在已定義的纏繞進給寬度及旋轉之一預張力下，纏繞該纏繞層；以及 加熱該纏繞層，以融化該帶之一基體及加熱該管狀配置。
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