WO2011064436A1 - Unión de elementos de estructuras aeronáuticas con otros elementos termoplásticos - Google Patents

Unión de elementos de estructuras aeronáuticas con otros elementos termoplásticos Download PDF

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Publication number
WO2011064436A1
WO2011064436A1 PCT/ES2010/070776 ES2010070776W WO2011064436A1 WO 2011064436 A1 WO2011064436 A1 WO 2011064436A1 ES 2010070776 W ES2010070776 W ES 2010070776W WO 2011064436 A1 WO2011064436 A1 WO 2011064436A1
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WO
WIPO (PCT)
Prior art keywords
thermoplastic
elements
layer
union
reinforced
Prior art date
Application number
PCT/ES2010/070776
Other languages
English (en)
French (fr)
Inventor
Angeles SÁNCHEZ BLÁZQUEZ
Original Assignee
Airbus Operations, S.L.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Airbus Operations, S.L. filed Critical Airbus Operations, S.L.
Publication of WO2011064436A1 publication Critical patent/WO2011064436A1/es

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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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5007—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like characterised by the structure of said adhesive tape, threads or the like
    • B29C65/5028—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like characterised by the structure of said adhesive tape, threads or the like being textile in woven or non-woven form
    • 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
    • B29C65/76—Making non-permanent or releasable joints
    • 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
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
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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
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/434—Joining substantially flat articles for forming corner connections, fork connections or cross connections
    • B29C66/4344—Joining substantially flat articles for forming fork connections, e.g. for making Y-shaped pieces
    • B29C66/43441—Joining substantially flat articles for forming fork connections, e.g. for making Y-shaped pieces with two right angles, e.g. for making T-shaped pieces, H-shaped pieces
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    • 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
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    • B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
    • B29C66/474—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially non-flat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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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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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/72—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 characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
    • B29C66/72141—Fibres of continuous length
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    • 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
    • B29C66/73—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 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
    • B29C66/739—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 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 material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—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 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 material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • 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
    • B29C66/70—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
    • B29C66/73—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 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
    • B29C66/739—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 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 material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—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 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 material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
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    • B29C66/91931—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature in explicit relation to the fusion temperature or melting point of the material of one of the parts to be joined
    • B29C66/91935—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to another temperature, e.g. to the softening temperature or softening point, to the thermal degradation temperature or to the ambient temperature in explicit relation to the fusion temperature or melting point of the material of one of the parts to be joined lower than said fusion temperature
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/20—Inserts
    • B29K2105/206—Meshes, lattices or nets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3076—Aircrafts
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/10—Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]
    • Y10T442/102—Woven scrim
    • Y10T442/172—Coated or impregnated
    • Y10T442/178—Synthetic polymeric fiber

Definitions

  • the present invention relates to the joining by welding of elements that are part of aeronautical structures, said elements being made of composite material, with other thermoplastic elements also belonging to aeronautical structures.
  • Mechanical assembly involves the use of different fastening methods to mechanically hold two (or more) elements together.
  • the fastening methods involve the use of additional elements, called fasteners, which are added to the elements to be assembled during said assembly operation.
  • the clamping mechanism implies a special forming on one of the elements to be assembled, so that no additional fasteners are necessary.
  • Mechanical clamping methods are divided into two main classes: the methods that allow disassembly and the methods that create a permanent bond. Threaded fasteners such as screws, bolts and nuts are examples of the first mechanical fastening method, while the rivets illustrate the second.
  • a welding technique can be used, which is usually achieved by melting part of the pieces to be joined or by melting a material of intermediate contribution in such a way that a single final piece is obtained in which there is no physical discontinuity, this union being made by an increase in temperature of the surfaces of the pieces to be welded, placed in contact. It is also possible, as mentioned above, to make this union by using adhesives, using in this case a polymer that adheres to the pieces to be joined.
  • the one of mechanical type joints has the disadvantages of needing threaded elements that require in addition to modifications in the parts to be assembled (drilling or tapping, for example), as well as a greater number of parts (screws, rivets, etc.), which always contributes to not meeting the mentioned priority of weight reduction.
  • thermoplastic material that are placed on the composite material prior to the manufacturing process thereof, such that, after a curing process, they are embedded in said composite material, to perform by means of them union with other thermoplastic elements using ultrasonic welding.
  • these layers or films presented the problem that they could become detached over the life of the composite material on which they adhered.
  • the union achieved had deficiencies of resistance and reliability, especially when these joints were to be used in the field of aeronautics.
  • the present invention is oriented to solve the aforementioned problem.
  • the present invention refers to the joining by ultrasonic welding of elements that are part of aeronautical structures, said elements being made of composite material, with other thermoplastic elements also belonging to aeronautical structures.
  • the composite element (called a substrate) comprises a layer of thermoplastic material, in the form of interwoven mesh and with a very small light, called carrier, this layer of thermoplastic material (carrier) being embedded in the breast of the structure of the most superficial layer of the composite material (substrate) with respect to the thermoplastic element (called fitting) on which said element (substrate) is to be attached.
  • said fitting can also be constituted by thermoplastic material that contains some type of reinforcement, as for example with fittings made of thermoplastic matrix composite material reinforced with fiberglass.
  • the element of the aeronautical structure (fitting) to be joined with the other thermoplastic element (carrier) is of the metallic type
  • said element must comprise, according to the invention, a layer of thermoplastic material, said layer being adhered on the outer surface of said element (fitting) with respect to the thermoplastic element (carrier) on which said element (substrate) is to be attached, whereby it becomes again in a similar case to that previously described.
  • the composite element (substrate) with the layer of thermoplastic material (carrier) embedded in its structure joins with the other thermoplastic or thermoplastic reinforced element (fitting) by a process of ultrasonic welding, being made a stable and permanent joint but at the same time removable, and obtaining a piece of unit type.
  • the element comprises, according to the invention, a layer of thermoplastic material (carrier), makes it possible to use ultrasonic welding to join it with another thermoplastic or thermoplastic reinforced element (fitting), being the uniting elements of the same nature.
  • thermoplastic material carrier
  • the invention relates to a method for joining elements that are part of aeronautical structures, said elements being made of composite material, with other thermoplastic or thermoplastic reinforced elements also belonging to aeronautical structures.
  • This method comprises the following stages:
  • Figure 1 shows in diagram the union of elements that are part of aeronautical structures with other thermoplastic or thermoplastic reinforced elements also belonging to aeronautical structures, according to the present invention.
  • Figure 2 shows a cross section in detail of the layer of thermoplastic material embedded in the outer surface of the composite element according to the present invention.
  • FIG 3 shows in schematic the method for joining elements that are part of aeronautical structures with other thermoplastic or thermoplastic reinforced elements also belonging to aeronautical structures, according to the present invention.
  • the present invention develops, in a first aspect, the connection by ultrasonic welding of elements 1 that are part of aeronautical structures (called substrates), said elements 1 being made of composite material, with other thermoplastic elements 2 (called fittings) also belonging to aeronautical structures.
  • said element 2 (fitting) may also be constituted of thermoplastic material containing some type of reinforcement, as for example occurs with 2 fittings made of fiberglass reinforced thermoplastic matrix composite material.
  • the element 1 is made of composite material and comprises a layer 3 of thermoplastic material, in the form of interwoven fabric mesh and with a very small light, called a carrier, this layer 3 being embedded within the structure of the more superficial layer of the composite material 1 with respect to the reinforced thermoplastic or thermoplastic element 2 on which said element 1 is to be attached.
  • the light 10 of the mesh that forms the layer 3 of thermoplastic material must be of a size such that it allows the resin to flow through said layer 3 so that it is perfectly embedded within the structure of the composite element 1 and , at the same time, it must provide the necessary points of union to achieve a perfect union, these points of union being constituted by the nodes of the previous mesh (see Figure 2).
  • a non-limiting example of the magnitude of said mesh light 10 could range from 0.20 to 0.25 mm.
  • Figure 2 shows in detail, in a cross-sectional section, in which the fibers of composite material of the element 1 are located at 90 °, how the layer 3 of thermoplastic material is embedded in said element 1.
  • the element 2 (fitting) to be joined with the other element of the aeronautical structure 1 (substrate) is of the metallic type
  • said element 2 must comprise, according to the invention, a layer of thermoplastic material, being said layer of thermoplastic material adhered on the outer surface of said element 2 with respect to element 1 with which said element 2 is to be attached, whereby it becomes again in a similar case to that previously described.
  • this element 1 of composite material with the layer 3 of thermoplastic material embedded in its structure joins with the other reinforced thermoplastic or thermoplastic element 2 by an ultrasonic welding process, a stable and permanent type connection being made, but at the same time removable, and obtaining a unit type piece, as shown in the diagram in Figure 1.
  • the fact that the element 1 comprises a layer 3 of thermoplastic material makes it possible to use ultrasonic welding to join it with another thermoplastic or thermoplastic reinforced element 2, as the elements to be joined, 2 and 3, thereof nature.
  • the layer 3 of thermoplastic material makes it possible for the element 1 of the aeronautical structure to be joined with another element 2 to be thermosetting, thermoplastic, or a mixture of thermoplastic material and thermosetting material.
  • the composite element 1 comprises a layer 3 of thermoplastic material in the form of interwoven fabric, this layer 3 being embedded in the surface of said element 1 during curing, to subsequently ultrasonically weld the other element 2 of Thermoplastic or thermoplastic reinforced material with which it will be joined.
  • This element 2 is of the same chemical nature as the aforementioned interwoven fabric that forms the previous layer 3.
  • the mentioned layer 3 is usually called a carrier because it is usually used as a "support” for fluid sizing products that, by capillarity through its small openings (light of the mesh that forms it), propitiates and facilitates a good extension of said product fluid in the sizing processes.
  • the aforementioned layer 3 (or carrier) is a lightweight, thermoplastic material that is embedded on top of the last of the carbon fiber fabrics from which the composite material of element 1 is formed, if it is one of composite material. The material of the layer 3 is conferred with the relevant curing process together with the element 1, so that it hardens and is embedded in the element 1.
  • FIG. 2 A non-limiting example of an illustrative micrograph of the position of the layer 3 or carrier with respect to the carbon fibers of the element 1 is shown in Figure 2, as discussed above.
  • the ultrasonic welding process is carried out so that the elements remain permanently attached and at the same time their extraction is feasible.
  • no fusion occurs and welding is achieved by applying pressure and heat through the friction of the surfaces to be joined until reaching the forging temperature of the material due to friction and the pressure exerted. Since no fusion occurs, this technique allows to unite dissimilar materials.
  • ultrasonic welding friction is achieved through the application of oscillatory pressures caused by shock waves that affect the surfaces to be joined with ultrasonic frequency. This oscillation causes an intimate contact achieving the union.
  • a device comprising a transducer is used, which in turn converts the electrical energy into a high frequency vibratory movement applied in the direction 5 by means of an adapter 4, as shown in the diagram in Figure 3.
  • the necessary pressures are low and are used to join small thicknesses and soft materials, as for example with polymers (thermoplastic materials), aluminum or copper, among the metallic materials.
  • the element 1 is made of composite material, and comprises a sufficient amount of thermoplastic material, said part of thermoplastic material being arranged in the structure of the element 1 of composite material, it is possible to join said element 1 with the element 2 of thermoplastic or thermoplastic material directly reinforced, using ultrasonic welding, without the need for element 1 to comprise layer 3 (carrier) of thermoplastic material.
  • the invention relates to a method for making the joining of elements 1 that are part of aeronautical structures, said elements 1 being made of composite material, with other Thermoplastic or thermoplastic reinforced elements 2 also belonging to aeronautical structures.
  • This method comprises the following stages:

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Abstract

Unión de elementos (1) que forman parte de estructuras aeronáuticas, estando dichos elementos (1) realizados en material compuesto, con otros elementos termoplásticos o termoplásticos reforzados (2) pertenecientes también a estructuras aeronáuticas, comprendiendo dicho elemento (1) al menos una parte de su estructura realizada en material termoplástico, estando dispuesta dicha parte de material termoplástico en la estructura de la capa más superficial del elemento (1) de material compuesto,con respecto al elemento termoplástico o termoplástico reforzado (2) con el que va a unirse, de tal modo que la unión entre los elementos (1, 2) se realiza por medio de soldadura ultrasónica sin fusión, aplicándose presión y calor a través de la fricción de las superficies de los elementos a unir (1, 2), consiguiéndose de este modo una unión permanente de los elementos (1, 2), siendo al mismo tiempo posible su extracción.

Description

UNIÓN DE ELEMENTOS DE ESTRUCTURAS AERONÁUTICAS CON OTROS
ELEMENTOS TERMOPLÁSTICOS CAMPO DE LA INVENCION
La presente invención se refiere a la unión mediante soldadura de elementos que forman parte de estructuras aeronáuticas, estando dichos elementos realizados en material compuesto, con otros elementos termoplásticos pertenecientes también a estructuras aeronáuticas.
ANTECEDENTES DE LA INVENCION
A lo largo de la historia, tanto en la industria aeronáutica como en otros sectores industriales, se han utilizado básicamente tres tipos de uniones para ensamblar componentes: el ensamblaje mecánico, como tipo de unión permanente o no permanente; las uniones soldadas y las uniones adhesivas, como tipos de uniones permanentes.
El ensamblaje de tipo mecánico implica el uso de diferentes métodos de sujeción para mantener unidas de forma mecánica dos (o más) elementos. En la mayoría de los casos, los métodos de sujeción implican el uso de elementos adicionales, llamados sujetadores, que se agregan a los elementos que van a ensamblarse durante la citada operación de ensamblado. En otros casos, el mecanismo de sujeción implica un conformado especial sobre uno de los elementos que se van a ensamblar, con lo que no son necesarios sujetadores adicionales. Los métodos de sujeción mecánica se dividen en dos clases principales: los métodos que permiten el desensamblaje y los métodos que crean una unión permanente. Los sujetadores roscados como tornillos, pernos y tuercas son ejemplos del primer método de sujeción mecánica, mientras que los remaches ilustran el segundo.
En el caso particular de la industria aeronáutica, los materiales más empleados en la actualidad, debido a sus propiedades de resistencia y bajo peso son los materiales compuestos, también denominados composites. Así, existen muchos elementos, de material compuesto, que conforman estructuras aeronáuticas y que comprenden distintas partes o piezas que deben ser montadas unas con otras, de tal modo que sean ensambladas de forma no permanente, para permitir así posteriores reparaciones o sustituciones. Sin embargo, existen también elementos de material compuesto que conforman estructuras aeronáuticas y que comprenden distintas partes o piezas, siendo muy complejo el fabricar de una sola pieza dichos elementos, por lo que se opta por fabricar diversas piezas, que posteriormente se unirán de forma permanente para conformar los citados elementos. En este último caso, las uniones permanentes de las distintas partes o piezas que conforman estos elementos se pueden realizar por soldadura o bien mediante el empleo de adhesivos.
Para realizar la citada unión de elementos de material compuesto que conforman estructuras aeronáuticas que comprenden distintas partes o piezas unidas de forma permanente, se puede emplear una técnica de soldadura, lo cual se consigue habitualmente fundiendo parte de las piezas a unir o bien fundiendo un material de aporte intermedio de tal forma que se obtenga una única pieza final en la que no exista discontinuidad física, realizándose esta unión mediante un incremento de temperatura de las superficies de las piezas a soldar, colocadas en contacto. También es posible, según se ha comentado anteriormente, realizar esta unión mediante el empleo de adhesivos, utilizándose en este caso un polímero que se adhiere a las piezas que se van a unir.
Generalmente, no hay un método simple de unión permanente que constituya la mejor elección para los elementos de material compuesto que conforman estructuras aeronáuticas. Sin embargo, la unión mediante adhesivos suele ser un buen método cuando se trata de unir piezas de materiales físicamente disimilares o metalúrgicamente incompatibles, polímeros termoestables, cerámicos, elastomeros, materiales muy delgados o sustratos de tamaño muy pequeño. El problema que plantean estas uniones con adhesivos está en que son necesarios elevados tiempos de fabricación para realizarlas, mermándose así sustancialmente su viabilidad industrial. La problemática asociada con las uniones de tipo mecánico se basa en el elevado peso que añaden las piezas adicionales (sujetadores) necesarias para realizar estas uniones, generalmente realizadas en metal, y por tanto con una elevada densidad, lo cual es contraproducente en el ámbito de la industria aeronáutica, en el que la prioridad de los nuevos desarrollos pasa por la reducción en peso.
De los métodos anteriormente citados, el de uniones de tipo mecánico lleva asociados los inconvenientes de necesitar de elementos roscados que precisan además de modificaciones en las piezas que se van a ensamblar (taladrado o roscado, por ejemplo), así como un mayor número de piezas (tornillos, remaches, etc.), lo cual siempre contribuye a no cumplir con la mencionada prioridad de reducción en peso.
Por otro lado, el método de unión mediante adhesivos no alcanza suficiente resistencia en la unión como alcanzan las uniones soldadas.
Por las razones anteriormente mencionadas, el método más económico
(en términos de materiales y costes de fabricación) y fiable para realizar la unión de este tipo de elementos es el de la soldadura.
Se conoce el uso de soldadura por ultrasonidos de uniones encoladas de elementos de material compuesto de matriz termoplástica que conforman estructuras aeronáuticas que comprenden distintas partes o piezas. Sin embargo, la unión por soldadura ultrasónica de forma directa, no es factible cuando se emplea para unir elementos de material compuesto de matriz termoestable o con un cierto porcentaje de termoestable en su composición.
Se conoce en la técnica el uso de filmes de material termoplástico que se sitúan sobre el material compuesto previamente al proceso de fabricación del mismo, de tal forma que, tras un proceso de curado, queden embebidas en dicho material compuesto, para realizar mediante ellas la unión con otros elementos termoplásticos empleando la soldadura por ultrasonidos. Sin embargo, estas capas o filmes presentaban el problema de que podían llegar a despegarse a lo largo de la vida útil del material compuesto sobre el que se adherían. Por otro lado, la unión conseguida presentaba deficiencias de resistencia y fiabilidad, máxime cuando dichas uniones iban a ser empleadas en el campo de la aeronáutica.
La presente invención está orientada a solucionar la problemática anteriormente mencionada.
SUMARIO DE LA INVENCION
Así, la presente invención, según un primer aspecto, se refiere a la unión mediante soldadura por ultrasonidos de elementos que forman parte de estructuras aeronáuticas, estando dichos elementos realizados en material compuesto, con otros elementos termoplásticos pertenecientes también a estructuras aeronáuticas.
Según la invención, el elemento de material compuesto (denominado sustrato) comprende una capa de material termoplástico, en forma de malla de tejido entrelazado y con una luz muy pequeña, denominado carrier, estando esta capa de material termoplástico (carrier) embebida en el seno de la estructura de la capa más superficial del material compuesto (sustrato) con respecto al elemento termoplástico (denominado fitting) sobre el que va a unirse dicho elemento (sustrato). Asimismo, según la invención, dicho fitting también puede estar constituido por material termoplástico que contenga algún tipo de refuerzo, como por ejemplo ocurre con los fittings de material compuesto de matriz termoplástica reforzada con fibra de vidrio.
En el caso particular de que el elemento de la estructura aeronáutica (fitting) que va a unirse con el otro elemento termoplástico (carrier) sea de tipo metálico, dicho elemento deberá comprender, según la invención, una capa de material termoplástico, estando dicha capa adherida sobre la superficie exterior del citado elemento (fitting) con respecto al elemento termoplástico (carrier) sobre el que va a unirse dicho elemento (sustrato), con lo que se vuelve a estar en un caso similar al descrito previamente.
Posteriormente, el elemento de material compuesto (sustrato) con la capa de material termoplástico (carrier) embebida en su estructura se une con el otro elemento termoplástico o termoplástico reforzado (fitting) mediante un proceso de soldadura por ultrasonidos, quedando realizada una unión estable y de tipo permanente pero al mismo tiempo extraíble, y obteniéndose una pieza de tipo unitario.
El hecho de que el elemento (sustrato) comprenda, según la invención, una capa de material termoplástico (carrier), hace posible que se pueda emplear la soldadura por ultrasonidos para unirlo con otro elemento termoplástico o termoplástico reforzado (fitting), al ser los elementos a unir de la misma naturaleza.
Por otro lado, para el caso de elementos de material compuesto, al ir la capa de material termoplástico embebida en el seno de la estructura de dicho elemento, se evita el problema de despegado y de poca fiabilidad de la unión al emplearse soldadura por ultrasonidos.
Además, la malla de material termoplástico (carrier) hace posible que el elemento de la estructura aeronáutica (sustrato) que se va a unir con otro elemento (fitting) pueda ser termoestable, termoplástico, o bien una mezcla de material termoplástico y de material termoestable.
Según un segundo aspecto, la invención se refiere a un método para realizar la unión de elementos que forman parte de estructuras aeronáuticas, estando dichos elementos realizados en material compuesto, con otros elementos termoplásticos o termoplásticos reforzados pertenecientes también a estructuras aeronáuticas. Este método comprende las siguientes etapas:
a) posicionamiento de una capa de material termoplástico (carrier) sobre la superficie exterior del elemento de material compuesto (sustrato) previamente al proceso de fabricación del elemento de material compuesto (sustrato) de tal forma que, tras un proceso de curado, quede embebida dicha capa (carrier) en el material compuesto (sustrato);
b) preparación de la superficie exterior del elemento de material compuesto (sustrato);
c) unión mediante soldadura por ultrasonidos de la capa de material termoplástico del elemento de la estructura aeronáutica (carrier) con el otro elemento (fitting), aplicando vibración de alta frecuencia con ayuda de un transductor;
d) en caso necesario, extracción del mencionado fitting y soldeo por ultrasonidos de dicho elemento en una nueva posición.
Otras características y ventajas de la presente invención se desprenderán de la descripción detallada que sigue de una realización ilustrativa de su objeto en relación con las figuras que se acompañan. DESCRIPCION DE LAS FIGURAS
La Figura 1 muestra en esquema la unión de elementos que forman parte de estructuras aeronáuticas con otros elementos termoplásticos o termoplásticos reforzados pertenecientes también a estructuras aeronáuticas, según la presente invención.
La Figura 2 muestra una sección transversal en detalle de la capa de material termoplástico embebida en la superficie externa del elemento de material compuesto, según la presente invención.
La Figura 3 muestra en esquema el método para realizar la unión de elementos que forman parte de estructuras aeronáuticas con otros elementos termoplásticos o termoplásticos reforzados pertenecientes también a estructuras aeronáuticas, según la presente invención.
DESCRIPCIÓN DETALLADA DE LA INVENCION
La presente invención desarrolla, en un primer aspecto, la unión mediante soldadura por ultrasonidos de elementos 1 que forman parte de estructuras aeronáuticas (denominados sustratos), estando dichos elementos 1 realizados en material compuesto, con otros elementos termoplásticos 2 (denominados fittings) pertenecientes también a estructuras aeronáuticas. Asimismo, según la invención, dicho elemento 2 (fitting) también puede estar constituido de material termoplástico que contenga algún tipo de refuerzo, como por ejemplo ocurre con los fittings 2 de material compuesto de matriz termoplástica reforzada con fibra de vidrio.
Según la invención, el elemento 1 es de material compuesto y comprende una capa 3 de material termoplástico, en forma de malla de tejido entrelazado y con una luz muy pequeña, denominada carrier, estando esta capa 3 embebida en el seno de la estructura de la capa más superficial del material compuesto 1 con respecto al elemento termoplástico o termoplástico reforzado 2 sobre el que va a unirse dicho elemento 1 . La luz 10 de la malla que conforma la capa 3 de material termoplástico debe ser de un tamaño tal que permita a la resina fluir a través de dicha capa 3 para que quede perfectamente embebida en el seno de la estructura del elemento 1 de material compuesto y, al mismo tiempo, debe proporcionar los puntos de unión necesarios para conseguir una perfecta unión, estando constituidos estos puntos de unión por los nodos de la malla anterior (ver Figura 2). Un ejemplo no limitativo de la magnitud de la mencionada luz 10 de malla podría oscilar entre 0.20 y 0.25 mm.
En la Figura 2 se observa en detalle, en una sección en corte transversal, en que las fibras de material compuesto del elemento 1 están situadas a 90°, cómo está embebida la capa 3 de material termoplástico en dicho elemento 1 .
En el caso particular de que el elemento 2 (fitting) que va a unirse con el otro elemento de la estructura aeronáutica 1 (sustrato) sea de tipo metálico, dicho elemento 2 deberá comprender, según la invención, una capa de material termoplástico, estando dicha capa de material termoplástico adherida sobre la superficie exterior del citado elemento 2 con respecto al elemento 1 con el que va a unirse dicho elemento 2, con lo que se vuelve a estar en un caso similar al descrito previamente.
Posteriormente, este elemento 1 de material compuesto con la capa 3 de material termoplástico embebida en su estructura, se une con el otro elemento termoplástico o termoplástico reforzado 2 mediante un proceso de soldadura por ultrasonidos, quedando realizada una unión estable y de tipo permanente, pero al mismo tiempo extraíble, y obteniéndose una pieza de tipo unitario, como la que se muestra en esquema en la Figura 1 . El hecho de que el elemento 1 comprenda una capa 3 de material termoplástico, hace posible que se pueda emplear la soldadura por ultrasonidos para unirlo con otro elemento termoplástico o termoplástico reforzado 2, al ser los elementos a unir, 2 y 3, de la misma naturaleza.
Por otro lado, para el caso de elementos 1 de material compuesto, al ir la capa 3 de material termoplástico embebida en el seno de la estructura de dicho elemento 1 , se evita el problema de despegado de la unión al emplearse soldadura por ultrasonidos.
La capa 3 de material termoplástico hace posible que el elemento 1 de la estructura aeronáutica que se va a unir con otro elemento 2 pueda ser termoestable, termoplástico, o bien una mezcla de material termoplástico y de material termoestable.
Según se ha comentado, el elemento 1 de material compuesto comprende una capa 3 de material termoplástico en forma de tejido entrelazado, quedando esta capa 3 embebida en la superficie de dicho elemento 1 durante su curado, para posteriormente soldar por ultrasonidos el otro elemento 2 de material termoplástico o termoplástico reforzado con el que va a unirse. Este elemento 2 es de la misma naturaleza química que el mencionado tejido entrelazado que conforma la capa 3 anterior.
La capa 3 mencionada se denomina habitualmente carrier porque suele ser utilizada como "soporte" de productos fluidos de encolado que, por capilaridad a través de sus pequeñas aberturas (luz de la malla que la forma), propicia y facilita una buena extensión de dicho producto fluido en los procesos de encolado. La citada capa 3 (o carrier) es un material termoplástico, ligero y que se encuentra embebido encima de la última de las telas de fibra de carbono a partir de las cuales está formado el material compuesto del elemento 1 , en caso de ser éste de material compuesto. Al material de la capa 3 se le confiere el pertinente proceso de curado junto con el elemento 1 , de modo que se endurezca y quede embebido en el elemento 1 . Un ejemplo no limitativo de una micrografía ilustrativa de la posición de la capa 3 o carrier respecto a las fibras de carbono del elemento 1 se muestra en la Figura 2, según se ha comentado anteriormente. A continuación, una vez que se encuentran solidariamente unidas la capa 3, elemento 1 y el elemento 2, se lleva a cabo el proceso de soldadura por ultrasonidos para que los elementos permanezcan permanentemente unidos y al mismo tiempo sea factible su extracción. En dicho proceso de soldadura no se produce fusión y la soldadura se consigue aplicando presión y calor a través de la fricción de las superficies a unir hasta llegar a la temperatura de forja del material debido al rozamiento y a la presión ejercida. Al no producirse fusión, ésta técnica permite unir materiales disimilares. En la soldadura por ultrasonidos la fricción se consigue por medio de la aplicación de presiones oscilatorias provocadas por ondas de choque que inciden en las superficies a unir con frecuencia ultrasónica. Dicha oscilación provoca un contacto íntimo logrando la unión. El calor generado es muy inferior a las temperaturas de fusión del material y, por lo tanto, no se precisa de ningún tipo de protección para la soldadura. Para aplicar la vibración se utiliza un dispositivo que comprende un transductor que a su vez convierte la energía eléctrica en un movimiento vibratorio de alta frecuencia aplicado en la dirección 5 mediante un adaptador 4, tal y como se representa en esquema en la Figura 3. Las presiones necesarias son bajas y se utilizan para unir pequeños espesores y materiales blandos, como por ejemplo ocurre con los polímeros (materiales termoplásticos), el aluminio o el cobre, de entre los materiales metálicos.
En el caso particular de que el elemento 1 sea de material compuesto, y comprenda una cantidad suficiente de material termoplástico, estando dispuesta dicha parte de material termoplástico en la estructura del elemento 1 de material compuesto, es posible realizar la unión de dicho elemento 1 con el elemento 2 de material termoplástico o termoplástico reforzado de forma directa, empleando soldadura por ultrasonidos, sin necesidad de que el elemento 1 comprenda la capa 3 (carrier) de material termoplástico.
Según un segundo aspecto, la invención se refiere a un método para realizar la unión de elementos 1 que forman parte de estructuras aeronáuticas, estando dichos elementos 1 realizados en material compuesto, con otros elementos 2 termoplásticos o termoplásticos reforzados pertenecientes también a estructuras aeronáuticas. Este método comprende las siguientes etapas:
a) posicionamiento de una capa 3 de material termoplástico sobre la superficie exterior del elemento 1 de material compuesto, previamente al proceso de fabricación de dicho elemento 1 , de tal forma que, tras un proceso de curado, dicha capa 3 quede embebida en el elemento 1 ;
b) preparación de la superficie exterior del elemento 1 de material compuesto;
c) unión mediante soldadura por ultrasonidos a través de la capa 3 de material termoplástico del elemento 1 de la estructura aeronáutica con el otro elemento 2, aplicando una vibración en la dirección 5 de alta frecuencia por medio de un dispositivo que comprende un transductor que a su vez convierte la energía eléctrica en un movimiento vibratorio de alta frecuencia, aplicado en la dirección 5 mediante un adaptador 4; d) extracción en caso necesario del mencionado elemento 2 y soldeo por ultrasonidos de dicho elemento 2 en una nueva posición.
En las realizaciones que acabamos de describir pueden introducirse aquellas modificaciones comprendidas dentro del alcance definido por las siguientes reivindicaciones.

Claims

REIVINDICACIONES
Unión de elementos (1 ) que forman parte de estructuras aeronáuticas, estando dichos elementos (1 ) realizados en material compuesto, con otros elementos termoplásticos o termoplásticos reforzados (2) pertenecientes también a estructuras aeronáuticas, caracterizada porque dicho elemento (1 ) comprende al menos una parte de su estructura realizada en material termoplástico, estando dispuesta dicha parte de material termoplástico en la estructura de la capa más superficial del elemento (1 ) de material compuesto, con respecto al elemento termoplástico o termoplástico reforzado (2) con el que va a unirse, de tal modo que la unión entre los elementos (1 , 2) se realiza por medio de soldadura ultrasónica sin fusión, aplicándose presión y calor a través de la fricción de las superficies de los elementos a unir (1 , 2), consiguiéndose de este modo una unión permanente de los elementos (1 , 2), siendo al mismo tiempo posible su extracción.
Unión de elementos (1 ) según la reivindicación 1 , en la cual el elemento (1 ) de material compuesto comprende una capa (3) de material termoplástico en forma de malla de tejido entrelazado, estando dicha capa (3) embebida en el seno de la estructura de la capa más superficial del elemento (1 ) con respecto al elemento termoplástico o termoplástico reforzado (2).
Unión de elementos (1 ) según la reivindicación 2, en la cual la capa (3) de material termoplástico en forma de malla de tejido entrelazado tiene una luz (10) de un tamaño tal que permita a la resina fluir a través de dicha capa (3), de tal modo que dicha capa (3) quede perfectamente embebida en el seno de la estructura del elemento (1 ).
Unión de elementos (1 ) según la reivindicación 3, en la cual la luz (10) de la malla que conforma la capa (3) tiene un valor comprendido entre 0,20 y 0,25 mm. Unión de elementos (1 ) según cualquiera de las reivindicaciones 3 ó 4, en la cual la malla que conforma la capa (3) comprende unos nodos que sirven de puntos de unión para conseguir una perfecta unión de la capa (3) en el seno de la estructura del elemento (1 ).
Unión de elementos (1 ) según cualquiera de las reivindicaciones anteriores, en la cual el elemento (1 ) es de material termoestable, o de una mezcla de material termoestable y material termoplástico.
Método para realizar la unión de elementos (1 ) que forman parte de estructuras aeronáuticas, estando dichos elementos (1 ) realizados en material compuesto, con otros elementos termoplásticos o termoplásticos reforzados (2) pertenecientes también a estructuras aeronáuticas, caracterizado porque dicho método comprende las siguientes etapas: a) preparación de la superficie exterior del elemento (1 ) de material compuesto, que comprende una parte de la estructura de su superficie exterior realizada en material termoplástico;
b) unión mediante soldadura por ultrasonidos sin fusión de la superficie exterior del elemento (1 ) con la superficie exterior del otro elemento termoplástico o termoplástico reforzado (2).
Método para realizar la unión de elementos (1 ) según la reivindicación 7 que comprende además una etapa previa a la etapa a), en la cual tiene lugar el posicionamiento de una capa (3) de material termoplástico sobre la superficie exterior del elemento (1 ) de material compuesto, previamente al proceso de fabricación de dicho elemento (1 ), de tal forma que, tras un proceso de curado, dicha capa (3) quede embebida en el elemento (1 ). Método para realizar la unión de elementos (1 ) según cualquiera de las reivindicaciones 7-8, el cual, en la etapa b), la unión mediante soldadura por ultrasonidos del elemento (1 ) de la estructura aeronáutica con el otro elemento termoplástico o termoplástico reforzado (2), se realiza aplicando una vibración en una dirección (5) de alta frecuencia por medio de un dispositivo que comprende un transductor que a su vez convierte la energía eléctrica en un movimiento vibratorio de alta frecuencia, aplicado en la dirección (5) mediante un adaptador (4).
10. Método para realizar la unión de elementos (1 ) según cualquiera de las reivindicaciones 5-7, que comprende además, después de la etapa b), una etapa en la cual se realiza la extracción del elemento termoplástico o termoplástico reforzado (2), realizándose posteriormente la unión de dicho elemento (2) mediante soldeo por ultrasonidos en una nueva posición.
PCT/ES2010/070776 2009-11-26 2010-11-25 Unión de elementos de estructuras aeronáuticas con otros elementos termoplásticos WO2011064436A1 (es)

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