CN105408079A - 生产热塑性纤维复合物的工艺及从其形成的风扇叶片 - Google Patents

生产热塑性纤维复合物的工艺及从其形成的风扇叶片 Download PDF

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CN105408079A
CN105408079A CN201480043537.4A CN201480043537A CN105408079A CN 105408079 A CN105408079 A CN 105408079A CN 201480043537 A CN201480043537 A CN 201480043537A CN 105408079 A CN105408079 A CN 105408079A
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P.S.马尼克
D.D.沃德
G.C.格梅因哈德特
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Abstract

一种用于制造热塑性纤维复合物的工艺包括将热塑性树脂加热至液态、单向地定向纤维、利用处于液态的热塑性树脂浸渍纤维来产生复合物薄层，以及执行自动化机器层合工艺来产生包括多个复合物薄层的复合物叠层。

Description

生产热塑性纤维复合物的工艺及从其形成的风扇叶片
本发明的背景
本发明涉及复合材料，并且更具体地涉及用于制造包括浸有聚合树脂的增强织物的复合材料的工艺。
高旁通燃气涡轮发动机的关键构件是风扇区段及其叶片。在从前方(向后看)查看时，风扇叶片是发动机的区别性特征，且是接触进入空气的发动机的最初构件。因此，风扇叶片必须能够在高旁通飞行器发动机所需的速度、高度和入口温度下运行。另外，风扇叶片必须能够缓解多种不利的环境影响，同时经得起且经历鸟类冲击和高速下的其它外来物损坏(FOD)。因此，风扇叶片的操作要求是高度抗冲击。
由于飞行器发动机的额外要求，风扇叶片还优选相对轻量、耐用和坚韧。在改善叶片操作和构造方面进行了大量研究和开发，以便通过具有较低旋转质量、较大损坏容限、较大振动阻尼和增加的空气动力效率来改善发动机性能。当改善叶片韧性时，大体上目标在于改善叶片的持久性和冲击强度，使得叶片可在厚度上减小，同时保持或改善其对破裂和冲击损坏的总体抵抗力。较轻的叶片导致改善的空气动力效率，且总体上减轻发动机的重量、成本和效率。
最近，包括发动机风扇叶片的飞行器发动机中的复合材料的集成和应用得到了较大发展。由聚合物基质复合(PMC)材料制成的风扇叶片包括两个主要构件：聚合树脂材料和由树脂浸渍的纤维增强材料以向复合物提供强度和结构。还考虑了热固性环氧PMC材料，诸如由碳(石墨)纤维或织物增强的环氧叠层，因为它们提供包括能够满足空气动力标准和减轻重量的优点，这促进了发动机效率且改善了比燃料消耗(SFC)。
复合物制造不但涉及浸渍，而且涉及层合工艺。在层合工艺期间，包括浸渍树脂的增强材料的预浸料坯被切割且拉成材料的板层或片。板层然后被切割、缝合或压制成层，以产生浸渍树脂的叠层复合结构，其可根据复合物的操作和用途来定形。
尽管以热固性环氧PMC制造的风扇叶片提供了抗冲击特征且可产生薄的叶片，但需要改善来继续发动机性能增进。
本发明的简要描述
本发明提供了适合于制造热塑性树脂/纤维复合物的工艺，复合物的特别但非限制性的示例包括飞行器发动机风扇叶片翼型件，其包括高旁通燃气涡轮发动机的风扇叶片。
根据本发明的第一方面，一种用于制造热塑性纤维复合物的工艺包括将热塑性树脂加热至液态、单向地定向纤维、可选地涂布纤维以改善复合物损坏容限、利用处于液态的热塑性树脂浸渍纤维来产生复合物薄层，以及执行机器层合工艺来产生包括多个复合物薄层的复合物叠层。
本发明的其它方面包括通过包含上文所述步骤的工艺生产风扇叶片翼型件。
本发明的其它方面和优点将从以下详细描述中更好地认识到。
附图的简要描述
图1呈现了可利用聚合物基质复合材料制造的类型的风扇叶片。
本发明的详细描述
本发明涉及用于制造用于飞行器发动机风扇叶片翼型件中的热塑性树脂/纤维复合物的工艺，包括高旁通燃气涡轮发动机的风扇叶片。
热固性树脂与热塑性树脂之间的差异为热固性树脂在室温下作为液体存在，而热塑性的在室温下作为固体存在。热塑性塑料提供了优于热固性塑料的两个显著优点：它们相比于可比较的热固性复合物具有较大的抗冲击性，且它们可再成形，从而允许它们比可比较的热固性塑料更容易再使用或修理。其较大的抗冲击性使得它们对于用于风扇叶片制造是合乎需要的。然而，在增强的复合物制造中使用热塑性塑料存在复杂性。因为热塑性塑料在室温下是固体，故它们需要再加热来使它们可成形为用于制造。通常，该工艺比涉及可比较的热固性树脂的类似浸渍工艺更耗时且可能成本过高。
简言之，此工艺的实施例涉及使具有热塑性树脂的单向预浸渍(预浸料坯)的增强材料定向来产生复合板层。非限制性示例为作为单向增强材料的碳(石墨)纤维，其浸渍有热塑性树脂，例如，聚醚醚酮(PEEK)，但可使用其它热塑性塑料，其非限制性示例包括聚醚酮酮(PEKK)、聚苯硫(PPS)、聚酰胺亚胺(PAI)和聚醚酰亚胺(PEI)。解偶联剂可作为涂层施加在增强材料上，以进一步改善所得的风扇叶片的复合损坏容限。工艺的另一步骤为机器层合，其中复合物板层被切割且从主体除去。该机器过程是优于手工层合方法的改善。然后执行固结工艺或高压釜处理步骤，其中复合物板层定形且固结。
单向预浸料坯工艺从热塑性树脂和增强材料构造复合材料。将热塑性树脂加热至液态，然后使增强材料浸渍有树脂以形成增强的聚合物基质。如上文所述，增强材料包括单向(纤维)，更优选且特别地是连续的碳(石墨)纤维和玻璃纤维。如本文使用的连续是指，相比于由通常随机地分散在复合物的基质材料中的较短纤维制成的不连续纤维增强材料，增强(纤维)材料由足够长而能够定向成在复合物的基质材料内具有指定的定向(单向)(例如(但不限于)平行于复合物上的负载方向)的纤维或纤维束(丝束)构成。在本发明中，纤维适合于单向浸渍，使得所有浸渍纤维成大致平行于彼此定向且保持。该工艺产生呈现出期望的结构和机械性质的复合材料。
由本发明所体现的解耦工艺涉及将涂层施加到单向增强纤维。涂层可在预浸料坯工艺之前施加，且优选允许纤维作为增强材料与热塑性基质更好地对接。该涂层的结果在于复合基质中分布的损坏机制，以在冲击损坏期间进一步改善复合物韧性。
由本发明所体现的机器层合工艺涉及将复合材料切割和拉制成板层且定形为薄层，其然后堆叠且定形为产生叠层。如本文使用的用语薄层是指整个板层、板层节段和成形和成条的板层的部分。该工艺还可涉及超声波协助的缝合工艺，其中增强纤维可通过多个板层***，从而总体上改善叠层的质量。机器层合工艺在相比于使用人工技术和劳动来切割板层以及构造和定形薄层的常规层合工艺考虑时节省了劳动成本。
最后，该工艺可使用就地固结工艺或高压釜处理以成形和冷却叠层来产生复合制品。固结工艺优选使用固结力来压制叠层和其板层/薄层成期望形状，且大体上为层合工艺的一部分。高压釜处理将叠层置于高压装置中以定形最终的复合物。适合的高压釜温度包括从大约600℉到大约840℉的温度，优选从大约680℉到大约760℉，其高于典型的热固性高压釜温度。一个示例性复合制品将为如图1中绘出的风扇叶片10。
尽管按照特定实施例描述了本发明，但清楚的是，其它形式可由本领域的技术人员采用。例如，可生产除风扇叶片之外的复合物构件，可改变工艺参数，且适合的材料可替代提到的那些。因此，将理解的是，本发明不限于特定的公开实施例。还应当理解的是，上文使用的短语和用语出于公开本发明的目的，且不一定用作对本发明的范围的限制。最后，尽管所附权利要求叙述了认作是与本发明相关联的某些方面，但它们不一定用作本发明的范围的限制。

Claims (11)

1.一种用于制造热塑性纤维复合物的工艺，所述工艺包括：
将热塑性树脂加热至液态；
使增强材料单向地定向；
利用处于液态的所述热塑性树脂浸渍所述增强材料来产生复合物薄层；以及
执行机器层合工艺来产生包括多个所述复合物薄层的复合物叠层。
2.根据权利要求1所述的工艺，其特征在于，所述工艺还包括利用解偶联剂涂布所述增强材料来改善复合物损坏容限。
3.根据权利要求1所述的工艺，其特征在于，所述机器层合工艺包括定形所述复合物叠层的就地固结工艺。
4.根据权利要求1所述的工艺，其特征在于，所述工艺还包括使用高压釜处理工艺定形所述复合物叠层。
5.根据权利要求1所述的工艺，其特征在于，所述热塑性树脂包括聚醚醚酮。
6.根据权利要求1所述的工艺，其特征在于，所述增强材料包括纤维。
7.根据权利要求1所述的工艺，其特征在于，所述增强材料包括连续玻璃纤维。
8.根据权利要求1所述的工艺，其特征在于，所述增强材料包括连续碳纤维。
9.根据权利要求1所述的工艺，其特征在于，所述机器层合工艺包括超声波协助的缝合，其中驱使额外的增强材料穿过多个所述复合物薄层来加强所述复合物叠层。
10.一种具有单向定向的增强材料的燃气涡轮发动机热塑性纤维复合物风扇叶片(10)，所述增强材料浸渍有由包括以下步骤的工艺形成的热塑性树脂：
将热塑性树脂加热至液态；
使增强材料单向地定向；
利用处于液态的所述热塑性树脂浸渍所述增强材料来产生复合物薄层；以及
执行机器层合工艺来产生包括多个所述复合物薄层的复合物叠层。
11.一种具有单向定向的增强材料的燃气涡轮发动机热塑性纤维复合物风扇叶片(10)，所述增强材料涂布有解偶联剂且浸渍有由包括以下步骤的工艺形成的热塑性树脂：
将热塑性树脂加热至液态；
使增强材料单向地定向；
利用解偶联剂涂布所述增强材料来改善复合物损坏容限；
利用处于液态的所述热塑性树脂浸渍所述增强材料来产生复合物薄层；以及
执行机器层合工艺来产生包括多个所述复合物薄层的复合物叠层。
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