CN107107489B - 预聚合的热固性复合部件及其制造方法 - Google Patents
预聚合的热固性复合部件及其制造方法 Download PDFInfo
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- CN107107489B CN107107489B CN201580057800.XA CN201580057800A CN107107489B CN 107107489 B CN107107489 B CN 107107489B CN 201580057800 A CN201580057800 A CN 201580057800A CN 107107489 B CN107107489 B CN 107107489B
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- thermosetting resin
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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
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
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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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- B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
- B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
- B29C35/0266—Local curing
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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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- 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
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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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- B29C65/4835—Heat curing adhesives
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- 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
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/01—General aspects dealing with the joint area or with the area to be joined
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract
本发明涉及一种由纤维增强复合材料制成的部件(10),该部件(10)包括由保持在热固性树脂中的一组纤维制成的一个结构件(11),和遍及该结构件(11)一个外表面(12)的全部或部分的一个剥离层(13)。该部件在所述结构件(11)和剥离层(13)之间的界面(15)处具有一个共聚梯度。本发明还涉及一种生产这种部件的方法。本发明还涉及粘合这种部件的方法。
Description
技术领域
本发明属于由热固性树脂复合材料制成的部件领域。特别是涉及一种预聚合的纤维增强复合材料部件。本发明还涉及一种制造这种部件的方法。
本发明特别适用于航空领域中结构件的生产,例如,加强的整体部件或由复合材料制成的必须经过组合的飞机或直升机的任何其他结构件(机身面板、机翼面板、加强件、框架、翼肋、纵梁、叶片等)。
背景技术
当今,复合材料广泛用于许多工业领域,例如,航空领域中的部件制造,包括结构件,也就是在使用过程中必须承受显著应力的部件。
一种复合材料通常由一种纤维增强材料和一种树脂组成,这种组合可以获得性能超过这些起始材料的复合体。因此,复合材料部件具有许多优点,尤其是它们的强度、轻度、和易成型方面的性质。
最常用于生产热固性复合材料部件的方法包括,通过堆叠预浸渍有热固性树脂的纤维的增强层或层片,称为预浸渍纤维预制件,并根据适用于待生产的最终复合材料部件的形状来生产一个结构件;然后在真空袋下、高压釜或烘箱中,通过聚合固化该树脂。所获得的部件在其整个厚度上聚合比例相同。
另一种广泛用于生产这种部件的方法主要包括,通过注入或灌注将热固性树脂均匀地扩散到纤维预制件中,纤维预制件起初是干燥的,具有待生产的部件的形状。在排出气体和分散树脂后,在一个模具或真空袋中通过聚合进行固化,从而制成所需的复合材料部件。本方法为RTM(树脂传递成型)或LRI(液体树脂灌注)。此方法与上述方法相同,所获得的部件在其整个厚度上具有相同的聚合比例。
飞机的某些结构件是将通过上述方法之一制成的单个部件彼此粘合连接而制成。例如,由蒙皮和多个加强件的组件构成的机身面板或机翼面板。
三种粘合组合方法用于航空学中:
-共固化粘合法,其通过聚合两个未聚合的部件而进行组合,两个部件之间的接头处使用或不使用粘附膜;
-共粘合法,其通过聚合一个已聚合的部件和一个未聚合部件而进行组合,两个部件之间的接头处使用粘附膜;
-二次粘合法,其通过聚合两个已聚合的部件而进行组合,两个部件之间的接头处使用粘附膜。
上述共固化粘合法具有不需要在组合前对部件进行打磨和清洁表面的准备的优点。该方法还为最终组件提供良好的机械强度。
与共固化粘合法不同,上述共粘合法和二次粘合法具有简化在粘合前各个聚合部件的制造、储存、处理和非破坏性测试操作的优点。它们也为最终组件提供良好的机械强度。
这些现有方法尽管令人满意,但各自仍存在许多缺点,其中包括:
-对于共粘合法和二次粘合法:
粘合接头缺乏可靠性,例如,在接头处可能出现机械强度较低,甚至非常低的粘合,也称为弱粘合;
不能通过非破坏性测试检测到这些弱粘合,因此不能检测粘合接头处机械强度较低的部件;
需要对部件进行表面准备;以及
依赖紧固件来消除粘合界面处分层的风险。
-对于共固化粘合法:
使用设备较复杂、处理未聚合部件也较复杂,导致组合两个部件成本较高;
在粘合前未聚合部件在特殊条件下(通常在-18°C)储存;以及
在组合和聚合之后执行非破坏性测试操作,导致测试该组件的复杂性和成本较高。
因此,需要提供一种解决方案,使得两个部件之间能够产生机械强度良好的粘合,而且该粘合接头具有与共固化粘合法得到的粘合接头相同的可靠性,同时,更容易使用以减少成本。
发明内容
本发明提出生产一种预聚合的纤维增强复合材料部件。
本发明涉及一种纤维增强复合材料部件,其包括:由保持在热固性树脂中的纤维组件形成的一个结构件,和遍及该结构件一个外表面的全部或部分的一个剥离层。该部件的特征在于结构件和剥离层之间的界面处具有共聚梯度。
该剥离层是在粘合操作之前用于保护部件的外表面的一种织物。该剥离层在聚合前定位在该部件的表面上,位于之后该部件必须与另一部件通过粘合进行组合的位置。剥离层在聚合之后、粘合操作之前,通过简单的剥离即可轻松地除去。
共聚梯度可以理解为部件的聚合比例随着该部件厚度方向上的位置而产生变化。
根据本发明的部件,共聚梯度仅存在于该结构件和剥离层之间的界面处。该共聚梯度从该结构件的外表面向剥离层递减。
在梯度区域中,树脂在界面至多几十微米厚度处的聚合比例较低。聚合比例较低可以理解为聚合比例低于40%。
通过现有技术所得到的现有部件,部件的整个厚度上的聚合是均匀的,即,聚合比例不受该部件厚度方向上位置的影响,即使在结构件-剥离层之间的界面处也是相同的。而根据本发明的部件是在除了结构件-剥离层之间界面的表面之外的其他部位均匀聚合。
这种共聚梯度尤其有助于已聚合的部件后续通过共固化来粘合,而这在现有的已聚合部件中是无法实现的。
在本发明的一个实施方式中,该部件是一个在结构件中至少聚合75%的部件。
本发明还涉及一种用于生产如上面至少一个实施方式中描述的纤维增强复合材料部件的方法,包括下列步骤:
-生产一个预浸渍有未聚合树脂的纤维预制件,该纤维预制件主要由一个层片或多个层片的堆叠获得;
-在外叠层的一个表面的全部或部分上沉积预浸渍有不含固化剂或含有微量固化剂的未聚合树脂的纤维织物;以及
-聚合该纤维预制件和纤维织物组件,从而使树脂包含在纤维预制件中。
在聚合步骤结束时,该预制件保持在树脂中并形成已聚合的最终部件的结构件,该纤维织物连接至该结构件并形成剥离层。在该结构件和该剥离层之间的界面处形成共聚梯度。
用于浸渍预制件的树脂包括在聚合步骤中使该树脂能够聚合的固化剂。
热固性树脂例如为环氧型树脂。
由于浸渍纤维织物的树脂不含固化剂或含有微量固化剂,因此,其在聚合步骤期间不会在预制件的热固性树脂的聚合温度下过多地聚合。
表达“含有微量固化剂”可以理解为指供应商推荐的固化剂的标称量为1%重量份至30%重量份。
由供应商推荐的待与树脂混合的固化剂的标称量根据产品的不同发生变化。例如,固化剂可以是从待添加固化剂树脂的重量的10%,即待添加固化剂树脂和固化剂重量比为100:10,到待添加固化剂树脂的重量的100%,即获得1:1的重量比,在这种情况下,固化剂与树脂的重量相同。
换句话说,纤维织物的树脂的组合物中固化剂的量可以定义为,部件一经聚合,结构件和剥离层之间的界面较少聚合,但又足够充分聚合以使得剥离层轻微地粘接到结构件的外表面,并且在没有外部帮助下不会自行剥离。在需要时,剥离层在外表面呈现为干燥。
在该方法的一个示例性实施方式中,预制件中包含的树脂和纤维织物中包含的树脂是相同的。它们的区别仅在于是否含有固化剂。
这种用于生产部件的方法的优势尤其在于其较少地修改现有的传统方法。其中仅改变了纤维织物。通常使用的干燥纤维织物由浸渍有不含固化剂或含有微量固化剂的树脂的纤维织物来代替。
在该方法的一个实施方式中,纤维预制件中包含的热固性树脂的聚合比例大于或等于75%。
本发明还涉及一种用于生产如上面至少一个实施方式中描述的纤维增强复合材料部件的方法。本发明包括如下步骤:
-生产一个预浸渍有未聚合的热固性树脂的纤维预制件,该预制件主要由一个层片或多个层片的堆叠获得;
-在预制件外叠层的一个表面的全部或部分上沉积一个中间树脂层,该树脂是未聚合的且不含固化剂或含有微量固化剂;
-在该中间树脂层沉积一种干燥纤维织物,使得织物上浸渍有中间层的树脂;以及
-聚合该纤维预制件、中间树脂层和纤维织物全套组件,从而使包含在纤维预制件中的热固性树脂聚合。
干燥纤维织物是指未用热固性树脂预浸渍的一个层片或多个层片的堆叠。
其例如由尼龙纤维、聚酯纤维或玻璃纤维形成。
在聚合步骤结束时,该预制件保持在树脂中且形成已聚合的最终部件的结构件,该纤维织物连接至该结构件且形成剥离层。在该结构件和剥离层之间的界面处形成共聚梯度。
浸渍该预制件的树脂的组合物和浸渍该纤维织物的树脂的组合物如前述方法所定义的那样。
中间层本身仅由树脂组成,没有一个纤维层片或多个纤维层片的堆叠。由于中间层的树脂不含固化剂或含有微量固化剂,因此,在聚合步骤期间,树脂基本不会在预制件的树脂的聚合温度下聚合。
中间层的树脂的组合物中固化剂的量可以定义为,部件一经聚合,结构件和剥离层间的界面较少聚合,但又足够充分聚合以使得剥离层轻微地粘接到结构件的外表面,并且在没有外部帮助下不会自行剥离。在需要时,剥离层在外表面上呈现为干燥。
在该方法的一个示例性实施方式中,预制件中包含的树脂和中间层中包含的树脂是相同的。它们的区别仅在于是否含有固化剂。
中间层沉积在该预制件外层的表面上,位于该部件一经聚合后将与另一部件通过粘合进行组合的位置。
在实施方式实例中,中间层通过沉积树脂膜、喷涂、或借助刷子沉积在外叠层的一个表面的全部或部分上。
这种用于生产部件的方法的优势尤其在于其在赋予最终部件必要特征的同时较少地变改了现有的传统方法。
在该方法的一个实施方式中,纤维预制件中包含的热固性树脂的聚合比例大于或等于75%。
本发明还涉及一种用于生产如上面至少一个实施方式中描述的纤维增强复合材料部件的方法,其包括如下步骤:
-生产一个干燥纤维预制件,该预制件主要由未经预浸渍的一个层片或多个层片的堆叠获得;
-在外叠层的一个表面的全部或部分上沉积预浸渍有不含固化剂或含有微量固化剂的未聚合树脂的纤维织物,
-通过传递形成基质的热固性树脂来浸渍干燥纤维预制件;以及
-聚合该纤维预制件和纤维织物全套组件,从而使包含在纤维预制件中的热固性树脂聚合。
在聚合步骤结束时,该预制件保持在树脂中且形成聚合的最终部件的结构件,该纤维织物连接至该结构件且形成剥离层。在该结构件和剥离层之间的界面处形成共聚梯度。
浸渍该预制件的热固性树脂组合物和浸渍该纤维织物的树脂的组合物与前述方法所定义的一致。
这种用于生产部件的方法的优势在于其较少改变现有传统方法(RTM或者LRI)。对于没有纤维织物的传统方法,将浸渍有不含固化剂或含有微量固化剂的树脂的纤维织物添加到干燥预制件的表面。对于具有纤维织物的传统方法,使用浸渍有不含固化剂或含有微量固化剂的树脂的纤维织物替代传统方法中的纤维织物。
在该方法的一个实施方式中,纤维预制件中包含的热固性树脂的聚合比例大于或等于75%。
换句话说,不管使用哪种生产纤维增强复合材料部件的方法,该部件都将在保留其表面的同时进行常规聚合,特别是在其将与另一部件通过粘合进行组合的位置,即未充分聚合区,统称为粘合区。为此,依据所选择的方法,中间层的树脂或者纤维织物的树脂包含较少的或者不包含固化剂。在部件的聚合期间,固化剂分子从预浸渍预制件的树脂轻微扩散到纤维织物的树脂,并且在较小的几十微米的厚度上获得一个梯度。因此粘合区限定于已聚合结构件和剥离层之间的界面。
简言之,在聚合步骤结束时,获得的部件具有一个已聚合的结构件和一个树脂薄层,该树脂薄层由剥离层进行保护、并且在结构件的表面上后续必须组合该部件的位置很少聚合,即未充分聚合,。
与通过现有方法获得的部件相比,能够在较小表面厚度上产生共聚梯度的事实为通过本发明的方法获得的部件提供额外的且非常有意义的优点:所获得的部件后续可以在生产部件的共固化粘合法中使用。而在现有方法得到的部件中,不可避免地在部件的整个厚度上产生均匀的聚合,即,聚合比例与部件厚度上的位置无关,即使在结构件-剥离层之间的界面处也是相同的。
本发明还涉及一种组合上述至少一个实施方式中描述的两个纤维增强复合材料部件的方法。该方法包括如下步骤:
-将剥离层从部件上剥离以露出各个粘合区;
-定位部件,使得各个粘合区相对放置,在两个粘合区间***一个粘附膜;
-在该粘合区使两个部件加压接触;以及
-聚合全套组件。
***的粘附膜包含固化剂,以便提供在未充分聚合的树脂中产生化学键所必需的固化剂分子。粘附膜可以在每个表面具有过量的固化剂。
本发明还涉及一种组合两个纤维增强复合材料部件的方法,这两个部件中的一个部件如上述至少一个实施方式中所述,第二个部件是处于由未聚合热固性树脂预浸渍的纤维预制件状态下的部件,该方法包括如下步骤:
-从根据本发明的一个实施方式的将剥离层从各个部件上剥离以露出粘合区;
-定位部件,使得粘合区与第二部件在应进行组合的位置相对放置;
-在该粘合区使两个部件加压接触;以及
-聚合全套组件。
固化剂的分子由未聚合的第二部件来提供。该未聚合的第二部件可以在粘合表面具有过量的固化剂。
在该方法的一个实施方式中,在定位该部件的过程中,将包含固化剂的粘附膜***粘合区和第二部件之间。
在该实施方式中,固化剂的分子由粘附膜来提供。粘合剂可以在与根据本发明的部件接触的表面上具有过量的固化剂。
不管使用哪种组合纤维增强复合材料部件的方法,未充分聚合的树脂的分子在剥离层被剥离期间始终附着在结构件的外表面(树脂在其强度最低的位置断裂,即,聚合最低的位置)。
接着,在聚合步骤期间,粘附膜的固化剂分子或者未聚合的第二部件的固化剂分子扩散至不包含任何强化学键的区域,直到完成全套组件的聚合。
此类方法可定义为表面共固化粘合法。
使用此类方法结合本发明的部件的优势在于能够:
-无需对部件进行表面准备;以及
-便于和简化部件的储存、处理、以及组合部件所需的设备。
换句话说,本发明在保留了二次粘合法的所有容易使用的优点的同时也受益于与仅在粘合区的共固化粘合法相关的优点,例如粘合接头的机械强度和可靠性。
附图说明
现在通过图1至图6表示的对本发明不具有任何限制性的特定实施方式的上下文对本发明进行更详细地描述。
图1所示为根据本发明的一个部件。
图2所示为生产该部件的方法中垂帘成型的步骤。
图3所示为生成该部件的方法中聚合该部件的步骤。
图4所示为组合两个部件的方法中将剥离层剥离的步骤。
图5所示为组合两个部件的方法中将两个部件相对于彼此进行定位的步骤。
图6所示为组合两个部件的方法中聚合两个组合部件的步骤。
具体实施方式
以下将详细描述将本发明应用于结构航空部件的情况的示例性实施方式。本发明的应用不限于此且可以扩展到由复合材料制成的所有部件。
如图1所示,根据本发明的一个复合材料部件10,包括一个由保持在热固性树脂中的纤维的组件聚合形成的结构件11。
结构件11可以具有任何形状。它可以为如图1所示的平面,或者具有至少一个曲面。
部件10旨在通过粘合与另一个部件进行组合以形成一个结构组件,如加强机身面板。
部件10包括一个遍及结构件的一个外表面12的全部或部分的剥离层13。剥离层旨在保护结构件11的外表面12的全部或部分直到后续的粘合操作。该剥离层定位且保持在结构件11的外表面12上,位于部件后续将和另一个部件进行组合的位置。
部件10在剥离层13和外表面12之间的界面15处具有几十微米厚度的具有共聚梯度的区域。该共聚梯度从结构件11的外表面12到剥离层13递减。
位于结构件和剥离层之间的界面15较少聚合,但又足够充分聚合以使得剥离层13轻微粘接到结构件11的外表面12,并且不会过早剥离。
为了生产这种部件,现在用非限制的方式描述三种方法。
第一方法示例(图2和图3)
在第一步骤中,生产出一个预浸渍预制件110。
将预制件110限定为其形状和体积基本对应于待生产的最终部件10的形状和尺寸。
预制件例如在模具30上生成,该模具的形状和体积基本对应于待生产的部件的形状和尺寸。
预制件110是由预浸渍有未聚合树脂的纤维的单层片111或至少两个层片111叠置而成。
这个(这些)层片中纤维的性质和取向根据部件一经生成后将经受的机械应力的类型来确定。
当预制件由多个层片叠置而成时,根据已知的计算方法确定层片的数量和在连续的层片中纤维的取向,这里不对这些已知的计算方法进行描述。
在一个示例性实施方式中,预制件110包括叠置的预浸渍纤维,例如由碳制成的单向片材。该预制件还可以由例如玻璃纤维或Kevlar纤维制成。
这个(这些)层片111是由热固类型树脂预浸渍的,例如环氧树脂,其具有固化剂。
在一个示例性实施方式中,这个(这些)层片111由环氧树脂预浸渍,其基本单体主要为DGEBA(双酚A二缩水甘油醚)、TGPAP(三缩水甘油基对氨基苯酚),或TGMDA(四缩水甘油基亚甲基二苯胺)型,且固化剂是胺型,例如二氨基二苯砜(DDS)。
在第二步骤中,将预浸渍纤维织物130局部沉积在预制件110上。
该纤维织物包括一个层片或叠置的多个层片。
在一个示例性实施方式中,纤维织物130包括叠置的例如织造纤维的预浸渍纤维。
在一个示例性实施方式中,纤维织物130包括聚酯纤维、尼龙纤维或玻璃纤维。
纤维织物130局部沉积在预制件110的外层的表面120上,位于该部件一经生成后通过粘合和另一个部件进行组合的位置。
纤维织物130由不含固化剂或含有微量固化剂的环氧型树脂预浸渍。
在一个示例性实施方式,纤维织物130由环氧树脂浸渍,该树脂的基本单体主要是DGEBA、TGPAP或TGMDA型。固化剂可以例如为胺型,例如DDS。
在第三步骤中,将真空袋和环保产品围绕预制件-纤维织物组件放置。
该步骤是常规的且用于制备聚合步骤的全套组件。
在第四步骤中,聚合该预制件-纤维织物全套组件。
真空袋通过已知方法密封。然后将该预制件-纤维织物全套组件抽空,其目的是压缩预制件-纤维织物全套组件,尤其是压缩层片。之后,在给定温度、给定时长和给定压力下对该预制件-纤维织物全套组件进行热处理。
在环氧型树脂的优选实施方式中,该树脂为聚合物热固性树脂,其交联反应在室温或高温度下发生。
在聚合步骤期间,包含在预制件中的树脂在其中展开,填充多个层片的纤维之间的空区域。由于纤维织物已经预浸渍有自身的树脂,所以其本身不浸渍预制件的树脂。
在聚合循环期间,纤维织物和预制件的树脂的黏度随着温度的升高而降低。如图3的箭头50所示,固化剂的分子和预制件的树脂中包含的聚合物链将迁移到不含固化剂或者含有微量固化剂的树脂层中。然后,观察到聚合物链在预制件的树脂和纤维织物的树脂之间产生和扩散。
这样的扩散发生在至多几十微米的厚度上,例如1μm至50μm之间。
使得扩散变化的参数为时间、温度(控制凝胶化外观的参数)和黏度。只要没有出现凝胶化,提供最低粘度的温度的时间越长,将利于更远的扩散。
在聚合结束时,在结构件11和剥离层13之间的界面处,获得几十微米范围的共聚梯度。
聚合一经完成,向纤维织物130的树脂中加入微量固化剂可以显著提高在剥离层13的聚合比例。因此,确保剥离层13更好地保持在部件10的结构件11的外表面12上,直到粘合操作。
在一个聚合步骤的特定实施方式中,预制件110中包含的树脂的聚合比例至少等于75%。
在第四步骤结束时,从模具中取出部件10,而不移除剥离层13。如图4至图6所示,在进行监测材料可靠性的可能操作,或者例如钻孔或机械加工等精整加工操作之后,获得能够通过粘合和另一个部件进行组合的部件。
第二方法示例
第二方法与第一方法具有以下相同的步骤:
a)生产一个预浸渍纤维预制件110;
b)将纤维织物130局部沉积在该预制件上;
c)安装真空袋;以及
d)聚合。
但是第二方法不同于第一方法之处在于:
-将浸渍有不含固化剂或含有微量固化剂的树脂的纤维织物130替换为一个干燥纤维织物;以及
-其包括一个在步骤a)和步骤b)之间的附加步骤,沉积不含固化剂或含有微量固化剂的树脂的中间层。
该中间层通过,例如喷涂,沉积在预制件110的外层的表面上。
在聚合结束时,在结构件11和剥离层13之间的界面处,获得几十微米范围的共聚梯度。
第三方法示例
在第一步骤中,生成一个干燥纤维预制件110。
与第一方法示例相同,该纤维预制件110由一个层片或至少两个层片叠置而成。此时,这些层片未浸渍有树脂。
该纤维预制件110包括干燥纤维,干燥纤维的性质和取向根据预定标准(机械负载等)来确定。
预制件110例如放置在一个模具内,该模具的形状和体积基本对应于待生产的部件的形状和尺寸。
在该方法的第二步骤中,将预浸渍有不含固化剂或含有微量固化剂的树脂的纤维织物130局部沉积在预制件上。
在该方法的第三步骤中,将预制件-纤维织物全套组件限制在全密封室内,以便产生后续聚合所需的条件。
全密封室例如由围绕该预制件纤维织物全套组件的一个模具/配对模具组件或一个真空袋来界定。
在该方法的第四步骤中,将含固化剂的热固性树脂注入到由模具或真空袋界定的全密封室内。
树脂通过位于模具/配对模具或真空袋的开口注入。注入树脂以便使其在密封室内均匀扩散。更具体地说,树脂在预制件内扩散,填充预制件的各层片的干燥纤维之间的空区域。
调节注入流速使得纤维织物中包含的树脂不会排出。
在第五步骤中,聚合预制件-纤维织物全套组件。该步骤与在第一方法示例中描述的步骤相同。
在聚合结束时,在结构件11和剥离层13之间的界面处,获得几十微米范围的共聚梯度。
通过上述方法中任何一种所获得的部件10在除了存在未充分聚合区的结构件11和剥离层13之间的界面以外的部分发生聚合。由于这个未充分聚合的区域,此类部件可以有利地通过共固化粘合法与另一个部件进行组合。
图4至图6所示为用于组合根据本发明的两个部件所需的多个不同步骤。
在第一步骤中(图4),通过剥离移除每个部件10的剥离层13。
移除每个剥离层13以露出未充分聚合区或粘合区。断裂发生在不太稳固的区域,即在聚合比例最低的区域。
在移除期间,剥离层13的树脂始终附着到由图4和图5中的附图标记60所示的结构件的表面。
在第二步骤中,将两个部件10相对于彼此放置。
定位两个部件10使得粘合区正面相对放置。
粘附膜20插在两个粘合区之间。该粘附膜由含固化剂的热固性树脂组成。粘附膜可在其每个表面具有过量的固化剂。这种粘附膜是必需的,以便为附着到结构件11的未充分聚合的树脂提供在后续聚合时所需的固化剂分子。这种粘附膜20还能够填充接触的两个粘合区之间可能存在的间隙。
在一个示例性实施方式中,粘附膜20基于环氧树脂。
然后,两个部件在粘合区通过压力接触。
在第三步骤中,将部件-粘附膜全套组件限制在全密封室内,以便产生后续聚合所需的条件。
在第四步骤中,聚合该部件-粘附膜全套组件。
在该第四步骤期间,粘附膜20的树脂和每个部件10的未充分聚合树脂融化(由于密封室内温度的升高而导致黏度降低)。粘附膜20中包含的固化剂分子、粘附膜和未充分聚合的树脂层60的聚合物链将会迁移和互相扩散。
这些新链与未充分聚合的树脂层中已存在的聚合物链键合,并使得由聚合物链形成的三维网状结构致密化,直到部件的树脂和粘附膜的树脂的界面完全聚合为止。
这种操作同时发生在粘附膜20的不同部位。
因此,在两个部件10之间得到一个完全聚合的接合,伴随这两个部件之间产生的聚合物链的连续三维网状结构。
在聚合结束时,该全套组件可视为单个部件,类似由传统共固化粘合法生产的任何组件。
不言而喻,本发明的部件10还可以通过相同方法与未聚合部件组合。
在这种情况下,在定位步骤期间,部件10的粘合区与未聚合部件在应进行组合的位置正面相对放置。粘附膜的引入是可选的,固化剂分子包含在未聚合部件中。
具有与传统共固化粘合法相同的优点,即:
-在组合操作前,不需要进行部件的表面准备;
-在粘合前,接头对轻度表面污染不敏感;以及
-由于在两个部件之间使用粘附膜而具有良好的机械强度。
此外,还具有与常规二次粘合法相同的优点,即:
-简化聚合设备和粘合设备;
-能够在不加热全部部件的情况下局部加热粘合区;
-简化非破坏性测试(组合前对每个单个部件进行简单测试);以及
-便于储存和操作。
有利地,本发明使得能够生产一种适用于共固化粘合法的预聚合部件。
Claims (7)
1.一种纤维增强复合材料部件(10),其包括由保持在热固性树脂中的纤维组件形成的一个结构件(11),和遍及所述结构件(11)一个外表面(12)的全部或部分的一个剥离层(13);其特征在于,所述部件在所述结构件(11)和剥离层(13)之间的界面(15)处具有一个共聚梯度。
2.一种生产如权利要求1所述的纤维增强复合材料部件(10)的方法,包括以下步骤:
- 生产一个纤维预制件(110),该纤维预制件(110)预浸渍有未聚合的热固性树脂;
- 在一个外叠层的一个表面(120)的全部或部分上沉积一个预浸渍有不含或含有微量固化剂的未聚合树脂的纤维织物(130);以及
- 聚合全套组件,使得所述纤维预制件(110)中包含的热固性树脂的聚合比例大于或等于75%。
3.一种生产如权利要求1所述的纤维增强复合材料部件(10)的方法,包括以下步骤:
- 生产一个纤维预制件(110),该纤维预制件(110)预浸渍有未聚合的热固性树脂;
- 在一个外叠层的一个表面的全部或部分上沉积一个中间树脂层,所述沉积的使用树脂是未聚合的且不含或含有微量固化剂;
- 在所述中间树脂层上沉积一个干燥纤维织物(130);以及
- 聚合全套组件,使得所述纤维预制件(110)中包含的热固性树脂的聚合比例大于或等于75%。
4.一种生产如权利要求1所述的纤维增强复合材料部件(10)的方法,包括以下步骤:
- 生产一个干燥纤维预制件(110);
- 在一个外叠层的一个表面(120)的全部或部分上沉积一个预浸渍有不含固化剂或含有微量固化剂的未聚合树脂的纤维织物(130);
- 通过传递形成基质的热固性树脂来浸渍所述纤维预制件(110);以及
- 聚合全套组件,使得所述纤维预制件中包含的热固性树脂的聚合比例大于或等于75%。
5.一种用于组合如权利要求1所述的两个纤维增强复合材料部件(10)的方法,该方法包括以下步骤:
- 从每个部件(10)上剥离所述剥离层(13)以露出每个部件的未充分聚合区,称为粘合区;
- 定位所述部件(10)使得所述各粘合区相对放置,在两个粘合区间***一个粘附膜(20);
- 使所述两个部件的所述粘合区加压接触;以及
- 聚合全套组件。
6.一种用于组合两个纤维增强复合材料部件的方法,其中所述两个部件中的一个部件(10)如权利要求1所述,而第二个部件是处于由未聚合热固性树脂预浸渍的纤维预制件的状态下的一个部件,该方法包括如下步骤:
- 剥离如权利要求1所述部件的所述剥离层(13)以露出一个未充分聚合区,称为粘合区;
- 定位所述部件,使得所述粘合区与所述第二部件在应进行组合的位置相对放置;
- 使所述两个部件的所述粘合区加压接触;以及
- 聚合全套组件。
7.如权利要求6所述的方法,其中,在所述定位所述部件的步骤期间,将一个粘附膜(20)***到所述粘合区和第二部件之间。
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CN103079810A (zh) * | 2010-08-30 | 2013-05-01 | 井上株式会社 | 纤维增强的成型体及其制造方法 |
CN103817922A (zh) * | 2012-11-16 | 2014-05-28 | 波音公司 | 复合材料接合***和方法 |
JP2014136383A (ja) * | 2013-01-17 | 2014-07-28 | Nhk Spring Co Ltd | 複合材及び複合材の製造方法 |
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US8834668B2 (en) * | 2008-11-19 | 2014-09-16 | The Boeing Company | Staged cocuring of composite structures |
US9254622B2 (en) * | 2012-04-23 | 2016-02-09 | University Of Washington | Bond ply for adhesive bonding of composites and associated systems and methods |
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CN103079810A (zh) * | 2010-08-30 | 2013-05-01 | 井上株式会社 | 纤维增强的成型体及其制造方法 |
CN103817922A (zh) * | 2012-11-16 | 2014-05-28 | 波音公司 | 复合材料接合***和方法 |
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US20170282446A1 (en) | 2017-10-05 |
US10576692B2 (en) | 2020-03-03 |
EP3188899A1 (fr) | 2017-07-12 |
WO2016034809A1 (fr) | 2016-03-10 |
FR3025131A1 (fr) | 2016-03-04 |
EP3188899B1 (fr) | 2018-07-11 |
FR3025131B1 (fr) | 2016-09-16 |
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