CN108422682B - 制造热塑性复合结构的方法及用于其中的预浸料带 - Google Patents

制造热塑性复合结构的方法及用于其中的预浸料带 Download PDF

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CN108422682B
CN108422682B CN201810018217.3A CN201810018217A CN108422682B CN 108422682 B CN108422682 B CN 108422682B CN 201810018217 A CN201810018217 A CN 201810018217A CN 108422682 B CN108422682 B CN 108422682B
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melting temperature
thermoplastic
temperature thermoplastic
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low melting
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CN108422682A (zh
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A·奥加勒
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Boeing Co
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Boeing Co
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    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
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    • B29C70/465—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating by melting a solid material, e.g. sheets, powders of fibres
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Abstract

本申请涉及制造热塑性复合结构的方法及用于其中的预浸料带。通过使复合预制件固结并成形为期望形状而生产热塑性复合结构。所述预制件包括高熔化温度热塑性预浸料的层片，通过固定配准地使所述层片粘附在一起的低熔化温度热塑性塑料将所述层片结合到一起。

Description

制造热塑性复合结构的方法及用于其中的预浸料带
技术领域
本公开总体涉及复合结构，更具体地涉及使用高温热塑性预浸料预制件制造复合层压结构的方法。
背景技术
采用高温热塑性聚合物的复合层压结构通常在超过300℃的温度下固结，在一些情况下在400℃以上的温度下固结。在一个应用中，铺设多层片预浸料预制件，然后使用压印成形或其他技术形成为期望形状。在成形过程之前或期间将预制件加热至固结温度。使用例如铺放并压紧热塑性预浸料条带的自动带式铺设(ATL)机器来铺设层片。
预制件的层片通常具有不同的带形式，诸如层片倍增器和层片剥离，其在堆叠时创建结构特征。因此，重要的是在铺设层片时以及随后在存储、运输、固结和/或成形时维持层片相对于彼此的配准。用于维持必要的层片配准的一种技术涉及在由带铺设设备铺放并压紧层片时通过熔化预浸料带将层片结合到一起。在高温热塑性预浸料的情况下，使用诸如激光的高能装置将热塑性塑料加热至熔化温度，如上所述，熔化温度通常介于300℃到400℃之间，或者更高。该结合方法具有若干缺点。将高温热塑性塑料加热至其熔化温度可在冷却期间导致聚合物的不均匀再结晶，致使复合结构的材料特性的非期望变化。另外，该带可以铺放的速度受限于将高温热塑性塑料加热至其熔化温度所需的时间。此外，使层片熔化以便将层片结合到一起减少了当成形时剪切(相对于彼此滑入)的能力，这可导致层片褶皱或屈曲。
发明内容
本公开总体涉及复合结构，更具体地涉及采用高温热塑性聚合物的复合层压件。
根据一个方面，提供了一种用于制造热塑性复合预制件的方法。该方法包括组装高熔化温度热塑性复合层片的堆叠以及在所述复合层片之间引入低熔化温度热塑性塑料。该方法还包括通过熔化所述低熔化温度热塑性塑料而将所述高熔化温度热塑性复合层片结合到一起。
根据另一方面，提供了一种制造热塑性复合结构的方法。该方法包括生产具有纤维增强热塑性层片的复合预制件，其中，所述层片包括高熔化温度热塑性塑料和低熔化温度热塑性塑料。该方法还包括通过熔化所述低熔化温度热塑性塑料将所述层片结合到一起以及使所述复合预制件固结。
根据又一方面，提供了一种用于制造复合材料的条带以用于制造复合结构的方法。该方法包括提供高熔化温度热塑性预浸料的条带以及在高熔化温度热塑性预浸料的所述条带的表面上施加低熔化温度热塑性塑料。
根据再一方面，提供了一种热塑性复合带，该热塑性复合带包括：高熔化温度热塑性预浸料的条带；以及低熔化温度热塑性塑料，所述低熔化温度热塑性塑料粘附至高熔化温度热塑性预浸料的所述条带的表面。所述低熔化温度热塑性塑料的熔化温度低于高熔化温度热塑性预浸料的所述条带的熔化温度。
根据再一实施方式，一种热塑性复合预制件包括：热塑性预浸料的层片的堆叠，所述堆叠具有能使所述层片固结的熔化温度；以及将所述层片结合到一起的热塑性聚合物。所述热塑性聚合物的熔化温度低于所述热塑性预浸料的熔化温度。
所公开实施方式的优点之一在于，高温热塑性层压件的层片可以结合到一起并保持配准，而无需熔化高温聚合物。因此，可以生产具有更均匀材料特性的复合层压结构。另一优点在于，可增加带铺放速度，并且可以使用低功率的热能源来实现层片结合。再一优点在于，层片在形成为最终形状时具有更大的剪切能力，因此减少层片褶皱或屈曲的可能性。
特征、功能及优点可以在本公开的各个实施方式中独立地实现或者可在其他实施方式中组合，其进一步细节可以参考以下描述和附图看到。
附图说明
被认为是说明性实施方式特征的新颖特征在所附权利要求书中阐述。然而，当结合附图阅读时，将参考本公开的说明性实施方式的以下详细描述最佳地理解说明性实施方式以及其优选使用模式、进一步目的和优点，其中：
图1是高温热塑性复合层压结构的立体图图示。
图2是用于生产图1所示结构的层片堆叠的立体图图示，稍微分解以更好地示出单独的层片。
图3是铺设层片的自动带铺设设备的立体图图示，其中热能源使层片表面上的低温热塑性颗粒熔化。
图4是沿着图3中的线4-4截取的横截面图图示，其中层片之间的间距被夸大以展现低温热塑性结合。
图5是类似于图4的图示，但示出了已固结的层片。
图6是低温热塑性塑料的颗粒已施加到其表面上的高熔化温度热塑性预浸料带的一段的平面图图示。
图7是图6中示出的预浸料带的端视图图示。
图8是熔融的低熔化温度热塑性塑料以连续但随机的模式施加在其上的一段预浸料带的平面图图示。
图9是类似于图8的图示，但其中模式是重复的。
图10是用于将低温热塑性塑料聚合物施加在高温热塑性预浸料带的表面上的设备的示意图图示。
图11是使用根据所公开实施方式生产的预制件来制造高温热塑性复合层压零件的方法的示意图图示。
图12是制造高温热塑性复合层压零件的方法的流程图图示。
图13是飞行器制造及保养方法的流程图图示。
图14是飞行器的框图的图示。
具体实施方式
首先参照图1，所公开实施方式涉及制造复合层压结构20的方法。在该实例中，复合层压结构20是具有基部24和一对腿26(形成U形横截面)的通道加强件22。尽管图示的通道加强件22呈直线，但是在其他实例中，通道加强件22可具有一个或更多个轮廓、扭曲、曲率和/或曲折或其他特征，并且可具有任何各种横截面形状，包括但不限于“I”、“J”、“Z”、“T”、“C”形。通道加强件22仅仅是可使用所公开实施方式的原理生产的广泛范围的零件和结构的说明。
现在参照图2，可通过组装结合到一起的复合层片30的堆叠28以形成平坦的复合预制件88(有时被称为坯件)而生产复合层压结构20。在图示的实例中，每个复合层片30均包括并排铺放的预浸料带38的条带32，其中纤维增强物40被保持在高熔化温度热塑性树脂46中。在其他实例中，然而，复合层片30可使用任何各种其他技术(包括自动纤维铺放(AFP)、手动铺设，编织和交织)铺设，并且可包括预浸料的片材(未示出)，而非高熔化温度热塑性复合预浸料32的条带。复合层片30可具有变化的纤维取向，这取决于通道加强件22的性能要求。尽管图中未示出，但是堆叠28可包括一个或更多个层片剥离、倍增器和/或其他特征，这取决于应用所需的特定层片排布。
参照图3，在图示的实例中，每个复合层片30均使用自动带铺设(ATL)设备82来铺设。ATL设备82可包括采取带放置头36的形式的末端执行器，末端执行器用于将复合预浸料带38铺放在基板48上，基板48可以是工具(未示出)或下面的一个复合层片30。复合预浸料带38包括纤维增强物40，纤维增强物40采取保持在高熔化温度热塑性树脂46中的单向增强纤维的形式。在图示的实例中，复合预浸料带38在其表面34上具有低熔化温度热塑性塑料54的颗粒，然而如将在下面讨论的，低熔化温度热塑性塑料54可在带38的表面34上呈现其他形式。
如本文中使用的，“高熔化温度热塑性塑料”46是通常熔化并且允许层压件在超过大约300℃的温度下固结的热塑性塑料。高熔化温度热塑性塑料46的实例包括但不限于PSU(聚砜)、PEI(聚乙烯亚胺)、PEKK(聚醚酮酮)和PEEK(聚醚醚酮)。如本文中使用的，“低熔化温度热塑性塑料”54是在低于高熔化温度热塑性塑料46的熔化温度的温度下熔化的热塑性塑料。低熔化温度热塑性塑料聚合物的实例包括但不限于聚乙烯和聚丙烯。
当包含高熔化温度热塑性塑料和低熔化温度热塑性塑料两者的预制件88被加热至低熔化温度热塑性塑料的熔化温度时，低温热塑性塑料熔化，但高温热塑性不熔化。在一些实例中，低熔化温度热塑性塑料54可具有低于大约300℃的熔化温度，然而，在其他实例中，低熔化温度热塑性塑料可具有超过300℃的熔化温度，高熔化温度热塑性塑料的熔化温度超过低熔化温度热塑性塑料的熔化温度。例如，非限制性地，在高熔化温度热塑性塑料的熔化温度为340℃的情况下，低熔化温度热塑性塑料可具有310℃的熔化温度。因此，可以使用诸如PEEK的热塑性塑料，其具有343℃的熔化温度以将熔化温度约为360℃的PEKK预浸料的层片结合到一起。
继续参照图3，带38的宽度“W”将取决于应用，并且在一些应用中，带38可包括切割带，即宽度较宽的带的切片。复合带38从放置头36上的供应卷轴(未示出)抽出并且随着放置头36在基板48之上移动而馈送至将带38压紧到下面层片30(或工具)的表面上的压实辊44。放置头36自动旋转并移位，以便以任何期望的纤维取向将带38转向到基板48上。随着放置头36在基板48之上移动，热源50将热能52引导到下面层片30的紧挨着压实辊44的头部的区域上。
热源50可包括在相对较低水平处生成热能52的装置，诸如不限于红外线加热器。然而，可采用热能的较高能源(诸如激光或电子束)。热源50生成足够的热能52以熔化存在于带38的表面34上的低熔化温度热塑性塑料54的颗粒62。然而，施加的热能52不足以熔化高熔化温度热塑性带38。换句话说，热源50将带38的表面34加热至足以熔化低熔化温度热塑性塑料54但不熔化预浸料带38的高熔化温度热塑性塑料46的温度。如先前指出的，所公开实施方式的原理适用于具有使用任何各种铺设技术铺设的复合层片30的预制件88。
图4是示出在已被热源50熔化并随后冷却之后的颗粒62的横截面图。随着已熔化的颗粒62的冷却，它们将层片30粘附并结合到一起，并且防止层片30在堆叠28内相对于彼此移位。因此，在整个铺设过程中维持层片30的配准，之后预制件88被转移到存储区或另一处理站以进行成形和/或固结。图5是类似于图4的视图，但示出了由于已加热至高熔化温度热塑性塑料46的熔化温度而固结并被压紧的层片30。
参照图6至图9，低熔化温度热塑性塑料54可以以任何各种方式施加到预浸料带38的表面34。在图6和图7中，采取颗粒62的形式的低熔化温度热塑性塑料54以干燥形式沉积，或者另选地，液化的低熔化温度热塑性塑料54可以以随机模式58(图6至图8)或规则/重复模式60(图9)喷涂到带38的表面34上。在冷却期间，熔化的干燥颗粒62凝固并粘附至带38的表面34。在图8中示出的另一实例中，通过以连续但随机的模式58使熔融的低熔化温度热塑性塑料54流到表面34上而将低熔化温度热塑性塑料54施加到带38。在图9中示出的再一实例中，熔融低熔化温度热塑性塑料54可以通过以重复模式60使之连续地流到表面34上而施加到带38。
在图中未示出的再一实例中，低熔化温度热塑性塑料54可以通过将液化的低熔化温度热塑性塑料喷涂到带38的整个表面34上而施加到带38。其他施加模式是可行的，包括例如但不限于：以使形状促进层片30之间的结合和/或最小化实现层片30之间期望程度的结合所需的低熔化温度热塑性塑料54的量的模式(未示出)来施加低熔化温度热塑性塑料54。用于施加低熔化温度热塑性塑料54的各种其他技术是可行的。在带38的整个表面34用低熔化温度热塑性塑料54覆盖的实例中，热能52可以被引导到带表面34上，使得所有或仅一部分低熔化温度热塑性塑料54被熔化。例如但不限于，低熔化温度热塑性塑料54可以以一种模式施加，然后被加热至其熔化温度，以仅在层片30的具体选择的区域中实现结合以便促进预制件成形为特定形状。此外，低熔化温度热塑性塑料54可以以促进产生具有特定形状的预制件88和/或促进将预制件88成形为特定形状的模式来施加。
图10以图解的方式图示了用于生产如先前描述将低熔化温度热塑性塑料54施加到其上的高熔化温度热塑性预浸料带38的***72。可包括切割带的高熔化温度热塑性预浸料带64从供应卷轴66抽出而经过施加器70，施加器70将低熔化温度热塑性塑料54施加到预浸料带64的表面34上。如前所述，施加器70可将低熔化温度热塑性塑料54(或呈干燥状态或呈液化状态)喷涂、流动或以其他方式沉积到预浸料带64的表面34上。施加的低熔化温度热塑性塑料54可包括颗粒，或者包括覆盖带38的表面34的一部分或整个区域的间断或连续的熔融材料流。
在一些实施方式中，由施加器70施加的低熔化温度热塑性塑料54可采取在接触之后不久粘附至带38的表面34的熔融形式。在其他实例中，低熔化温度热塑性塑料54被热能源74(诸如，例如但不限于，红外线加热器(未示出))加热至其熔化温度，随后带38穿过冷却器76，由此冷却低熔化温度热塑性塑料54使得其凝固并粘附至带38的表面34。然后，完成的预浸料带38在卷绕到卷取卷轴80上之前穿过一个或更多个被驱动或从动辊78。卷轴80可用作预浸料带38的供应，预浸料带38被承载在带放置头36(图3)上，带放置头36将带38馈送到压实辊44，压实辊44将带38压紧到基板48上。
图11以图解的方式图示了使用所公开实施方式的原理来制造热塑性复合零件的生产***。ATL设备82可包括末端执行器84(诸如先前描述的带放置头36)，末端执行器84由可包括(非限制性地)机器人85的数字控制的操纵器操作。机器人85铺设一组92预制件88，如先前讨论的，每个预制件88均包括由低熔化温度热塑性塑料54结合到一起的多个高熔化温度热塑性预浸料层片30。预制件88或者单独地或者成组地固结在合适的固结压机90中，之后可堆积为堆叠94。预制件88可单独地从堆叠94抽出并被往复移动装置96等转移至炉98，在炉98中将预制件88加热至高温热塑性预浸料46的至少熔化温度。然后，将每个被加热的预制件88放置到成形机器(诸如，但不限于，冲压机100)中，在成形机器中，在一对匹配工具102之间将预制件88成形为期望零件形状。其他成形技术是可行的，包括但不限于真空袋压实、高压釜处理和悬垂成形。
现在将注意力转向图12，图12广义地图示了根据所公开实施方式制造复合结构20的方法步骤。开始于步骤104处，将低熔化温度热塑性塑料54施加到多个高熔化温度热塑性复合层片30的表面34上。在步骤106处，将高熔化温度热塑性复合层片30组装成堆叠94。如前所述，堆叠94可通过使用自动或手动铺设技术来铺设层片30进行组装。在步骤108处，形成高熔化温度热塑性复合预制件88，包括：通过熔化低熔化温度热塑性塑料54，比如通过将低熔化温度热塑性塑料加热至其熔化温度，将高熔化温度热塑性复合层片30结合到一起。低熔化温度热塑性塑料54可通过将液化或干燥形式的低熔化温度热塑性塑料54施加到层片30的表面34而引入到层片30之间。在步骤110处，使预制件88固结并成形为期望形状，包括：加热预制件以及熔化高熔化温度热塑性复合层片30。
本公开的实施方式可用在各种潜在应用中，特别是用在运输工业中，包括例如：航空航天、船舶、汽车应用及使用热塑性复合零件的其他应用。因此，现在参照图13和图14，可在如图13中示出的飞行器制造及保养方法112以及如图14中示出的飞行器114的背景下使用本公开的实施方式。所公开实施方式的飞行器应用可包括(例如，非限制性地)用在飞行器114的机体137中的结构加强件。在预生产期间，示例性方法112可包括飞行器114的规范和设计116以及材料采购118。在生产期间，发生飞行器114的部件及子组件制造120以及***整合122。此后，飞行器114可经历认证和交付124，以便置于服役126之中。在为客户服役的同时，飞行器114定期做日常维护及检修128，其还可包括改造、重构、翻新和其它维护或检修。
方法112的每种工艺均可由***整合商、第三方或运营商(例如，客户)执行或进行。出于对此描述的目的，***整合商可包括(非限制性地)任何数量的飞行器制造商和主***分包商；第三方可包括(非限制性地)任何数量的供货商、分包商和供应商；并且运营商可以是航空公司、租赁公司、军事单位、服务组织等。可采用根据所公开实施方式的高温热塑性复合零件和结构，作为飞行器114的材料采购118、部件及子组件制造120、机体130和内饰134的一部分。
如图14所示，由示例性方法112生产的飞行器114可包括具有多个***132和内饰134的机体130。高级***132的实例包括推进***136、电气***138、液压***140和环境***142中的一种或多种***。可包括任何数量的其他***。虽然示出了航空航天实例，但本公开的原理可应用到其它行业，诸如海洋和汽车行业。
在制造及保养方法112中的任何一个或多个阶段期间可采用本文中体现的***和方法。例如，对应于生产过程120的部件或子组件能以类似于在飞行器114处于服役时生产的部件或子组件的方式来制作或制造。另外，在生产阶段120和122期间，可利用一个或多个设备实施方式、方法实施方式或它们的组合，例如大大加快飞行器114的组装并降低成本。类似地，在飞行器114处于服役时，例如且非限制性地，在维护及检修128期间，可利用一个或多个设备实施方式、方法实施方式或它们的组合。
如本文中使用的，短语“…中的至少一个”当用在一列条目中时，意指可使用一个或更多个所陈列条目的不同组合并且在陈列的每个条目中可能仅需要一个。例如，“条目A、条目B和条目C中的至少一个”可包括(非限制性地)条目A、条目A和条目B，或条目B。该实例还可包括条目A、条目B，以及条目C或条目B和条目C。条目可以是特定的对象、事物或类别。换句话说，“…中的至少一个”意指可从列表中使用任何组合条目和条目数量，但不需要列表中的所有条目。
本发明还涉及不与权利要求书混淆的以下条款。
A1、一种制造热塑性复合预制件88的方法，该方法包括以下步骤：
组装高熔化温度热塑性复合层片46的堆叠28；
在所述复合层片46之间引入低熔化温度热塑性塑料54；以及
通过熔化所述低熔化温度热塑性塑料54而将所述高熔化温度热塑性复合层片46结合到一起。
A2、还提供了根据段落A1所述的方法，其中：
引入低熔化温度热塑性塑料54的步骤包括：将所述低熔化温度热塑性塑料54施加到所述层片46中的每个的表面34，由此所述低熔化温度热塑性塑料54位于所述层片46之间；并且
熔化所述低熔化温度热塑性塑料54的步骤包括：将所述层片46中的每个的所述表面34上的所述低熔化温度热塑性塑料54加热至所述低熔化温度热塑性塑料54的熔化温度。
A3、还提供了根据段落A1所述的方法，其中，引入低熔化温度热塑性塑料54的步骤包括：将所述低熔化温度热塑性塑料54的颗粒62施加到所述层片46中的每个的表面34上。
A4、还提供了根据段落A1所述的方法，其中，引入低熔化温度热塑性塑料54的步骤包括：将液化的低熔化温度热塑性塑料54施加到所述层片46的表面34上。
A5、还提供了根据段落A1所述的方法，其中，组装堆叠28的步骤包括：将具有所述低熔化温度热塑性塑料54的高熔化温度热塑性复合预浸料64的条带32铺放到表面34上。
A6、还提供了根据段落A5所述的方法，其中，熔化所述低熔化温度热塑性塑料54的步骤包括：在铺放高熔化温度热塑性复合预浸料64的所述条带32时，加热所述条带32下方的所述低熔化温度热塑性塑料54。
A7、还提供了根据段落A1所述的方法，其中，引入低熔化温度热塑性塑料54的步骤包括：以促进将所述高熔化温度热塑性复合层片46结合到一起的模式58，60将所述低熔化温度热塑性塑料54施加到所述高熔化温度热塑性复合层片46的表面34上。
A8、还提供了根据段落A1所述的方法，其中，引入低熔化温度热塑性塑料54的步骤包括：以促进所述复合层片46成形为期望形状的模式58，60将所述低熔化温度热塑性塑料54施加到所述高熔化温度热塑性复合层片46的表面34上。
A9、还提供了根据段落A1所述的方法，其中，引入低熔化温度热塑性塑料54的步骤包括：通过以下手段之一将所述低熔化温度热塑性塑料54施加到所述高熔化温度热塑性复合件46的表面34上：
将所述低熔化温度热塑性塑料54的干燥颗粒62沉积到所述表面34上；
使熔融的低熔化温度热塑性塑料54流到所述表面34上；以及
将液化的低熔化温度热塑性塑料54喷涂到所述表面34上。
根据本发明的又一方面，提供了：
B1、一种制造热塑性复合结构20的方法，该方法包括以下步骤：
生产具有纤维增强热塑性层片30的复合预制件88，其中，所述层片30包括高熔化温度热塑性塑料46和低熔化温度热塑性塑料54；
通过熔化所述低熔化温度热塑性塑料54将所述层片30结合到一起；以及
使所述复合预制件88固结。
B2、还提供了根据段落B1所述的方法，其中：
所述高熔化温度热塑性塑料46是预浸料；并且
生产复合预制件88的步骤包括：将所述低熔化温度热塑性塑料54施加到所述预浸料的表面34。
B3、还提供了根据段落B2所述的方法，其中，施加所述低熔化温度热塑性塑料54的步骤通过以下手段中的一种来执行：
将液化状态下的所述低熔化温度热塑性塑料54沉积到所述预浸料的所述表面34上；
将所述低熔化温度热塑性塑料54的颗粒62沉积到所述预浸料的所述表面34上；以及
在所述预浸料的大致整个表面34上喷涂所述低熔化温度热塑性塑料54。
B4、还提供了根据段落B2所述的方法，其中，生产复合预制件88的步骤包括：
组装所述层片30的堆叠28，包括铺设所述层片30中的每个；以及
熔化所述预浸料的所述表面34上的所述低熔化温度热塑性塑料54。
B5、还提供了根据段落B4所述的方法，其中，在铺设所述层片30期间执行熔化所述低熔化温度热塑性塑料54的步骤。
B6、还提供了根据段落B1所述的方法，其中，固结步骤包括：
通过加热所述预制件88来熔化所述高熔化温度热塑性塑料54；以及
压缩所述预制件88。
B7、还提供了根据段落B6所述的方法，该方法进一步包括：
将所述预制件88成形为期望形状，
其中，加热所述预制件88会熔化所述低熔化温度热塑性塑料54以在成形步骤期间允许所述层片30相对于彼此滑动。
B8、还提供了根据段落B1所述的方法，其中，生产复合预制件88的步骤包括：
通过使用自动带铺设机器82铺放热塑性预浸料的条带32来铺设所述层片30；以及
在通过将热能52引导到所述预浸料的所述条带32的表面34上来铺放所述预浸料的所述条带32时熔化所述低熔化温度热塑性塑料54。
根据本发明的又一方面，提供了：
C1、一种制造复合材料的条带32，64以用于制造复合结构20的方法，该方法包括以下步骤：
提供高熔化温度热塑性预浸料64的条带32，64；以及
在高熔化温度热塑性预浸料64的所述条带32，64的表面34上施加低熔化温度热塑性塑料54。
C2、还提供了根据段落C1所述的方法，其中，施加低熔化温度热塑性塑料54的步骤通过以下手段中的一种来执行：
将所述低熔化温度热塑性塑料54的颗粒62沉积到所述高熔化温度热塑性预浸料64的所述表面34上；以及
使液化的低熔化温度热塑性塑料54流到所述高熔化温度热塑性预浸料64的所述表面34上。
C3、还提供了根据段落C1所述的方法，该方法进一步包括：
通过将所述低熔化温度热塑性塑料54加热至其熔化温度而将所述低熔化温度热塑性塑料54粘附在所述高熔化温度热塑性预浸料64的所述表面34上。
C4、还提供了根据段落C3所述的方法，该方法进一步包括：
通过冷却所述低熔化温度热塑性塑料54来凝固所述低熔化温度热塑性塑料54；以及
将所述高熔化温度热塑性预浸料64卷绕到卷轴80上。
根据本发明的又一方面，提供了：
D1、一种热塑性复合带64，该热塑性复合带64包括：
高熔化温度热塑性预浸料64的条带32；以及
低熔化温度热塑性塑料54，所述低熔化温度热塑性塑料54粘附至高熔化温度热塑性预浸料64的所述条带32的表面34，所述低熔化温度热塑性塑料54的熔化温度低于高熔化温度热塑性预浸料64的所述条带32的熔化温度。
D2、还提供了根据段落D1所述的热塑性复合带64，其中：
高熔化温度热塑性预浸料64的所述条带32的熔化温度超过大约300℃；并且
所述低熔化温度热塑性塑料54的熔化温度低于大约300℃。
D3、还提供了根据段落D2所述的热塑性复合带64，其中：
高熔化温度热塑性预浸料64的所述条带32是PSU、PEI、PEKK和PEEK中的一者；并且
所述低熔化温度热塑性塑料54是聚乙烯和聚丙烯中的一者。
根据本发明的又一方面，提供了：
E1、一种热塑性复合预制件88，该热塑性复合预制件88包括：
热塑性预浸料46的层片30的堆叠28，所述堆叠28具有能使所述层片30固结的熔化温度；以及
将所述层片30结合到一起的热塑性聚合物54，所述热塑性聚合物54的熔化温度低于所述热塑性预浸料46的熔化温度。
E2、还提供了根据段落E1所述的热塑性复合预制件88，其中：
所述热塑性预浸料46的熔化温度超过大约300℃；并且
所述热塑性聚合物54的熔化温度低于大约300℃。
已经出于说明和描述的目的呈现了对不同说明性实施方式的描述，并且不旨在穷尽或限制于所公开形式的实施方式。对于本领域普通技术人员来说，许多修改和变化将是显而易见的。此外，与其他说明性实施方式相比，不同的说明性实施方式可提供不同的优点。所选择的一个或多个实施方式被选择和描述以便最好地解释实施方式和实际应用的原理，并且使本领域普通技术人员能够理解具有适于特定用途和预期的各种修改的各种实施方式的公开内容。

Claims (13)

1.一种制造热塑性复合预制件的方法，该方法包括以下步骤：
组装高熔化温度热塑性复合层片的堆叠；
在所述复合层片之间引入低熔化温度热塑性塑料；以及
通过熔化所述低熔化温度热塑性塑料而将所述高熔化温度热塑性复合层片结合到一起，
其中，引入低熔化温度热塑性塑料的步骤包括：将所述低熔化温度热塑性塑料的颗粒施加到所述层片中的每个层片的表面上。
2.根据权利要求1所述的方法，其中：
引入低熔化温度热塑性塑料的步骤包括：将所述低熔化温度热塑性塑料施加到所述层片中的每个层片的表面，由此所述低熔化温度热塑性塑料位于所述层片之间；并且
熔化所述低熔化温度热塑性塑料的步骤包括：将所述层片中的每个层片的所述表面上的所述低熔化温度热塑性塑料加热至所述低熔化温度热塑性塑料的熔化温度。
3.根据权利要求1所述的方法，其中，引入低熔化温度热塑性塑料的步骤包括：将液化的低熔化温度热塑性塑料施加到所述层片的表面上。
4.根据权利要求1所述的方法，其中，组装堆叠的步骤包括：将表面上具有所述低熔化温度热塑性塑料的高熔化温度热塑性复合预浸料的条带进行铺放。
5.根据权利要求4所述的方法，其中，熔化所述低熔化温度热塑性塑料的步骤包括：在铺放高熔化温度热塑性复合预浸料的所述条带时，加热所述条带下方的所述低熔化温度热塑性塑料。
6.根据权利要求1所述的方法，其中，引入低熔化温度热塑性塑料的步骤包括：以促进所述高熔化温度热塑性复合层片结合到一起的模式将所述低熔化温度热塑性塑料施加到所述高熔化温度热塑性复合层片的表面上。
7.根据权利要求1所述的方法，其中，引入低熔化温度热塑性塑料的步骤包括：以促进所述复合层片形成为期望形状的模式将所述低熔化温度热塑性塑料施加到所述高熔化温度热塑性复合层片的表面上。
8.根据权利要求1所述的方法，其中，引入低熔化温度热塑性塑料的步骤包括：通过以下手段之一将所述低熔化温度热塑性塑料施加到所述高熔化温度热塑性复合层片的表面上：
将所述低熔化温度热塑性塑料的干燥颗粒沉积到所述表面上；
使熔融的低熔化温度热塑性塑料流到所述表面上；以及
将液化的低熔化温度热塑性塑料喷涂到所述表面上。
9.一种热塑性复合带，该热塑性复合带包括：
高熔化温度热塑性预浸料的条带；以及
低熔化温度热塑性塑料，所述低熔化温度热塑性塑料粘附至高熔化温度热塑性预浸料的所述条带的表面，所述低熔化温度热塑性塑料的熔化温度低于高熔化温度热塑性预浸料的所述条带的熔化温度，其中，所述低熔化温度热塑性塑料的颗粒被施加到所述条带的表面上。
10.根据权利要求9所述的热塑性复合带，其中：
高熔化温度热塑性预浸料的所述条带的熔化温度超过300°C；并且
所述低熔化温度热塑性塑料的熔化温度低于300°C。
11.根据权利要求9所述的热塑性复合带，其中：
高熔化温度热塑性预浸料的所述条带是PSU、PEI、PEKK和PEEK中的一者；并且
所述低熔化温度热塑性塑料是聚乙烯和聚丙烯中的一者。
12.一种热塑性复合预制件，该热塑性复合预制件包括：
热塑性预浸料的层片的堆叠，所述堆叠具有能使所述层片固结的熔化温度；以及
将所述层片结合到一起的热塑性聚合物，所述热塑性聚合物的熔化温度低于所述热塑性预浸料的熔化温度，其中，所述热塑性聚合物的颗粒被施加到所述层片中的每个层片的表面上。
13.根据权利要求12所述的热塑性复合预制件，其中：
所述热塑性预浸料的熔化温度超过300°C；并且
所述热塑性聚合物的熔化温度低于300°C。
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