JP2018518402A - 複合構造体の製造方法 - Google Patents
複合構造体の製造方法 Download PDFInfo
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Abstract
Description
一定の面に基部レイアップを設ける工程であって、その基部レイアップは第1の補強材料層を含んで成る、基部レイアップを設ける工程と、
その基部レイアップ上にコア層を設ける工程であって、そのコア層は開放セル状構造体を含んで成り、その開放セル状構造体は固着していない粒子によって少なくとも部分的に
充填されている、コア層を設ける工程と、
そのコア層の上に頂部レイアップを設ける工程であって、その頂部レイアップは第2の補強材料層を含んで成る、頂部レイアップを設ける工程と、
圧力差によってその組立品中にマトリックス材料を案内する工程と、
そのマトリックス材料を硬化する工程と、を備える。
動する場合、そのミクロスフェアはその樹脂流動に沿って引き寄せられ、その部品にわたってミクロスフェアの分配に有意なばらつきを招くであろう。ハニカムは、ミクロスフェアの動きを抑制する一方でハニカムを通じた流体の流動を依然として可能にし、したがって、その部分にわたって一定で制御可能かつ高い体積分率を有し、そのミクロスフェアを予め固着するためのリソースを必要としない、複合フォームコア部品の生産を可能にする。
アに対するスキンの固着強度との減少を招く。さらに、凝集力、粘着力、及び密にまとめられた構成によって、粒子がそれら自体を互いに対して、及び別に用意可能であるセル状構造体内のハニカム壁に対して保持し、次いでその構造の一体性を保ちながらコア層を移すことができる。これは、水などの表面張力が高い搬送液の場合に特に当てはまる。
図1〜3では、下部内面14を有する鋳型12を含んで成る組立品10を示す。鋳型12は、その中に配置されるレイアップ構成を収容するのに十分高い側部を有する平らな開放鋳型である。下面14には、第1の導管18へと接続されている第1の開口部16が設けられる。基部レイアップ20は、下部内面14上に構成されており、
メッシュの形態の真空媒体22と、
剥離材料24と、
補強材料26と、
障壁層27と、を含んで成る。
に樹脂が注入された時に、次いで硬化され、ミクロスフェアで充填されたセル状コア28に固着された補強スキン26及び38を有する複合サンドイッチ構造体を作ることができる。
搬送液の使用法に応じて、ミクロスフェアは処理要件にしたがって様々なちょう度を有し得る。例えば、搬送液が使用されずミクロスフェアが乾燥したままの場合、搬送液の除去又は蒸発の必要がなくなる。しかし、これによってミクロスフェアが簡単に空気で運ばれることができるようになり、それらを密な構成にまとめることはより難しく、湾曲部を有する形状を製造する場合にミクロスフェアが浮いてハニカムセルの外に出ることを阻止することができない。搬送液が使用される場合は、これらの問題は克服され得る。ミクロスフェアと搬送液との液体混合物及び続く過剰な搬送液の除去によって、その混合物の素早く簡単な運搬、堆積、及び拡散が可能になる。また、搬送液の凝集力によって、ミクロスフェアは密にまとめられ、一緒に保持される。これに加えて、材料の気密封止に先立ってその材料を通したガスの引き出しを行うために真空ソースを使用することによって、成形に先立ってミクロスフェアがさらに圧縮され、それによって材料内でミクロスフェアのより高い体積分率が得られる。
な部品を製造するために互いに隣り合って、又は互いの上に積まれてもよい。コア前駆体材料の複数の別のシートの間に結果として生じる任意の間隙は、続いて乾燥粒子又は搬送液中の粒子のいずれかによって充填され得る。最終的な鋳型中へのコア層の配置に先立ってそれらのコア層を用意するさらなる利益は、それらの用意に、用意プロセスの速度と効率とを改善可能な専用の鋳型を使用することができることである。
樹脂は、第1の導管に接続された真空ポンプによって第1の導管よりむしろ第2の導管から注入されてよい。これに代えて、又はこれに加えて、搬送液の除去、樹脂の供給、又は真空ソースのために、本組立品にさらなる導管が付与されてもよい。マトリックス材料又は樹脂を組立品の底部から注入する利点は、揮発性物質は自然と組立品の上へと上昇することから、揮発性物質が追い払われて空隙容量が最小化され得ることである。
Claims (18)
- 複合サンドイッチ構造体の製造方法において、
一定の面に基部レイアップを設ける工程であって、前記基部レイアップは第1の補強材料層を含んで成る、基部レイアップを設ける工程と、
前記基部レイアップ上にコア層を設ける工程であって、前記コア層は開放セル状構造体を含んで成り、前記開放セル状構造体は固着していない粒子によって少なくとも部分的に充填されている、コア層を設ける工程と、
前記コア層の上に頂部レイアップを設ける工程であって、前記頂部レイアップは第2の補強材料層を含んで成る、頂部レイアップを設ける工程と、
圧力差によって前記組立品中にマトリックス材料を案内する工程と、
前記マトリックス材料を硬化する工程と、を備える方法。 - 前記開放セル状構造体はハニカム材料であり、前記ハニカムは開放セル状構造体を有する、請求項1に記載の方法。
- 前記粒子は1種類以上の粒子異なる種類の粒子を含み、前記セル状構造体のセルは1種類以上の粒子で充填されている、請求項1又は2に記載の方法。
- 第1の群のセルは1種類の粒子又は粒子の組み合わせで充填されており、第2の群のセルは異なる種類の粒子又は粒子の組み合わせで充填されている、請求項3に記載の方法。
- 予備形成された構造体が、局所的サンドイッチ構造体特性をもたらすために前記コア層の複数の領域に配置されている、請求項1〜4の何れか一項に記載の方法。
- 前記セル状構造体を充填している前記粒子は、搬送液と混合されている、請求項1〜5の何れか一項に記載の方法。
- 前記搬送液は、注入に使用される前記マトリックス材料である、請求項6に記載の方法。
- 過剰な搬送液が除去される、請求項6に記載の方法。
- 前記組立品は気密封止されたエンクロージャ内に封止され、前記エンクロージャには、前記エンクロージャの内部との流体連通を可能にする1つ以上の導管が設けられる、請求項1〜8の何れか一項に記載の方法。
- 前記マトリックス材料は前記導管を介して前記組立品に対して提供される、請求項9に記載の方法。
- 固着していない粒子を有する前記コア層が前記基部レイアップ上に直接に載置される、請求項1〜10の何れか一項に記載の方法。
- 前記基部レイアップ上に移すのに先立って、固着していない粒子を有する前記コア層が用意される、請求項1〜10の何れか一項に記載の方法。
- 用意された複数のコア層は、前記鋳型において互いに隣り合って、又は互いの上に配置される、請求項12に記載の方法。
- 前記コア層の少なくとも一方の側に障壁層を設ける、請求項1〜13の何れか一項に記
載の方法。 - 前記面は鋳型の底部内面であり、前記鋳型は側壁を備える、請求項1〜14の何れか一項に記載の方法。
- 前記マトリックスは圧力差によって分配し、前記圧力差は、1つ以上の導管を介して前記気密封止されたエンクロージャに連結している真空ソースを使用して生じる、請求項1〜15の何れか一項に記載の方法。
- 前記基部レイアップと前記鋳型との間、前記頂部レイアップと前記頂部鋳型又は真空バッグとの間、又はその両方に剥離材料を設ける、請求項1〜16の何れか一項に記載の方法。
- 前記粒子は、ミクロスフェアと、繊維と、板状体と、ナノチューブと、コアシェル粒子と、自己組織化高分子と、フライアッシュと、ナノクレイと、溶融コロイド粒子と、自己組織化コポリマーとを含む群から選択される、請求項1〜17の何れか一項に記載の方法。
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