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CN105829092A - 复合结构体 - Google Patents

复合结构体 Download PDF

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Publication number
CN105829092A
CN105829092A CN201480068612.2A CN201480068612A CN105829092A CN 105829092 A CN105829092 A CN 105829092A CN 201480068612 A CN201480068612 A CN 201480068612A CN 105829092 A CN105829092 A CN 105829092A
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isolation part
resinous substrates
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D·蒂尔布鲁克
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Hexcel Composites Ltd
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Hexcel Composites Ltd
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    • B32B5/12—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
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    • B29C70/882—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced partly or totally electrically conductive, e.g. for EMI shielding
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    • B29C70/882—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced partly or totally electrically conductive, e.g. for EMI shielding
    • B29C70/885—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced partly or totally electrically conductive, e.g. for EMI shielding with incorporated metallic wires, nets, films or plates
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
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    • B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
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    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
    • H—ELECTRICITY
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    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/0045—Perforating
    • 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
    • B29K2705/00—Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
    • B29K2705/08—Transition metals
    • B29K2705/10—Copper
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    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
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Abstract

复合结构体(10)包括一个或多个导电路径(12)和一个或多个用于将路径(12)与结构体(10)主体隔离的隔离部。

Description

复合结构体
技术领域
本发明涉及复合结构体以及在复合材料中提供导电路径的方法，特别但不排他地对于机身结构体。
背景技术
飞机易受雷击的攻击。例如，商用飞机通常每年被攻击一次或两次。不同于它们的金属对应物，飞机中的复合结构体不容易导离由雷击产生的极限电流和电磁力。复合材料或者根本不导电(例如，玻璃纤维)或导电性显著低于金属(例如，碳纤维)，因此来自雷击的电流寻找可用的金属路径。鉴于此，雷击保护(LSP)已经成为重要的考虑事项，因为在超过30年之前复合材料已首次用于飞机。
如果闪电袭击未作保护处理的结构体，多达200,000A的电流寻找电阻最小的路径。在此过程中，如果通过紧固件周围间隙的以及在暴露边缘之间的电弧处于不同电势(称为边缘辉光)，这可能会使金属控制缆线汽化、焊接控制表面上的枢要、和使燃料箱内的燃料蒸气爆炸。这些直接的影响也通常包括最接近的雷击区域中的树脂汽化，由此可能烧穿层合体。雷击的其它潜在危害直接影响可包括，将热气体或热颗粒喷射进飞机结构体中，和冒火花。间接影响包括：当结构体中的磁场和电势差诱导产生瞬变电压时，这可能会损坏甚至是破坏未经EMF(电磁场)屏蔽或雷电保护的机载电子设备。保护复合结构体的需要已经促使开发多种专门的LSP材料。
传统LSP策略有三个目标：提供足够的导电路径，由此雷电电流留在结构体的外部；消除该导电路径中的间隙，以防止在连接点形成电弧和燃料蒸气点燃；以及通过在需要之处进行接地、EMF屏蔽和应用涌流抑制装置保护接线、缆线和灵敏设备不受涌流或瞬变的伤害。
传统上，复合结构体中的导电路径已经按以下途径之一建立：(1)将金属箔结合于结构体作为外铺层；(2)将铝或铜网结合于结构体作为外铺层或将一个铺层埋在下面；或(3)将导电材料的线材结合到层合体中。所有这些都要求将导电路径连接于飞机的其余部分，从而给电流足够数目的途径以安全离开飞机。这通常如下实现：使用金属连接带(即，电搭接)以将导电表面层与内部"接地面"相连，所述内部"接地面"包括金属部件例如发动机、导管等。因为雷击可涉及复合结构体中的金属紧固件，可能期望通过用塑料帽或多硫化物覆层包封紧固件螺母或套管来防止这些紧固件之间产生电弧或冒火花。
对于外部表面保护，已经开发了多种金属和金属化纤维产品，通常为机织和非织造的筛网和膨胀箔(expandedfoils)。这些网状产品能够使雷电的电流迅速沿结构体的表面传输，减少其集中。铝线是首批LSP材料之一，与碳纤维交织作为层合体的一部分。但是，使用铝和碳纤维会面临电化学腐蚀的危险。铜线可解除电化学腐蚀的威胁，但是重量是铝的三倍。当玻璃纤维可用于飞机时，该领域开始研究箔，然后是膨胀箔，其可以与层合体的外部铺层共固化。也使用包覆纤维(镍或铜电沉积到碳和其它纤维上)，但是其在EMF屏蔽应用中的表现远优于作为直接雷击保护体。
Astrostrike铝网由AstrosealProducts(Chester，Conn.)制造，其由实心箔制成，然后穿孔并膨胀以提高成型性能以及增强与复合结构体的粘合性。
多个供应商提供膨胀箔，其不需要较贵的机织法来制备，且据说相比于机织物可提供较大的悬垂性和整合性。Dexmet(Naugatuck，Conn.)提供众多种用于飞机的导电金属产品，包括铝，铜，磷青铜，钛和其它材料。
Strikegrid是由Alcore(Edgewood，Md.)提供的磷酸阳极化的连续膨胀铝箔(CEAF)产品，Alcore为M.C.GillCorp.集团公司的分部。其声称具有较好的耐腐蚀性和环境寿命，由于专利性覆层。其提供形式是在24英寸至36英寸(610mm至914mm)宽和2密尔至4密尔厚的连续卷上。
铝LSP网也由ECCGmbH&Co.KG(之前为C.Cramer&Co.，Heek-Nienborg，Germany)提供。
较新的进展是"一体化"LSP预浸料，其包含预埋的机织或非机织金属网。在叠层中应用第一层软毛(first-down)，产品显著降低了装配和制造成本，根据它们的供应商。
StrikeGuardLSP预浸料由APCM(Plainfield，Conn.)制造，且由合伙人/经销商AdvancedMaterialsandEquipment(Barkhamsted，Conn.)出售和支持。APCM的LSP预浸料由机织或非机织金属网制成，所述金属网浸渍有热熔粘合剂树脂，所述树脂由添加剂改性以增强基质的导电性，从而使整个预浸料为导电性体系。金属网选择包括各种尺寸的铜、铝、磷青铜和镍/铜包覆的聚酯纤维，其与重量相关的尺寸为0.08lb/ft2至0.060lb/ft2。预浸料也可具有轻质非机织覆盖物以增强表面光洁度，减少多孔性和在涂漆前所需的二次抛光。
HenkelCorp.的(BayPoint，Calif.)LSP铺膜将其SynSkin复合铺膜和Hysol膜粘合剂与Astroseal的轻质导电Astrostrike筛网合并，以得到雷击铺层家族。筛网也减少用于涂漆的表面制备的成本，降低原材料部件数目和装配时间，并且可以与预浸料共固化。据报告，SynSkin的填料材料和树脂基质独特组合使其一旦固化之后几乎不可能打磨透，并且与全环氧膜粘合剂相比可在打磨填充过程中对导电筛网提供显著较好的保护。
CytecEngineeredMaterials(Tempe，Ariz.)也以SURFACEMASTER905复合铺膜的形式制造LSP产品。
只有当适当地结合到飞机的整体保护体系时，LSP产品才可提供足够的保护。当将复合的机翼、机身表皮和水平尾翼接合时，将铜镗(薄或削尖的保护物，用作连接点)放置为层合体内的导电硬点，不仅与包埋的铜网接触而且与桥接机身和机翼之间间隙的粘合带接触。
对于其复合材料密集的中型787商业客机，BoeingCo.(Seattle，Wash.)已经对其雷击保护策略开发了多层法。Boeing在复合机身和机翼的外层使用薄金属网或箔以迅速耗散电流和按路线向机外放电并屏蔽机载电子设备。为避免可能导致冒火花的机翼-表皮紧固件之间的微小间隙和它们的孔洞，Boeing精确安装各紧固件，然后将其密封在内。Boeing使用非导电性填料或玻璃纤维来密封机翼表皮接触内部翼梁的边缘由此防止间隙，这种间隙可能会使电子在雷击过程中喷出，这是一种称为"边缘辉光"的现象。在燃料箱中，Boeing通过安装氮气发生系统(NGS)来消除燃料蒸气爆炸的威胁，该系统是通过用惰性氮气填充空间来使机翼箱内的可燃性蒸气最少。
常规地，LSP的焦点已经变成增加复合结构体的导电性。但是，保护飞机的关键部件也是重要的。
本发明总地旨在避免和/或减轻上述问题和/或提供改进。
发明内容
根据本发明，提供了复合结构体以及方法，如所附权利要求任一项所限定的。
当将包含导电纤维如碳纤维的纤维增强部件组装进具有金属紧固件的复合结构体时，雷击很可能会直接放电到暴露于飞机外部的任何紧固件上。与受袭击的紧固件直接接触的导电纤维可能因此经历电负荷的非常快速的增加。这在一些情况下可能导致在结构体内部表面上存在的任何暴露的纤维末端形成非常强的电场和电势。如果电场足够高到超过结构体内部气氛的介电击穿阈值，则可能发生介电击穿，由此使得放电到处于较低电势的表面的另一部件。该现象称为'边缘辉光'。
当纤维增强结构是机翼且内部表面构成飞机燃料箱的一部分时，边缘辉光很有可能导致燃料箱点燃，这会威胁飞机的安全。鉴于此，对于这种现象的管理存在严格的要求。
根据本发明，提供了一种复合结构体，其包括一个或多个导电路径和一个或多个用于将路径与结构体主体隔离的隔离部。
所述路径能够通过将电流导离关键部件来保护复合飞机结构体不发生放电现象例如边缘辉光。另外，所述路径能够控制导电方向。
在一种实施方式中，结构体包括纤维增强体和增强树脂基质，所述路径由所述纤维增强体和所述增强树脂基质形成。优选地，路径由与结构体本体的纤维增强体和基质相同的纤维增强体和相同的树脂基质形成。
本发明的一个问题可如下解决：将一个或多个离散体引入到连接复合结构体中易受雷击影响的金属元件的纤维中。这保护任何内部表面免于边缘辉光。
在本发明的另一种实施方式中，路径是离散的。隔离部可以在纤维增强体中包含离散体。在形成复合结构体的层合体铺叠工艺过程中，可以将纤维离散体引入到铺层的特定位置。这可以按以下方式进行，所述方式使得能够确保离散体之间的距离比树脂/纤维组合的临界纤维长度长，从而避免损害机械性质。
临界纤维长度(Lc)定义为
L c = σ f * d 2 τ c
其中σf*是纤维极限拉伸强度[Pa]，d是纤维直径[m]，τc是基质/纤维结合强度或基质剪切屈服强度(较小的那个)[Pa]。
隔离部在纤维的方向上延伸的一个尺寸可以对应于n×临界纤维长度，其中n＝1至100，优选地n＝1至50，更优选地n＝1至10。
在本发明进一步的实施方式中，隔离部由隔离部树脂基质形成。
在本发明的另一种实施方式中，提供了控制复合结构体中电流通路的方法，包括：在所述结构体中提供一个或多个导电路径，和将所述路径与所述结构体主体隔离。
借助于隔离部将路径与结构体隔离。
在优选的实施方式中，复合结构体由树脂预浸渍的纤维增强材料层(或预浸料层)的叠层制备。将各层或铺层排列以将金属元件直接连接于结构体的内部表面。可以在一个或多个铺层中引入一个或多个切口以确保路径隔离。然后将结构体固化，这可得到填充有树脂的切口离散体或隔离部。
可以按任何可想到的方式引入切口或离散体，包括用刀片切缝，激光切割，拉伸，超声破碎纤维。也可以用遥控设备例如ATL、AFP或其它系统的附件将其自动引入、或甚至通过手动操作将其引入。
在固化过程中，复合材料中的树脂流进切口并固化，由此形成对从金属元件引导到表面的电荷的回复性绝缘屏障。这可保护不发生边缘辉光。可以在每层引入几个纤维离散体，以增强保护效力，或以确保产生安全区域，该区域将会容忍离散体相对于经保护表面的位置公差，这是由于在制造过程中的修整和钻孔操作带来的公差。
最后，复合结构体可以包括用于感知或结构健康监测的其它设备。
附图说明
以下将示例性地以及参照附图描述本发明的具体实施方式，其中：
图1表示根据非本发明一种实施方式的结构体的平面图解；和
图2表示根据本发明一种实施方式的另一种结构体的平面图解。
本发明提供一种复合结构体，其包括用于将金属元件彼此连接的路径。借助于隔离部将该路径与复合结构体本体隔离。这些隔离部优选通过结构体的增强树脂形成。
在飞机中，路径可以优选配置在机械紧固件和/或框架和/或LSP表面结构和/或发动机和/或其它金属元件例如粘合带之间。
路径可以由导电性增强纤维例如碳纤维形成。
可替换地，可以使用金属化织物和/或金属化纤维。现在简要公开这样的纤维和/或织物的实例。DiamondFiberComposites(Cincinnati，Ohio)使用基于化学的包覆法(可得到均匀的包覆物)用各种金属包覆碳纤维，所述金属包括镍，铜，银，金，钯，铂和其它金属混合物(多层包覆物)。这些包覆的纤维可以作为连续纤维长度、短切纤维、机织物和非织造纱/垫获得。
ElectroFiberTechnologies(Stratford，Conn.)包覆到碳、石墨、玻璃、聚酯和其他合成纤维上的单金属或双金属混合物。该公司提供短切纤维(长度降至1mm/0.04英寸)和3K至80K的长丝束以及非织造纱和垫。
TechnicalFibreProducts(Newburgh，N.Y.)使用碳、镍包覆的碳、镀铝玻璃、碳化硅、不锈钢和镍纤维提供导电非织造垫和纱。
TextileProductsInc.(Anaheim，Calif.)提供用AS4-3K碳纤维和铝线制成的Style#4607216g/m2碳/铝混织布。其也提供用T650/35-3K碳纤维和铝线制成的Style#4608218g/m2混织布。两者都是平纹、14密尔厚和107cm/42英寸宽。
Varinit(Greenville，S.C.)提供导电增强织物，开发和制造产品以满足用户要求。
根据图1和2说明本发明的实施方式。图1显示复合结构体10，其由多个单向碳纤维增强层12，14，18的叠层组成，所述多个单向碳纤维增强层浸渍有树脂基质以形成预浸料。预浸料层由以下组成：不含导电表面材料的预浸料12，形式为膨胀铜箔(ECF)的含有导电表面材料的预浸料14，和形式为碳纤维丝束的含有连续导电层的预浸料18。在复合结构体中钻出螺孔16，并排列螺孔16使得插入螺孔16中的机械紧固件与层18直接接触。这可使得由于雷击而在紧固件上或紧固件附近产生的电流可以导离紧固件。
在图2中，参考数字对应于图1的相同部件。存在形式为碳纤维丝束18的切口的隔离部20以控制在雷击之后电流从紧固件导离到复合结构体中所需位置再到电流可以远离结构体的点的方向。
图2的复合结构体可以通过在增强纤维丝束中提供切口形成。在结构体的叠放阶段过程中通过激光切割引入切口或离散体。在叠放之后，树脂流进间隙并固化，由此形成对电荷和电流的回复性绝缘屏障。
可以在每层引入几个纤维离散体，以增强保护效力，或以确保产生安全区域，该区域将会容忍离散体相对于经保护表面的位置公差，这是由于在制造过程中的修整和钻孔操作带来的公差。
隔离离散体是临界纤维长度的几倍，由此确保复合结构体的机械性质不会减弱。
上述树脂基质可以包括任何适宜的树脂，这包括热固性材料、热塑性材料、或两者的混合物。优选地，树脂不含导电成分，所述导电成分可能在纤维离散体中积累且会减弱其绝缘性质。
因此提供了一种结构体和一种方法，它们能够有效控制复合结构体中的电荷和/或电流，特别是在但不排他地在飞机或风能结构体中。

Claims (15)

1.一种复合结构体(10)，其包括一个或多个导电路径(12)和一个或多个用于将路径(12)与结构体(10)主体隔离的隔离部。
2.前述权利要求任一项的结构体(10)，其中所述结构体包括纤维增强体和增强树脂基质，所述路径(12)由所述纤维增强体和所述增强树脂基质形成。
3.前述权利要求任一项的结构体(10)，其中路径(12)由与所述结构体主体相同的纤维增强体和相同的树脂基质形成。
4.前述权利要求任一项的结构体(10)，其中路径(12)是离散的。
5.结构体(10)，其中所述隔离部由隔离部树脂基质形成。
6.权利要求5的结构体(10)，其中所述隔离部树脂基质包括增强树脂基质。
7.权利要求2至6任一项的结构体，其中所述结构体包括多个纤维增强体的铺层，所述隔离部延伸穿过至少两个铺层。
8.前述权利要求任一项的结构体，其中所述隔离部的长度对应于n×临界纤维长度，其中n＝1至10，优选地n＝1至5。
9.前述权利要求任一项的结构体，其中所述导电路径由单向碳纤维形成。
10.权利要求9的结构体，其中所述碳纤维由金属包覆。
11.控制复合结构体中电流通路的方法，包括：在所述结构体中提供一个或多个导电路径，和将所述路径与所述结构体主体隔离。
12.权利要求11的方法，其中借助于隔离部将所述路径与所述结构体隔离。
13.权利要求11或12的方法，其中所述复合结构体由树脂预浸渍的纤维增强材料层的叠层制备，排列所述层以将金属元件直接连接于所述结构体的内部路径。
14.权利要求11至13任一项的方法，其中将一个或多个离散体引入到一个或多个层中以确保所述路径是被隔离的。
15.权利要求11至14任一项的方法，其中在固化之后的结构体具有树脂填充的离散体或隔离部。
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