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CN111634409B - 复合加劲件 - Google Patents

复合加劲件 Download PDF

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Publication number
CN111634409B
CN111634409B CN202010124126.5A CN202010124126A CN111634409B CN 111634409 B CN111634409 B CN 111634409B CN 202010124126 A CN202010124126 A CN 202010124126A CN 111634409 B CN111634409 B CN 111634409B
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section
region
stiffener
composite stiffener
constant cross
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CN111634409A (zh
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张军伟
马丁·盖顿德
约舒亚·博纳文图拉
约翰·伍科克
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Airbus Operations GmbH
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Abstract

一种用于加劲件加固的面板的复合加劲件。该加劲件具有纵向方向和在加劲件的端部处终止的延伸尽头区域。加劲件还具有恒定截面区域，该恒定截面区域在该纵向方向上位于延伸尽头区域内侧、且具有横向于纵向方向的恒定的横截面，该恒定的横截面具有位于相邻的脚部之间的冠部。该延伸尽头区域具有横向于纵向方向的变化的横截面，该变化的横截面具有位于相邻的脚部之间的冠部且该冠部朝向加劲件的该端部减小高度从而形成斜坡。该复合加劲件包括许多由无皱褶织物层制成的覆盖层。

Description

复合加劲件
技术领域
本发明涉及一种用于加劲件加固的面板的复合加劲件以及制造加劲件的方法。
背景技术
加劲件通常附接到面板或与面板成一体以向面板提供加固。例如，桁条是长形的加劲构件，其可以附接到飞行器机翼的蒙皮或盖并沿大体翼展方向延伸。相同的基本布局可见于垂直安定面和水平安定面中。在飞行器机身中也能找到类似的结构，其中加劲件沿飞行器纵向方向延伸。加劲件提供必要的加固，以承受由飞行器在飞行过程中以及在地面上时所经受的空气动力学载荷和结构载荷。
在桁条终止的区域中，桁条的横截面改变，以利于将载荷从桁条传递到面板。桁条的高度(垂直于面板的平面)通常朝着被称为延伸尽头区域的终端减小。
桁条延伸尽头会导致对于制造复合桁条而言的复杂几何结构的区域。在这些复杂几何结构的区域中可能会发生诸如起皱之类的制造问题。不同的纤维层材料因它们不同的悬垂性而会或多或少地适合于这些区域。皱褶和其他制造缺陷、诸如气泡和纤维错位可能会带来局部应力点，并且因此会降低桁条的整体性能。简化制造过程以使纤维层的切割和固化的复合桁条的切割最小化来限定几何结构可降低制造成本和时间。
发明内容
本发明的第一方面提供了一种用于加劲件加固的面板的复合加劲件，其中，加劲件具有纵向方向、在加劲件的端部处终止的延伸尽头区域以及恒定截面区域，该恒定截面区域在纵向方向上位于延伸尽头区域的内侧并且具有横向于纵向方向的恒定的横截面，该恒定的横截面具有位于相邻的脚部之间的冠部，其中，延伸尽头区域具有横向于纵向方向的变化的横截面，该变化的横截面具有位于相邻的脚部之间的冠部，并且该冠部朝向加劲件的端部减小高度从而形成斜坡，并且该复合加劲件包括多个由无皱褶织物层制成的覆盖层(blankets of non-crimp fabric layers)。
在相邻的脚部之间具有冠部的桁条可以被称为例如“Ω”形或“高顶礼帽”形或“硬礼帽”形的桁条。在每个脚部与冠部之间可以延伸有腹板。织物层可以从一个脚部的侧边缘连续地延伸并向上穿过一个腹板到达冠部，并向下穿过另一腹板到达冠部的另一侧上的脚部的侧边缘。
无皱褶织物(NCF)通常被设置为包括两个或可能地更多个的纤维层的“覆盖层”。每个纤维层可以是单向的。所述纤维层例如通过缝合而结合在一起以形成覆盖层。覆盖层中的纤维层通常具有不同的纤维取向。包括具有不同单向纤维取向的两个纤维层的覆盖层被称为双轴NCF。也可以获得三轴和四轴织物。
NCF覆盖层的优点在于，因为覆盖层中的多个织物层被缝合在一起使得它们能够被作为一件铺放，所以NCF覆盖层可以使铺放更快速。然而，NCF覆盖层存在与例如编织织物或单向织物相比悬垂性相对较差的问题，这是由于覆盖层中的各层的纤维取向不同以及在各层之间进行了缝合。覆盖层中的层数越少，悬垂性越好，因此对于悬垂性能而言，双轴NCF覆盖层可能是首选的。具有与加劲件的纵向方向对齐的0度纤维层的NCF覆盖层提供了沿主载荷方向的出色的载荷承载性能。
Ω形加劲件的延伸尽头区域的特定几何形状——在加劲件的在延伸尽头区域中的冠部中具有斜坡——对在加劲件中使用NCF材料提出了挑战。发明人已经发现了在加劲件中使用NCF材料、且一旦在树脂灌注之前铺放好后即无需对加劲件中的纤维材料进行切割的实现具有成本效益的制造的方法。
在第一示例中，加劲件包括NCF覆盖层和编织纤维层两者，在较难形成的延伸尽头区域中，NCF覆盖层脱落(dropped off)而仅留下编织纤维层。编织纤维层提供的若干优点在于，它们提供了更好的悬垂性且在延伸尽头区域中不存在0度纤维层，这提供了更好的受力性能。
延伸尽头区域可以包括一个或更多个编织织物层。
所述一个或更多个编织织物层可以从斜坡的顶部延伸到斜坡的底部。
复合加劲件还可以包括在恒定截面区域与延伸尽头区域之间的过渡区域。恒定截面区域可具有夹在编织织物层之间的多个由无皱褶织物层制成的覆盖层。所述由无皱褶织物层制成的覆盖层中的至少一个由无皱褶织物层制成的覆盖层可在过渡区域中脱落。编织纤维层还提供了良好的损伤容限。因此，有利的是将编织纤维层设置为铺层的外层(顶部层和底部层)。
恒定截面区域中的所有由无皱褶织物层制成的覆盖层均可以在过渡区域中脱落。
延伸尽头区域可以包括编织织物层且不包括无皱褶织物覆盖层。
在第二示例中，加劲件包括NCF覆盖层，所述NCF覆盖层中的至少一个NCF覆盖层延伸到加劲件的该端部处并且被切割以形成省缝(darts)，使得NCF覆盖层可以垂下以形成该延伸尽头区域的形状。在铺层中仅使用NCF覆盖层提供了经济性，但要花费额外的时间来形成省缝。
延伸尽头区域可以包括一个或更多个无皱褶织物覆盖层。覆盖层可以在延伸尽头区域中具有切出的省缝并使自身重叠。
延伸尽头区域可以具有包括斜坡的斜坡部分以及在该斜坡与加劲件的该端部之间的大致平面状的趾部。
由无皱褶织物层制成的覆盖层中的每个由无皱褶织物层制成的覆盖层可包括：第一层，该第一层具有与加劲件的纵向方向对齐的0度纤维取向；以及第二层，该第二层具有不与加劲件的纵向方向对齐的纤维取向。
恒定截面区域可以具有Ω形截面。
恒定截面区域的横截面可具有延伸穿过冠部和相邻的脚部的连续层。
加劲件可以包括碳纤维复合材料。
本发明的另一方面提供了一种飞行器结构，该飞行器结构包括用桁条加固的面板，该桁条是根据第一方面的加劲件。
本发明的另一方面提供了一种制造加劲件的方法，该方法包括将多个由无皱褶织物层制成的覆盖层和多个编织织物层作为干态织物铺放在模具上，并且对所述干态织物共注入以树脂，然后共固化以形成加劲件。该加劲件可以是根据第一方面的加劲件。
该方法可以包括：将夹在编织织物层之间的多个由无皱褶织物层制成的覆盖层铺放在恒定截面区域中，对由无皱褶织物层制成的覆盖层中的至少一个由无皱褶织物层制成的覆盖层进行切割使得该覆盖层在过渡区域中脱落。
该方法还可以包括对所有的由无皱褶织物层制成的覆盖层进行切割，使得所有的覆盖层在过渡区域中脱落。
延伸尽头区域可以包括编织织物层且不包括无皱褶织物覆盖层。
该方法还可以包括将多个编织织物层铺放在模具的用于限定延伸尽头区域中的斜坡的形状的部分上，随后进行共固化步骤而无需对铺放在模具上的编织织物层进行切割的中间步骤。
附图说明
现在将参照附图描述本发明的实施方式，在附图中：
图1是飞行器的平面图；
图2是飞行器机翼盒段的示意性平面图；
图3是飞行器机翼盒段的示意性截面图；
图4是桁条加固的面板的剖视图；
图5是桁条(加劲件)的三维视图；
图6是穿过桁条的恒定截面区域的横向截面图；
图7是穿过桁条的纵向截面图，该纵向截面图示出了恒定截面区域、延伸尽头区域以及过渡区域；
图8是NCF双轴覆盖层的示意图；
图9是桁条铺层的示意图，其中，NCF覆盖层夹在编织纤维层之间；
图10是被铺放在模具上的铺层的截面图；以及
图11是切出了省缝的NCF覆盖层的示意图。
具体实施方式
图1显示了具有左机翼2和右机翼3的飞行器1。每个机翼均具有悬臂结构，该悬臂结构的长度在翼展方向上从翼根延伸至翼梢，翼根结合到飞行器机身4。机翼2、3在结构上相似，因此将仅参照图2和图3详细描述右机翼3。所示的飞行器1是常规的跨音速喷气式客运飞行器，但是应当理解，本说明书可以涉及多种飞行器，包括军用飞行器、民用飞行器、通用航空飞行器、喷气式飞行器、螺旋桨式飞行器、高翼飞行器、低翼飞行器等。
机翼的主要结构元件是由图3的截面图中所示的上盖5、下盖6和前翼梁7、后翼梁8形成的机翼盒段。盖5、6和翼梁7、8均为碳纤维增强聚合物(CFRP)层压部件。每个盖均具有空气动力学表面(上盖5的上表面和下盖6的下表面)，在飞行器飞行期间空气在该表面上流动。每个盖还具有内表面，该内表面上带有“桁条”或加劲件。每个盖均带有大约30至40个加劲件，因此，为清楚起见，图2中仅示出了5个。桁条标记为40。
如图3所示，每个翼梁具有C形横截面，其中上翼梁凸缘和下翼梁凸缘分别结合到盖5、6中相应一个盖的内表面，并且翼梁腹板在翼梁凸缘之间延伸。盖5、6中的一个或更多个盖可以与翼梁7、8成一体以形成Ω形或“u”形或“n”形的机翼盒段部件。
机翼盒段还具有多个横向肋条13，每个肋条均结合至盖5、6和翼梁7、8。这些肋条包括位于机翼盒段的根部处的内侧肋条10和沿机翼盒段的长度方向与最里面的肋条间隔开的多个另外的肋条13。机翼上有许多这样的肋条13，为清楚起见，在图2中仅示出了10个。
机翼盒段可以分为多个燃料箱，诸如由内侧肋条10、以实线表示的中跨肋条13a、盖5、6以及翼梁7、8界定的内侧燃料箱；以及由中跨肋条13a、机翼盒段的梢端处的外侧肋条12、盖5、6和翼梁7、8界定的外侧燃料箱。
内侧肋条10是附接肋条，该附接肋条形成机翼盒段的根部并且结合至机身4的本体内的中央机翼盒段20。如图2中可见的，加劲件40在靠近内侧肋条10和外侧肋条12处停止但穿过肋条13。
图4示出了附接至上翼盖5的桁条40的示意性剖视图，并且特别地示出了桁条40终止的区域。桁条沿与机翼的翼展方向大致对齐的纵向方向并具有“Ω”形横截面形状。桁条40具有横向于纵向方向的大体恒定的横截面以及在桁条40的端部处终止的延伸尽头区域41。
参照图5至图7更详细地示出了桁条40。桁条40的恒定截面区域42在纵向方向x上位于延伸尽头区域41的内侧(即远离延伸尽头区域41)。恒定截面区域42具有横向于纵向方向x的恒定的横截面，该恒定的横截面具有位于相邻的脚部44a、44b之间的冠部43。冠部通过相应的腹板45a、45b结合至脚部44a、44b。腹板45a、45b大致在垂直于上翼盖5的平面x-y的直立方向z上，因此腹板45a、45b在桁条40的恒定截面区域42中大致平行于纵向方向x。
延伸尽头区域41具有横向于纵向方向x的变化的横截面，该变化的横截面也具有位于相邻的脚部44a、44b之间的冠部43。在延伸尽头区域41中，冠部43朝向加劲件40的端部处的趾部46减小高度从而形成斜坡47。延伸尽头区域41具有与内侧恒定截面区域42相似的基本“Ω”形，但在脚部44a、44b上方的冠部43的高度从斜坡的顶部48到斜坡的底部49大致线性地减小。在斜坡的顶部48与恒定截面区域42之间存在过渡区域50，将参照图7更详细地描述该过渡区域50。
首先转到图6，其示出了穿过恒定截面区域42的横截面，可以看出，加劲件包括层叠的纤维层，所述层叠的纤维层包括最下层的编织织物层51、最上层的编织织物层52和位于最下层的编织织物层51与最上层的编织织物层52之间的多个由无皱褶织物(NCF)层制成的覆盖层53。
图7示出了在xz平面中沿着加劲件40的中央纵向轴线x穿过加劲件40的横截面。在恒定截面区域42中，可以看到所述多个由无皱褶织物层制成的覆盖层53夹在编织织物层51、52之间。编织织物层51、52连续地穿过恒定截面区域42、过渡区域50、延伸尽头区域41和趾部46。由无皱褶织物层制成的覆盖层53终止于过渡区域50中。优选地，各个由无皱褶织物层制成的覆盖层53沿着纵向方向x以交错的方式终止。因此，由无皱褶织物层制成的覆盖层53的堆叠体的高度朝向加劲件的该端部减小，从而在冠部43、腹板45a、45b和脚部44a、44b中朝向桁条的该端部形成锥形。在过渡区域50中，所有由无皱褶织物层制成的覆盖层53都终止，从而在延伸尽头区域41中仅编织织物层51、52留在斜坡47的顶部48处。
图8示出了所述无皱褶织物覆盖层53中的一个无皱褶织物覆盖层的分解图，该无皱褶织物覆盖层包括具有0°纤维取向的第一层53a和具有45°纤维取向的第二层53b。第一层53a和第二层53b例如通过缝合而结合在一起，如由虚线53c大致指示的。在此示例中，0°纤维取向与加劲件40的纵向轴线x对齐。
在加劲件40的恒定截面区域42中，具有多个纤维取向为0°的层可有利于为加劲件40提供纵向弯曲刚度。但是，在延伸尽头区域41中，该弯曲刚度通常是不期望的，因为延伸尽头区域41的目的是提供柔韧性，以将加劲件载荷过渡到该加劲件所附接的面板、例如上翼盖5或下翼盖6中。
可以将所述多个由无皱褶织物层制成的覆盖层53布置成堆叠体以实现大致平衡的铺层。为此，一些覆盖层53可以包括具有0°/45°纤维取向的双轴NCF覆盖层，而其他由NCF织物制成的覆盖层53可以具有0°/135°纤维取向。在优选的实施方式中，双轴0°/45°纤维取向的NCF覆盖层的数目等于0°/135°纤维取向的NCF覆盖层的数目。具有0°/45°纤维取向和0°/135°纤维取向的不同的NCF覆盖层可以在整个堆叠体中交替并且在整个NCF覆盖层53的堆叠体中的中间平面的两侧具有镜像的铺层。
通过在过渡区域50中终止NCF覆盖层53，以便仅将编织织物层51、52留在延伸尽头区域41中，可以优化加劲件的延伸尽头区域中的受力性能。另外，编织织物层51、52通常会具有比NCF覆盖层53更好的悬垂性能，因此无需对编织织物层51、52进行任何收省即可形成延伸尽头区域41的复杂形状。编织织物可以是例如5综片(harness)织物，但也可以使用任何其他适合的编织织物。良好的悬垂性能以及无需对编织纤维织物层51、52进行收省有助于改善加劲件的可制造性以及最终复合加劲件40的质量。
图10示意性地示出了制造加劲件40的方法，其中，将干态或半预浸碳纤维材料层铺放在模具60上。最上面的编织纤维织物层52首先放置在模具60上，接着是所述多个NCF覆盖层53，最后是最下面的编织纤维织物层51。然后对干态的或半预浸料层以常规方式注入适合的树脂并固化。一旦固化，就可以将加劲件40从模具60中移除。
模具60具有遵循包括过渡区域50和延伸尽头区域41的成品加劲件40的外模制表面的形状，使得在固化之后可以将成品加劲件40从模具60中移除，而无需在于模具60上铺放期间或者在从模具60上移走固化的复合加劲件40之后对纤维织物层进行任何切割或机加工。通过避免这些切割步骤，加劲件40的可制造性得以显著地改善。
在替代性实施方式中，加劲件40可在延伸尽头区域中包括NCF覆盖层53，但对前文中描述的加劲件40的整体形状不做任何改变。由于NCF覆盖层53的悬垂性不如编织纤维织物，因此如图11所示，在NCF覆盖层53中可能需要切出省缝70。
当具有省缝70的NCF覆盖层53被铺放在模具60上时，覆盖层53的在省缝70两侧的边缘被放到一起并且略微重叠。省缝70的存在为NCF覆盖层53在遵循模具60的在延伸尽头区域41中的形状方面提供了充分的可成形性。
在NCF覆盖层53被收省的情况下，则可以在加劲件40的铺层中仅使用NCF覆盖层53，并可以省去编织纤维织物层51、52。替代性地，可以保留编织纤维织物层51、52。当具有省缝70的NCF覆盖层用在延伸尽头区域41中时，可使存在与恒定截面区域42中的一些NCF覆盖层53在过渡区域50中脱落。换句话说，与恒定截面区域42相比，延伸尽头区域41可具有更少的数目的NCF覆盖层53。尽管在延伸尽头区域41中存在NCF覆盖层53可能不是最优选的，因为可能需要在将覆盖层53铺放于模具60上之前事先从覆盖层53中切出省缝70，但这种布置仍是有利的，因为在从模具60中移除固化后的加劲件40之后无需对固化后的加劲件40进行进一步切割。
在出现单词“或”的情况下，这应被理解为是指“和/或”，使得所涉及的项目不一定是相互排斥的，而可以以任何适当的组合使用。
尽管以上已经参考一个或更多个优选实施方式描述了本发明，但是应当理解，在不脱离所附权利要求所限定的本发明范围的情况下，可以进行各种改变或改型。

Claims (16)

1.一种用于加劲件加固的面板的复合加劲件，其中，所述复合加劲件具有纵向方向、在所述复合加劲件的端部处终止的延伸尽头区域以及恒定截面区域，所述恒定截面区域在所述纵向方向上位于所述延伸尽头区域内侧、且具有横向于所述纵向方向的恒定的横截面，所述恒定的横截面具有位于相邻的脚部之间的冠部，其中，所述延伸尽头区域具有横向于所述纵向方向的变化的横截面，所述变化的横截面具有位于相邻的脚部之间的冠部且该冠部朝向所述复合加劲件的所述端部减小高度从而形成斜坡，并且所述复合加劲件包括位于所述恒定截面区域与所述延伸尽头区域之间的过渡区域，其中，所述恒定截面区域具有夹在编织织物层之间的多个由无皱褶织物层制成的覆盖层，并且所述由无皱褶织物层制成的覆盖层中的至少一个由无皱褶织物层制成的覆盖层在所述过渡区域中脱落，其中，所述编织织物层连续地穿过所述恒定截面区域、所述过渡区域和所述延伸尽头区域。
2.根据权利要求1所述的复合加劲件，其中，所述编织织物层从所述斜坡的顶部延伸至所述斜坡的底部。
3.根据权利要求1所述的复合加劲件，其中，在所述恒定截面区域中的所有的所述由无皱褶织物层制成的覆盖层在所述过渡区域中脱落。
4.根据权利要求1或3所述的复合加劲件，其中，所述延伸尽头区域包括所述编织织物层并且不包括所述由无皱褶织物层制成的覆盖层。
5.根据权利要求1所述的复合加劲件，其中，所述延伸尽头区域具有包括所述斜坡的斜坡部分，以及在所述斜坡与所述复合加劲件的所述端部之间的大致平面状的趾部。
6.根据权利要求1所述的复合加劲件，其中，所述由无皱褶织物层制成的覆盖层中的每个由无皱褶织物层制成的覆盖层包括：第一层，所述第一层具有与所述复合加劲件的纵向方向对齐的0度纤维取向；以及第二层，所述第二层具有不与所述复合加劲件的纵向方向对齐的纤维取向。
7.根据权利要求1所述的复合加劲件，其中，所述延伸尽头区域包括一个或更多个所述由无皱褶织物层制成的覆盖层。
8.根据权利要求7所述的复合加劲件，其中，所述由无皱褶织物层制成的覆盖层在所述延伸尽头区域中具有切出的省缝并使自身重叠。
9.根据权利要求1所述的复合加劲件，其中，所述恒定截面区域具有Ω形截面。
10.根据权利要求1所述的复合加劲件，其中，所述恒定截面区域的横截面具有延伸穿过所述冠部和所述相邻的脚部的连续层。
11.根据权利要求1所述的复合加劲件，包括碳纤维复合材料。
12.一种飞行器结构，包括用桁条加固的面板，所述桁条是根据权利要求1至11中的任一项所述的复合加劲件。
13.一种制造复合加劲件的方法，包括将多个由无皱褶织物层制成的覆盖层和多个编织织物层作为干态织物铺放在模具上，并且对所述干态织物共注入以树脂，随后进行共固化以形成所述复合加劲件，其中，所述复合加劲件具有：纵向方向；延伸尽头区域，所述延伸尽头区域在所述复合加劲件的端部处；恒定截面区域，所述恒定截面区域在所述纵向方向上位于所述端部内侧，且所述恒定截面区域的横截面具有位于相邻的脚部之间的冠部，其中，所述延伸尽头区域具有变化的横截面，所述变化的横截面具有位于相邻的脚部之间的冠部且该冠部朝向所述复合加劲件的所述端部减小高度从而形成斜坡；以及过渡区域，所述过渡区域在所述恒定截面区域与所述延伸尽头区域之间，其中，所述方法包括将夹在编织织物层之间的多个由无皱褶织物层制成的覆盖层铺放在所述恒定截面区域中，并且对所述由无皱褶织物层制成的覆盖层中的至少一个由无皱褶织物层制成的覆盖层进行切割以使所述至少一个由无皱褶织物层制成的覆盖层在所述过渡区域中脱落，其中，所述编织织物层连续地穿过所述恒定截面区域、所述过渡区域和所述延伸尽头区域。
14.根据权利要求13所述的方法，还包括对所有的所述由无皱褶织物层制成的覆盖层进行切割以使所有的所述由无皱褶织物层制成的覆盖层在所述过渡区域中脱落。
15.根据权利要求13或14所述的方法，其中，所述延伸尽头区域包括所述编织织物层且不包括所述由无皱褶织物层制成的覆盖层。
16.根据权利要求13或14所述的方法，还包括：将所述多个编织织物层铺放在所述模具的用于限定所述延伸尽头区域中的所述斜坡的形状的部分上，随后进行所述共固化的步骤而无需对铺放在所述模具上的所述编织织物层进行切割的中间步骤。
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