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WO2021135033A1 - 一种复合材料铺层型材结构及其成型工艺 - Google Patents

一种复合材料铺层型材结构及其成型工艺 Download PDF

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Publication number
WO2021135033A1
WO2021135033A1 PCT/CN2020/090173 CN2020090173W WO2021135033A1 WO 2021135033 A1 WO2021135033 A1 WO 2021135033A1 CN 2020090173 W CN2020090173 W CN 2020090173W WO 2021135033 A1 WO2021135033 A1 WO 2021135033A1
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profile structure
composite material
composite
cavity
layer
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PCT/CN2020/090173
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English (en)
French (fr)
Inventor
田爱琴
肖鹏
吴沛沛
梁海廷
孙厚礼
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中车青岛四方机车车辆股份有限公司
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Publication of WO2021135033A1 publication Critical patent/WO2021135033A1/zh

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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
    • B29C70/30—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
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005—Body finishings

Definitions

  • the invention relates to the technical field of composite material structures, in particular to a composite material layered profile structure and a molding process.
  • the present invention provides a composite material layered profile structure and forming process, and good comprehensive mechanical properties are obtained through optimization of the layered structure.
  • the profile structure body has at least one internal cavity, and the profile structure is formed by laminating multiple layers of composite fiber fabric; wherein the surface layer of the profile structure is The inner layer located in the inner cavity is formed by covering with a multiaxial composite fiber fabric, and the middle layer is formed by covering with a unidirectional composite fiber fabric.
  • the inner layup includes: a basic inner layup, which surrounds the inner cavity, and forms a split seam along the length of the profile at the butt joint position; reinforcement layup, overlap layup Cover the butt joint formed by the inner layer of the foundation.
  • the slit is located in a straight section or a large curvature section of the internal cavity.
  • edges on both sides of the reinforcing ply extend to cover the small curvature section of the internal cavity.
  • the two-way composite fiber fabric, the two-way twill composite material fabric, and the pattern composite material fabric are formed by covering the surface layer by gravity thickening treatment.
  • the composite fiber fabric is specifically a carbon fiber fabric as a reinforcement.
  • the present invention also provides a molding process of the composite material layered profile structure, which includes the following steps: preparing the cavity sub-body, respectively using a multi-stage transition mold corresponding to each of the internal cavity to form the corresponding cavity
  • the molding of the profile structure, each of the cavity sub-bodies are sequentially arranged and shaped via a molding die, and covered with a surface layer.
  • the composite fiber fabric is sequentially transferred from the planar shape to the corresponding cavity sub-body through the corresponding multi-stage transition mold.
  • the surface layer is covered by a pressure roller assisted introduction process.
  • the step of introducing a reinforcing ply is further included: introducing a corresponding reinforcing ply at the butt position formed by the inner ply of the foundation of each cavity sub-body.
  • the composite material layered profile structure provided by the present invention has an internal cavity. Specifically, the surface layer of the profile structure and the inner layer located in the internal cavity are both covered with a multiaxial composite fiber fabric. It is formed to provide shear resistance for the profile structure; the middle layer is formed by covering the unidirectional composite fiber fabric to provide bending resistance for the profile. On this basis, based on the design of the internal cavity structure, a combination of multiaxial fiber cloth and unidirectional fiber cloth is adopted to ensure that the profile components have good comprehensive mechanical properties.
  • the inner base layer is laid around the inner cavity of the profile structure, and the reinforcing layer is overlapped at the butt position formed by the inner layer of the base; that is, in the profile
  • the joints of the inner cavity surrounding the multiaxial cloth are reinforced by lap covering, which can completely avoid the strength drop caused by the butt joint of the fiber cloth, and provides a technical guarantee for further improving the overall mechanical properties of the component.
  • Fig. 1 is a schematic cross-sectional view of the composite laminate profile structure in the specific embodiment
  • FIG. 2 is a schematic diagram of the cavity forming transition process of the process described in the specific embodiment
  • Fig. 3 is a schematic diagram of the positional relationship of the pressure roll introduction process of the process described in the specific embodiment.
  • the present embodiment uses the composite material ply-layer profile with the cross-sectional shape shown in the figure as the main body of description to describe the technical solution of the composite material ply structure in detail. It should be understood that the specific shape and number of the internal cavity of the profile structure body do not constitute a substantial limitation on the technical solution claimed in the present application.
  • Figure 1 is a schematic cross-sectional view of the composite laminate profile structure.
  • the profile structure is formed by a combination of multiaxial cloth and unidirectional fiber, that is, it is formed by laying multiple layers of composite fiber fabric.
  • the profile structure body has a plurality of internal cavities. Based on the design of the internal cavity structure, a combination of multiaxial fiber cloth and unidirectional fiber cloth is adopted to ensure that the profile components have good comprehensive mechanical properties.
  • the surface ply 1 of the profile structure and the inner ply 2 located in the inner cavity are formed by laying multiaxial composite fiber fabric to provide shear resistance for the profile structure; the middle layer 3 is paving a unidirectional composite fiber fabric. Overlay formation to provide bending resistance to the profile. On this basis, it is ensured that the profile members have good comprehensive mechanical properties.
  • the composite fiber fabric specifically adopts a composite material with a carbon fiber fabric as a reinforcement, and further preferably uses carbon or graphitized resin as a matrix.
  • a composite material with a carbon fiber fabric as a reinforcement and further preferably uses carbon or graphitized resin as a matrix.
  • the inner layer 2 can be further optimized.
  • the inner layer 2 includes the basic inner layer 21 and the reinforcement Laying layer 22, in which the basic inner layer layer 21 is laid around the internal cavity, and at the butt joint position is formed along the length direction of the profile (direction perpendicular to the drawing) a seam 23, the reinforcing layer 22 overlaps It is laid on the butt joint formed by the inner base layer 21 to fully cover the butt joint 23 formed.
  • the joints of the inner cavity of the profile surrounding the multiaxial cloth are reinforced by lap covering, which can completely avoid the strength drop caused by the butt joint of the fiber cloth, and provides technology for further improving the overall mechanical properties of the component. Guaranteed.
  • the slit 23 is preferably located in a straight section or a large curvature section of the inner cavity.
  • the “large curvature section” refers to the position of the wall surface of the small curvature section relative to the inner wall of the inner cavity, rather than the curvature value of the specific wall surface; that is, the joints of the foundation inner ply 21 are located opposite to the load-bearing stress. Smaller wall surface to reduce the adverse effect of the existence of seams on strength.
  • the curvature of the wall surface of section A of the same internal cavity is greater than the curvature of the wall surface of section B.
  • the slit 23 is arranged on the wall surface of the large curvature section A; and the slit 23 in the other internal cavity is located on the straight section C Wall surface.
  • the edges on both sides of the reinforced ply 22 extend to cover the small curvature section of the internal cavity.
  • the reinforced ply 22 extends to cover the wall surface of section B of the small curvature section to maximize Reduce the adverse effect of the existence of seams on the strength, and obtain excellent comprehensive mechanical properties.
  • the special layup design in the cavity effectively solves the problem of reduced mechanical properties of complex cross-section composite pultruded profiles caused by the butt joint of multiaxial cloth in the vertical pultrusion direction.
  • the surface layer adopts gravity thickening treatment carbon fiber fabric, for example, but not limited to, two-way composite fiber fabric, two-way twill composite material fabric, pattern composite fabric or ⁇ 45° fine woven fabric, preferably made of carbon fiber
  • the fabric is a reinforced composite material, and uses carbon or graphitized resin as the matrix.
  • this embodiment also provides a molding process of the composite material layered profile structure, which includes the following steps:
  • FIG. 2 shows a schematic diagram of the cavity forming transition process.
  • Figure 2 shows a square cavity as an example. In the initial state, the cloth is in a horizontal form. By cutting out a metal plate of a specific shape, it gradually transitions from a trapezoid and a right angle to the shape of a square cavity. It is understandable that Fig. 2 is only an illustrative description of a few typical mold shapes during the mold transition process, and specific settings can be made according to the specific shape and actual size during the cavity sub-body molding process.
  • the introduction of the reinforcement ply is carried out before the forming step of the profile structure, specifically, the corresponding reinforcement ply is introduced at the butt position formed by the base inner ply of each cavity sub-body.
  • the profile structure is formed, and the cavity sub-bodies are sequentially arranged and shaped through the forming mold, and the surface layer is covered.
  • the surface layer 1 adopts gravity thickening treatment, so that the solid particles suspended in the liquid become thick slurry and separated from the liquid; here, the gravity thickening treatment can be realized by the existing technology, so This article will not repeat them.
  • the surface layer 1 is specifically covered by the press roller 4 to assist the introduction process.
  • Fig. 3 shows the positional relationship of the press roll introduction process.
  • the pressing rollers 4 pressed against the surface layup 1 are arranged in two groups, respectively located on both sides of the surface layup 1, to form a good pulling effect during the pultrusion displacement process to ensure product yield.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Road Paving Structures (AREA)
  • Laminated Bodies (AREA)

Abstract

一种复合材料铺层型材结构及其成型工艺，该型材结构本体具有至少一个内部型腔，且所述型材结构由多层复合材料纤维织物铺覆形成；其中，所述型材结构的表面铺层和位于所述内部型腔的内铺层采用多轴复合材料纤维织物铺覆形成，中间层采用单向复合材料纤维织物铺覆形成。应用本方案，能够有效解决复杂断面复合材料拉挤型材在垂直拉挤方向由多轴布对接引起的力学性能降低的问题，通过铺层结构优化获得良好的综合力学性能。

Description

一种复合材料铺层型材结构及其成型工艺
本申请要求于2020年01月02日提交中国专利局的申请号为202010003045.X、发明名称为“一种复合材料铺层型材结构及其成型工艺”的中国专利申请的优先权，其全部内容通过引用结合在本申请中。
技术领域
本发明涉及复合材料结构技术领域，具体涉及一种复合材料铺层型材结构及成型工艺。
背景技术
随着轨道交通车辆高速快速化发展，车体结构轻量化已成为当前轨道车辆设计中的重要研究课题，其中，复合新材料的有效应用是结构轻量化的主流技术方向。现有的复合材料构件多采用夹芯板或缠绕成型结构，例如车体、裙板等车体构件，但是，基于该成型结构无法获得优异的综合力学性能。
有鉴于此，亟待另辟蹊径提出一种复合材料铺层技术方案，在满足结构轻量化设计需求的基础上，有效提升构件的力学性能。
发明内容
为解决上述技术问题，本发明提供一种复合材料铺层型材结构及成型工艺，通过铺层结构优化获得良好的综合力学性能。
本发明提供的复合材料铺层型材结构，所述型材结构本体具有至少一个内部型腔，且所述型材结构由多层复合材料纤维织物铺覆形成；其中，所述型材结构的表面铺层和位于所述内部型腔的内铺层采用多轴复合材料纤维织物铺覆形成，中间层采用单向复合材料纤维织物铺覆形成。
优选地，所述内铺层包括：基础内铺层，环绕所述内部型腔铺覆，并在对接位置处形成沿所述型材的长度方向设置的分缝；补强铺层，搭接铺覆于所述基础内铺层形成的对接位置处。
优选地，在所述型材结构的横截面内，所述分缝位于所述内部型腔的直线段或者大曲率段。
优选地，所述补强铺层的两侧边沿延伸覆盖至所述内部型腔的小曲率段。
优选地，所述表面铺层的采用重力增稠处理的双向复合材料纤维织物、双向斜纹复合材料织物、花纹复合材料织物铺覆形成。
优选地，所述复合材料纤维织物具体为以碳纤维织物为增强体。
本发明还提供一种上述复合材料铺层型材结构的成型工艺，包括下述步骤：型腔子体的制备，分别采用与每个所述内部型腔相应的多段过渡模具形成相应的所述型腔子体；型材结构的成型，各所述型腔子体经由成型模具依次排布塑形，并铺覆表面铺层。
优选地，在所述型腔子体的制备步骤中，所述复合材料纤维织物自平面形态依次通过相应的所述多段过渡模具过渡至相应的所述型腔子体。
优选地，所述表面铺层采用压辊辅助导入工艺铺覆。
优选地，在所述型材结构的成型步骤之前还包括补强铺层的导入步骤：在每个所述型腔子体的基础内铺层形成的对接位置处导入相应的补强铺层。
与现有技术相比，本发明提供的复合材料铺层型材结构具有内部型腔，具体地，型材结构的表面铺层和位于内部型腔的内铺层均采用多轴复合材料纤维织物铺覆形成，为型材结构提供抗剪性能；中间层采用单向复合材料纤维织物铺覆形成，为型材提供抗弯性能。在此基础上，基于内部型腔结构的设计，采用多轴纤维布与单向纤维布组合的铺层方式，确保型材构件具备良好的综合力学性能。
在本发明的优选方案中，其基础内铺层环绕型材结构的内部型腔铺覆，并采用补强铺层搭接铺覆于基础内铺层形成的对接位置处；也就是说，在型材内腔环绕多轴布的接缝处采用搭接铺覆的形式进行补强，可完全规避纤维布料对接所产生的强度下降现象，为进一步提高构件的整体力学性能提供了技术保障。
附图说明
图1为具体实施方式中所述复合材料铺层型材结构的横截面示意图；
图2为具体实施方式中所述工艺的型腔成型过渡过程示意图；
图3为具体实施方式中所述工艺的压辊导入工序位置关系示意图。
图中：
表面铺层1、内铺层2、基础内铺层21、补强铺层22、分缝23、中间层3、压辊4。
具体实施方式
为了使本领域的技术人员更好地理解本发明的技术方案，下面结合附图和具体实施例对本发明作进一步的详细说明。
不失一般性，本实施方式以图中所示截面形状的复合材料铺层型材作为描述主体，详细说明复合材料铺层结构技术方案。应当理解，该型材结构本体的内部型腔具体形状及个数，对本申请请求保护的技术方案并未构成实质限制。
请一并参见图1，该图为所述复合材料铺层型材结构的横截面示意图。
如图所示，该型材结构采用多轴布与单向纤维组合的铺层方式成型，也即由多层复合材料纤维织物铺覆形成。其型材结构本体具有多个内部型腔。基于内部型腔结构的设计，采用多轴纤维布与单向纤维布组合的铺层方式，确保型材构件具备良好的综合力学性能。
其中，该型材结构的表面铺层1和位于内部型腔的内铺层2采用多轴复合材料纤维织物铺覆形成，为型材结构提供抗剪性能；中间层3采用单向复合材料纤维织物铺覆形成，为型材提供抗弯性能。在此基础上，确保型材构件具备良好的综合力学性能。
作为优选，复合材料纤维织物具体采用以碳纤维织物为增强体的复合材料，并进一步优选以碳或石墨化的树脂作为基体。由此，可获得较高的比强度、比刚性，轻量化效果。
为了合理控制内腔环绕多轴布的接缝处对整体强度产生的影响，可针对内铺层2作进一步优化，结合图1所示，该内铺层2包括基础内铺层21 和补强铺层22，其中，基础内铺层21环绕内部型腔铺覆，并在对接位置处形成沿型材的长度方向(垂直于图面的方向)设置的分缝23，补强铺层22搭接铺覆于基础内铺层21形成的对接位置处，全覆盖所形成的对接分缝23。如此设置，在型材内腔环绕多轴布的接缝处采用搭接铺覆的形式进行补强，可完全规避纤维布料对接所产生的强度下降现象，为进一步提高构件的整体力学性能提供了技术保障。
另外，在型材结构的横截面内，该分缝23优选位于内部型腔的直线段或者大曲率段。这里，“大曲率段”是指相对于内部型腔的内壁的小曲率段的壁面位置，而非指代具体壁面的曲率值；也就是说，基础内铺层21的接缝位于承载应力相对较小的壁面，以降低接缝的存在对强度产生的不良影响。例如，图中所示，同一内部型腔的A段壁面的曲率大于B段壁面的曲率，优选分缝23设置在大曲率A段壁面；而另一内部型腔中分缝23位于直线段C壁面。
在此基础上，补强铺层22的两侧边沿延伸覆盖至内部型腔的小曲率段，如图所示，补强铺层22延伸覆盖至小曲率段的B段壁面，从而最大限度地降低接缝的存在对强度产生的不良影响，获得优异的综合力学性能。整体上，腔内特殊的铺层设计有效解决了，复杂断面复合材料拉挤型材在垂直拉挤方向由多轴布对接引起的力学性能降低的问题。
其中，表面铺层的采用重力增稠处理碳纤维织物，例如但不限于，双向复合材料纤维织物、双向斜纹复合材料织物、花纹复合材料织物或者±45°的精编织物铺覆形成，优选以碳纤维织物为增强体的复合材料，并以碳或石墨化的树脂作为基体。
针对前述复合材料铺层型材结构，本实施方式还提供一种该复合材料铺层型材结构的成型工艺，包括下述步骤：
首先，型腔子体的制备。具体地，分别采用与每个内部型腔相应的多段过渡模具形成相应的型腔子体；请一并参见图2，该图示出了型腔成型过渡过程示意图。图2以四方形腔体为例进行了示意，初始状态下布料为水平形态，通过开出特定形状金属板逐渐从梯形、直角依次过渡到四方形腔体的形状。可以理解的是，图2中仅为模具过渡过程几个典型模具形态的示例性说明，在型腔子体成型过程中可依据具体形状及实际尺寸进行相 应的具体设置。
在型材结构的成型步骤之前进行补强铺层的导入，具体地，在每个型腔子体的基础内铺层形成的对接位置处导入相应的补强铺层。
最后，进行型材结构的成型，各型腔子体经由成型模具依次排布塑形，并铺覆表面铺层。作为优选，表面铺层1的采用重力增稠处理，使悬浮于液体中的固体粒子变为浓稠的拢浆而从液体中分离出来；这里，重力增稠处理可采用现有技术实现，故本文不再赘述。
该表面铺层1具体采用压辊4辅助导入工艺铺覆，请一并参见图3，该图示意了压辊导入工序位置关系。图中所示，压抵表面铺层1的压辊4设置为两组，分别位于表面铺层1的两侧，以在拉挤成型位移过程中形成良好的牵拉作用，确保产品良率。
需要说明的是，本申请请求保护的复合材料铺层型材结构非局限于图中所示的型腔结构，应当理解，只要应用本方案铺层设计构思均在本申请请求保护的范围内。
以上仅是本发明的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下，还可以做出若干改进和润饰，这些改进和润饰也应视为本发明的保护范围。

Claims (10)

  1. 一种复合材料铺层型材结构，其特征在于，所述型材结构本体具有至少一个内部型腔，且所述型材结构由多层复合材料纤维织物铺覆形成；其中，所述型材结构的表面铺层和位于所述内部型腔的内铺层采用多轴复合材料纤维织物铺覆形成，中间层采用单向复合材料纤维织物铺覆形成。
  2. 根据权利要求1所述的复合材料铺层型材结构，其特征在于，所述内铺层包括：
    基础内铺层，环绕所述内部型腔铺覆，并在对接位置处形成沿所述型材的长度方向设置的分缝；
    补强铺层，搭接铺覆于所述基础内铺层形成的对接位置处。
  3. 根据权利要求2所述的复合材料铺层型材结构，其特征在于，在所述型材结构的横截面内，所述分缝位于所述内部型腔的直线段或者大曲率段。
  4. 根据权利要求2所述的复合材料铺层型材结构，其特征在于，所述补强铺层的两侧边沿延伸覆盖至所述内部型腔的小曲率段。
  5. 根据权利要求1所述的复合材料铺层型材结构，其特征在于，所述表面铺层的采用重力增稠处理的双向复合材料纤维织物、双向斜纹复合材料织物、花纹复合材料织物铺覆形成。
  6. 根据权利要求5所述的复合材料铺层型材结构，其特征在于，所述复合材料纤维织物具体为以碳纤维织物为增强体。
  7. 权利要求1所述复合材料铺层型材结构的成型工艺，其特征在于，包括下述步骤：
    型腔子体的制备，分别采用与每个所述内部型腔相应的多段过渡模具形成相应的所述型腔子体；
    型材结构的成型，各所述型腔子体经由成型模具依次排布塑形，并铺覆表面铺层。
  8. 根据权利要求7所述的复合材料铺层型材结构的成型工艺，其特征在于，在所述型腔子体的制备步骤中，所述复合材料纤维织物自平面形态依次通过相应的所述多段过渡模具过渡至相应的所述型腔子体。
  9. 根据权利要求8所述的复合材料铺层型材结构的成型工艺，其特征 在于，所述表面铺层采用压辊辅助导入工艺铺覆。
  10. 根据权利要求9所述的复合材料铺层型材结构的成型工艺，其特征在于，在所述型材结构的成型步骤之前还包括补强铺层的导入步骤：在每个所述型腔子体的基础内铺层形成的对接位置处导入相应的补强铺层。
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