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TW201436999A - 具有表面開孔之可固化預浸材 - Google Patents

具有表面開孔之可固化預浸材 Download PDF

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Publication number
TW201436999A
TW201436999A TW102147661A TW102147661A TW201436999A TW 201436999 A TW201436999 A TW 201436999A TW 102147661 A TW102147661 A TW 102147661A TW 102147661 A TW102147661 A TW 102147661A TW 201436999 A TW201436999 A TW 201436999A
Authority
TW
Taiwan
Prior art keywords
prepreg
fabric
tow
curable
resin film
Prior art date
Application number
TW102147661A
Other languages
English (en)
Other versions
TWI643730B (zh
Inventor
Mark Roman
Steve Howard
Jack Boyd
Scott Lucas
Original Assignee
Cytec Ind Inc
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Filing date
Publication date
Application filed by Cytec Ind Inc filed Critical Cytec Ind Inc
Publication of TW201436999A publication Critical patent/TW201436999A/zh
Application granted granted Critical
Publication of TWI643730B publication Critical patent/TWI643730B/zh

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Classifications

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    • B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
    • B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
    • B29B15/10—Coating or impregnating independently of the moulding or shaping step
    • B29B15/12—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length
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    • B29C70/06—Fibrous reinforcements only
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    • B29C70/22—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure
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Abstract

本發明係關於一種可固化預浸材，其具有提高之在固結及固化之前及/或期間從預浸材中及預浸材疊層中之預浸材層之間移除氣體之能力。各可固化預浸材為已經歷在至少一個主表面中建立開孔陣列之處理的樹脂浸漬編織織物。開孔的位置係特定於該織物之織造圖樣。另外，當將該等預浸材鋪放且使經歷壓實製程以形成複合部件時，相較於使用無相同表面開孔之預浸材，可達成縮短的壓實時間。

Description

具有表面開孔之可固化預浸材
纖維強化聚合物複合材料為由樹脂基質及增強纖維所組成之高性能結構材料。該等纖維強化聚合物複合材料已用於製造要求高強度及/或低重量、及耐抗侵蝕性環境之結構部件。該等結構部件之實例包括飛機組件(例如，機尾、機翼、機身、螺旋槳)。該等纖維強化基質樹脂，承載由複合材料支撐之大部分負載，而該基質樹脂承載由複合材料支撐之小部分負載且亦可將負載自破損纖維轉移至完整纖維。以此方式，該等聚合物複合材料可支撐比基質樹脂或纖維中任一者可單獨支撐更大之負載。另外，藉由定製呈特定幾何結構或定向之增強纖維，複合材料可經有效設計成使重量及體積減至最小。
纖維強化聚合物複合材料傳統上係由樹脂浸漬纖維片材(亦稱為預浸材)製成。為了自預浸材形成複合部件，可將複數個預浸材層鋪放於模具中，及可施用加熱致使基質樹脂流動，從而可固結該等預浸材層。施加的熱可另外固化或聚合基質組分。
然而，以此方式固結預浸材以形成複合材料存在問題。於疊層期間，氣體(諸如空氣及其他揮發物)會陷留於個別預浸材內部及預浸材層之間。另外，揮發物亦可於加熱及/或固化預浸材期間析出。極難自疊層移除該等氣體，此乃因基質實質上抑制氣體流動且會導致於最終固化複合材料中之孔隙度。孔隙度係指於固化複合材料中之孔隙。該孔隙度會進一步不利地影響最終固化複合材料之機械性能。
已開發可增強複合材料製造期間陷留氣體之移除之技術，然而，問題仍存在。例如，可使用邊緣通氣器來施加真空至預浸材之邊緣以自預浸材層側部抽出氣體。然而，以此方式自預浸材移除陷留氣體緩慢且可能無法實質上移除所有陷留氣體。
自該等預浸材製造複合部件需要壓實及特定固化週期以製造部件及形成用於呈任何結構之最終用途所需之結構性質。潛在性地且取決於製造方法，於固化之前的壓實週期可為耗時的，增加額外費用。將期望有一種方法可在適用之情況下有助於縮短固化之前之壓實時間長。
本文中揭示一種可固化預浸材，其具有提高之在固結及固化之前及/或期間自預浸材中及預浸材疊層中之預浸材層之間移除氣體之能力。各可固化預浸材為經過處理以在至少一個主表面中建立開孔陣列之樹脂浸漬編織織物。開孔之位置係特定於織物之織造圖樣。另外，當將該等預浸材鋪放且使經歷壓實製程以形成複合部件時，相較於使用無相同表面開孔之預浸材，可達成縮短的壓實時間。
11‧‧‧第一編織方向上之絲束
12‧‧‧第二/橫向方向上之絲束
13‧‧‧第二/橫向方向上之絲束
14‧‧‧第二/橫向方向上之相鄰絲束
20‧‧‧纖維絲束
21‧‧‧上層樹脂膜
22‧‧‧下層樹脂膜
23‧‧‧封閉氣穴
30‧‧‧開孔
40‧‧‧開孔
50‧‧‧緞紋編織織物
51‧‧‧上層樹脂膜
52‧‧‧下層樹脂膜
53‧‧‧離型紙
54‧‧‧離型(或背襯)紙
55‧‧‧氣穴
56‧‧‧聚酯膜
57‧‧‧開孔
70‧‧‧位置
80‧‧‧連續織物網
81‧‧‧受熱壓力輥
82‧‧‧受熱壓力輥
83‧‧‧樹脂膜
84‧‧‧樹脂膜
85‧‧‧供給輥
86‧‧‧供給輥
87‧‧‧加熱板
88‧‧‧冷卻板
89‧‧‧拉輥
90‧‧‧拉輥
91‧‧‧捲起輥
95‧‧‧平織編織織物
96‧‧‧上層樹脂膜
97‧‧‧下層樹脂膜
98‧‧‧離型/背襯紙
99‧‧‧離型/背襯紙
100‧‧‧開孔
101‧‧‧間隙
130‧‧‧中心核
131‧‧‧預浸材疊層
132‧‧‧預浸材疊層
P‧‧‧空穴
T1‧‧‧「向下」絲束部分
T2‧‧‧「向上」絲束部分
Tf‧‧‧織物之厚度
圖1示意性地繪示編織織物部分，其中一個編織方向上之纖維絲束在橫向方向上之絲束上方及接著在橫向方向上之絲束下方穿過。
圖2示意性地顯示根據本發明之一個實施例之經部分浸漬之織物。
圖3示意性地顯示根據本發明之一個實施例在預浸材之一個表面中建立之開孔。
圖4示意性地顯示根據本發明之一個實施例在預浸材之相對表面中建立之開孔。
圖5示意性地顯示根據一個實施例之經部分浸漬之預浸材。
圖6顯示於熱處理之後之圖5之預浸材。
圖7示意性地顯示緞紋編織織物之一部分。
圖8示意性地顯示具有形成於圖7之緞紋編織織物上之表面開孔之樹脂表面。
圖9示意性地顯示根據另一個實施例之已經歷熱處理以建立表面開孔之經部分浸漬之預浸材。
圖10示意性地顯示平織編織織物之一部分。
圖11示意性地顯示具有形成於平織編織織物上之表面開孔之樹脂表面。
圖12繪示可製造預浸材織物之例示性預浸漬系統。
圖13示意性地顯示根據一個實例之一種用於組裝蜂窩核夾層結構之組態。
圖14示意性地顯示自圖13中所示之總成製得之蜂窩核夾層結構。
圖15至17為顯示經熱處理之預浸材表面分別於1分鐘、4分鐘、及7.5分鐘下之俯視圖的顯微圖，其中該預浸材係根據一個實例使用緞紋編織織物製得。
圖18為顯示經熱處理之預浸材表面之俯視圖的顯微圖，其中該預浸材係根據另一個實例使用平織編織織物製得。
圖19為顯示具有形成於表面之下之氣泡之固化預浸材表面之俯視圖的顯微圖。
圖20顯示由未經處理之預浸材材料所組成之固化複合板之截面視圖。
圖21顯示由經熱處理之預浸材材料所組成之固化複合板之截面視圖。
圖22顯示標準壓實製程及所得孔隙度對於自未經處理之5320- 1/8HS預浸材材料採用在固化之前於真空下保持16小時製成之複合材料之效應。
圖23顯示增強之壓實製程及所得孔隙度對於自經熱處理之5320-1/8HS預浸材材料採用在固化之前於真空下保持16小時製得之複合材料之效應。
圖24顯示標準製程及所得孔隙度對於自未經處理之5320-1/8HS預浸材材料採用在固化之前於真空下保持0.5小時製得之複合材料之效應。
圖25顯示增強之製程及所得孔隙度對於自經熱處理之5320-1/8HS預浸材材料採用在固化之前於真空下保持0.5小時製得之複合材料之效應。
圖26顯示標準製程及所得孔隙度對於自未經處理之5320-1/PW預浸材材料採用在固化之前於真空下保持16小時製得之複合材料之效應。
圖27顯示增強之製程及所得孔隙度對於自經熱處理之5320-1/PW預浸材材料採用在固化之前於真空下保持16小時製得之複合材料之效應。
圖28顯示標準製程及所得孔隙度對於自未經處理之5320-1/PW預浸材材料經歷固化之前於真空下保持0.5小時製得之複合材料之效應。
圖29顯示增強之製程及所得孔隙度對於自經熱處理之5320-1/PW預浸材材料經歷採用在固化之前於真空下保持0.5小時的處理製得之複合材料之效應。
本文所揭示之可固化預浸材係由經樹脂浸漬之編織織物所組成。該編織織物具有兩個相對的面及如下織造圖樣：其中第一編織方 向上之一或多根絲束浮在第二編織方向上之一或多根絲束上方，接著在第二編織方向上之一或多根絲束下方穿過，其中當在第一編織方向上之第一絲束在第二編織方向上之第二絲束上方跨過接著在第二編織方向上之相鄰第三絲束下方穿過時，或當在第一絲束在第二編織方向上之第二絲束下方穿過接著在第二編織方向上之相鄰第三絲束上方跨過時，於該織物之一面上建立上方/下方跨過位置。本文中該上方/下方跨過位置係指第一絲束在相鄰第二與第三絲束之間向上或向下之部分。
用於製造預浸材之編織織物係自纖維絲束製成。該等絲束係呈如下織造圖樣交織：其中第一編織方向上之一或多根絲束浮在第二編織方向上之一或多根絲束上方，接著在該相同第二編織方向上之一或多個絲束下方穿過。歸因於該編織組態所致，織物之兩主面包含空穴於其中，因而，整個該織物既不平滑亦不平坦。
圖1示意性地繪示，歸因於編織織物之編織組態所致，在每當存有在另一個橫向絲束上方跨過或在另一個橫向絲束下方穿過(亦即，上方/下方跨過位置)之絲束部分，存在建立於織物表面中之空穴P。再從左到右地參照圖1，當第一編織方向上之絲束11在第二/橫向編織方向上之另一根絲束12上方跨過接著在該相同第二/橫向編織方向上之相鄰絲束13下方穿過時，建立「向下」絲束部分T1，及當絲束11在絲束13下方穿過接著在第二/橫向編織方向上之相鄰絲束14上方穿過時，建立「向上」絲束部分T2。該等「向上」及「向下」絲束部分導致空穴P。換言之，若織物躺在水平平坦表面上，則每當存在絲束相對於該平坦表面之升高變化時，建立空穴P。應理解圖1僅顯示織物編織之一個實例，及諸如三軸式編織(tri-axial weave)之更複雜織物編織包含於本文中。
可固化預浸材進一步具有可固化熱熔融樹脂膜，其覆蓋織物之 各面且部分穿透織物之厚度，在厚度方向留下實質上不含該樹脂膜之織物之中間區段。根據一個實施例，開孔陣列係在一或兩層樹脂膜中形成，其中各開孔暴露在織物織造圖樣中之上方/下方跨過位置處形成之空穴(圖1中的P)。於一些實施例中，樹脂膜在除了開孔所在處以外之任何處連續。根據另一個實施例，樹脂中之開孔陣列與織物編織中之間隙對準。該實施例係關於諸如平織編織織物之特定編織織物。
該等開孔經組態以使得諸如空氣之氣體可自織物之中間區段流至預浸材之至少一個外表面、或可自預浸材之至少一個外表面流至中間區段、或可自預浸材之一個外表面流至相對的表面、或其組合。該等開孔亦可使得氣體轉移以及建立真空，其為樹脂浸漬高真空區域提供驅動力。
本文所揭示之開孔係特定於織物編織，不像用於形成全面孔圖樣或隨機孔圖樣之藉由習知機械技術形成之具有表面開孔之預浸材。
基於本文目的，術語「可固化」意指非完全固化的，且包括未固化情況。
各絲束為纖維長絲之集束。各集束中長絲之數量可為1000的倍數，例如，為1000至75,000。出於本文所揭示之預期目的，涵蓋每集束具有少於15,000根長絲之絲束。術語「長絲」係指具有高長度對寬度比之相對撓性之連續結構。
用於纖維絲束之纖維材料包括(但不限於)玻璃(包括電氣或E級玻璃)、碳(包括石墨)、芳族聚醯胺(例如Kevlar)、高模數聚乙烯(PE)、硼、石英、玄武岩、陶瓷、聚酯、聚-對-伸苯基-苯并雙噁唑(PBO)、及其組合。對於製造高性能複合材料(例如，用於航太應用之材料)而言，具有大於3500MPa之拉伸強度之纖維是理想的。
織物之編織組態不受限制且可包括平織編織、緞紋編織、斜紋編織、及類似者。於一卷織物中，縱向絲束係在經向上及橫向絲束在 緯向上。於平織編織中，該等經向及緯向絲束形成簡單的十字形交叉圖樣。各緯向絲束以在一根經向絲束上方跨過接著在下一根經向絲束下方穿過及依此類推之方式跨越經向絲束。緞紋編織之特徵為兩根或更多根緯向絲束在單根經向絲束上方穿過，或反之亦然，兩根或更多根經向絲束浮在單根緯向絲束上方。斜紋編織之特徵為緯向絲束在一或多根經向絲束上方穿過且接著在一或多根經向絲束下方穿過及依此類推，其中列之間偏移以建立特徵性對角線圖樣。
圖2示意性地繪示根據本發明之一個實施例之經部分浸漬之織物(即，預浸材層或預浸材織物)。具有纖維絲束20之織物在具有上層樹脂膜21及下層樹脂膜22之兩個主面上均被覆蓋。各樹脂膜部分穿透該織物之厚度(Tf)，從而留下實質上不含該樹脂之該織物之中間區段。於部分浸漬之後，如圖2中所說明，在樹脂膜與織物之間形成複數個封閉氣穴23。該等封閉氣穴與在織物編織中之上方/下方跨過位置處形成之空穴重合。
如應用所決定，可固化多孔預浸材中織物-相對-基質樹脂之重量比可改變。於一個實施例中，織物之重量分率可自基於預浸材總重量之20重量%至80重量%改變。於另一個實施例中，當在使用多孔預浸材作為複合基板或預浸材疊層上之表面膜時，該多孔預浸材中織物之重量分率小於20重量%。基質樹脂佔預浸材之分率亦可視需要改變。於某些實施例中，基於預浸材總重量計，基質樹脂可佔據預浸材之約20重量%至80重量%之間。
預浸漬方法
根據一個實施例，製造上文所揭示之可固化預浸材之方法包括利用可固化基質樹脂部分地浸漬編織織物接著進行熱處理以建立表面開孔陣列。利用基質樹脂部分地浸漬編織織物之方法不受限制，但「熱熔融」預浸漬方法為較佳。一般而言，該預浸漬方法之特徵為利 用呈熔融形式之熱熔融樹脂組合物浸漬織物層，以獲得經部分浸漬之預浸材。可藉由將織物層夾在兩層樹脂膜之間及藉由熱板、受熱輥對所得層壓物施壓、或藉由其中在熱金屬帶之間對層壓物施壓之方法來進行浸漬。或者，織物僅於一側上經樹脂膜層壓，留下另一側實質上不含樹脂。
實例為，可固化熱熔融樹脂組合物可呈薄樹脂膜形式施加至離型紙上，及自其釋離所得之樹脂膜係經層壓及形成於織物層上。施加熱以減低樹脂膜之黏度，使得其呈熔融狀態且可穿透織物至期望的程度，較佳地，僅部分地穿透織物，以留下中心乾燥部分。應理解浸漬期間施用的提高之溫度低於熱熔融樹脂之初始固化溫度。在層壓期間亦施加足夠的壓力，以使樹脂膜部分穿透織物層之厚度，因而獲得在厚度方向上經樹脂組合物部分浸漬之織物層。基質樹脂在浸漬即刻後保持未固化。對於一些實施例，施加於織物各面上之樹脂膜可具有10至200gsm(g/cm2)之膜重量，及織物可具有100至600gsm之織物面積重量(FAW)。於部分浸漬之後，連續樹脂膜覆蓋織物之一或兩個主面且部分穿透織物之厚度，留下實質上不含樹脂之織物之中間區段。
於熱處理期間，離型或背襯紙留在預浸材樹脂膜之暴露表面上並施加熱直到樹脂膜變為流態。於某些實施例中，熱處理期間之樹脂黏度於90℃下小於500泊。進行加熱直到樹脂膜之於氣穴上方之部分破損敞開，建立樹脂膜中對應於氣穴位置之開孔。樹脂膜係因隨著樹脂側向移向鄰近空穴之區域而自離型膜表面去濕而破裂。於一些情況中，樹脂膜在氣泡邊緣處破裂離去並側向向內移動，留下於自預浸材剝離離型紙時移除之微小樹脂滴。如圖3中所說明，該等開孔可建立於預浸材之一個表面中(開孔30)，或如圖4中所說明建立於預浸材兩個相對的表面中(開孔40)。由於熱處理的結果，開孔建立用於自預浸材之外表面輸送空氣或其他氣體至織物之中間區段之流體通道。
可作為織物已藉由標準預浸漬方法經樹脂膜部分浸漬後之後處理，來進行用於建立預浸材中開孔之熱處理。或者，熱處理可在預浸漬處理期間在原位進行。應理解熱處理期間施加的提高之溫度低於基質樹脂之初始固化溫度，及係用於引發樹脂流動以使封閉氣穴敞開。此種樹脂流動會導致較低的體積因數。體積因數係定義為未固化預浸材材料之厚度相對其完全固化時之厚度之比。
於一個實施例中，經樹脂浸漬之緞紋編織織物會經受後處理以建立開孔陣列。參照圖5，緞紋編織織物50夾在上層樹脂膜51與下層樹脂膜52之間。上層樹脂膜51係形成於離型紙53上及下方樹脂模52係形成於離型(或背襯)紙54上。該離型紙可塗覆有聚矽氧膜。使所得層壓物在例如預浸漬機器中經受熱壓以形成經部分浸漬之預浸材。於樹脂浸漬之後，氣穴55建立於樹脂膜之下。接著，參照圖6，附著至下層樹脂膜52之離型紙54改用聚酯膜56替代。在移除一層離型紙後將聚酯膜置於一側上以利於捲起最終預浸材。再參照圖6，其上具有離型紙及聚酯膜之經部分浸漬之預浸材接著以加熱循環方式加熱，藉此上層樹脂膜52之位於氣穴上方之樹脂部分破損敞開且移動/流動離開氣穴。結果，開孔57建立於樹脂膜51中。熱處理可藉由將預浸材暴露至設定至預定溫度之熱源達一段選定時段來進行。於熱暴露期間，預浸材可係固定，或可經由連續方法移動通過加熱區段。或者，可使用其他加熱源，諸如熱板、雷射、受熱鼓、超音波、熱空氣噴射等等。熱處理之溫度及時段可根據可實現流動之最小樹脂黏度及足以發生流動之時間而改變。較薄的樹脂膜流動更為快速，因而較大重量的膜需要更長的時間。實例為，可對呈已經由標準連續預浸材製造方法形成之連續薄片形式之預浸材材料卷施用後處理。於該後處理中，連續預浸材處於張力下鬆開且繼續傳送通過其中將預浸材暴露至熱之水平加熱烘箱，且接著在捲取輥上捲起。可根據烘箱長度控制熱暴露時間相對 傳送速度以建立所欲開孔。於一個實施例中，浸漬用樹脂為室溫(20℃至25℃)下為黏彈性固體及在250℉至350℉(121℃至177℃)之溫度範圍內為可固化之熱熔融環氧基基質；可在120℉至250℉(49℃至121℃)範圍內進行加熱週期達0.25至20分鐘。
圖7顯示例示性緞紋編織組態(更特定言之係8H(8-Harness)緞紋編織)、及可在如上所述利用樹脂膜部分浸漬緞紋編織織物時建立氣穴所處之位置70。應瞭解，事實上，顯示於圖7中之交叉絲束實際上更為接近地靠在一起且更為緊密地編織。圖8示意性地顯示於如上參照圖5及6所述之樹脂浸漬及熱處理之後之經熱處理之預浸材表面、及樹脂膜中開孔相對織物編織中之上方/下方跨過位置之位置。
圖9示意性地顯示已經歷熱處理以建立形成貫穿上方及下層樹脂膜96、97之開孔100之經部分浸漬之平織編織織物95。樹脂膜96、97分別由離型/背襯紙98、99支撐。
圖10顯示一例示性平織編織織物及形成於其中之間隙101。應瞭解，事實上，顯示於圖7中之交叉絲束實際上更為接近地靠在一起且更為緊密地編織。圖11示意性地顯示於如上參照圖9所述之樹脂浸漬及熱處理之後之經熱處理之預浸材表面、及樹脂膜中開孔相對織物編織中之間隙101之位置。請注意該等開孔與間隙11對準。
圖12示意性地顯示可製造預浸材織物及提供原位熱處理之例示性預浸漬系統。參照圖12，將連續織物網(fabric web)80傳送至由一對受熱壓力輥81、82形成之第一壓力輥隙。織物網80夾在由供給輥85、86鬆開之兩層樹脂膜83、84之間。樹脂膜83、84各者係形成於連續離型紙上。藉助於壓力輥81、82將樹脂膜83、84分別壓至織物網80之頂面及底面。來自壓力輥81、82之壓力及熱導致樹脂膜83、84部分地浸漬織物網80，因而形成經部分浸漬之預浸材。該經部分浸漬之預浸材接著在加熱板87上方穿過。在此時，進行加熱以在預浸材中建立開 孔。於熱處理之後，所得多孔預浸材傳送穿過冷卻板88上方，於該處，多孔預浸材係經冷卻以固化樹脂。經冷卻之預浸材接著藉由拉輥89、90傳送且由額外導引輥導至將其捲起之捲起輥91。此類型方法特別適用於在基於使用平織編織織物(特定言之低GSM織物)之預浸材中建立開孔，其中歸因於織物及浸漬膜之薄度，熱處理係快速的。
形成於經熱處理之預浸材中之開孔為不規則形狀且大小不均等。開孔的形狀及大小取決於織造圖樣及熱處理時間。開孔的大小隨著樹脂經時流動而增大。作為實例，開孔可為直徑在0.1至3mm範圍內之實質上圓形截面或寬度及長度在0.1mm至3mm範圍內之近似矩形截面。另外，於特定長之處理時間後，作為實例，1至8分鐘之處理時間可足以建立開孔。此外，於特定處理時段後，一些開孔可變成彼此相連，取決於開孔彼此間之初始接近程度。於一些實例中，由於有缺陷的處理條件，例如，當在熱處理期間離型紙未黏著至樹脂膜時，一些陷留氣穴可未敞開。
基質樹脂
用於製造本文所述之可固化預浸材之基質樹脂係基於可固化熱熔融組合物，其特徵在於可固化熱熔融組合物最初於近似室溫(20℃至25℃)下為固態或半固態，於施用材料時之提高之溫度下變為熔融態，於冷卻後固化，且可藉由固化而硬化。此外，基質樹脂應具有足以容許形成氣穴且隨後藉由熱處理於氣穴上方形成開孔之黏度及潤濕特性。於一個實施例中，熱熔融樹脂組合物為由一或多種熱固性樹脂作為主要組分所組成之可固化熱固性樹脂組合物，且實質上不含諸如丙酮、甲基乙基酮(MEK)、二氧戊環、醇之任何有機溶劑。當用於製造最終固化產品時，藉由使用觸媒或固化劑、加熱或二者之組合來固化該等熱固性樹脂。
合適的熱固性樹脂可包括(但不限於)環氧樹脂、不飽和聚酯、雙 馬來醯亞胺、及其組合。該等熱固性樹脂可藉由使用熱、或固化劑、或其組合完全固化。觸媒可用於加速固化反應。當在熱固性樹脂完全固化時，其變硬且無法回轉化成其最初形式。
於一個實施例中，基質樹脂為包含一或多種多官能環氧樹脂作為主要聚合組分之環氧基熱固性組合物。合適的環氧樹脂包括芳族二胺、芳族單一級胺、胺基苯酚、多元酚、多元醇、多羧酸之聚縮水甘油基衍生物。合適的環氧樹脂之實例包括雙酚諸如雙酚A、雙酚F、雙酚S及雙酚K之聚縮水甘油醚；及基於甲酚及苯酚之酚醛樹脂之聚縮水甘油醚。
合適的雙馬來醯亞胺樹脂可包括1,2-乙烷二胺、1,6-己烷二胺、三甲基-1,6-己烷二胺、1,4-苯二胺、4,4'-亞甲基雙苯胺、2-甲基-1,4-苯二胺、3,3'-亞甲基雙苯胺、3,3'-磺醯基雙苯胺、4,4'-磺醯基雙苯胺、3,3'-氧聯雙苯胺、4,4'-氧聯雙苯胺、4,4'-亞甲基雙環己胺、1,3-苯二甲胺、1,4-苯二甲胺、及4,4'-環己烷雙苯胺之N,N'-雙馬來醯亞胺、及其混合物。
基質樹脂可進一步包含少量之熱塑性材料，諸如聚碸、聚醚碸、聚醚酮(例如，聚醚酮(PEK)、聚醚醚酮(PEEK)、聚醚酮酮(PEKK)及類似者)、其組合、及其前驅物。添加一或多種熱塑性材料至基質樹脂以增強預浸材之韌性、黏著性及懸垂性。
如本文中所述之基質樹脂可進一步包含少量之添加劑，以影響基質之機械性質、流變性質、電性質、光學性質、化學性質、及/或熱性質中之一或多種。該等添加劑可進一步包括與基質起化學反應、與基質相互作用、或與基質不起反應之材料。添加劑之實例可包括(但不限於)增韌顆粒、阻燃劑、紫外光(UV)穩定劑、抗氧化劑、著色劑、及填充物(例如，煙燻二氧化矽、氧化鋁、碳酸鈣、滑石)以增強損傷耐受性、韌性、耐磨性中之一或多者。
如本文所揭示，具有表面開孔之預浸材(即，多孔預浸材)係經組態以達成開孔之尺寸穩定性。開孔一旦形成即可保持尺寸穩定達一段選定時段。於某些實施例中，開孔可在多孔預浸材貯存期間保持尺寸穩定。可藉由定制基質樹脂之黏度提供尺寸穩定性。基質樹脂係於約室溫下經調配以形成尺寸穩定的開孔，但該樹脂可在固結或固化期間於提高之溫度下流動以填充該等開孔。
如本文中所述，「完全浸漬」係指包埋實質上所有織物纖維於基質樹脂中。如本文中所述，「部分浸漬」係指少於完全浸漬之浸漬，藉此存在乾纖維未包埋於基質樹脂中之區域。於一較佳實施例中，將基質樹脂施用至織物層的兩個表面，但樹脂僅部分穿透該織物之厚度，以使在厚度方向留下實質上不含樹脂之該織物之中間區段。
如本文中所用，術語「尺寸穩定性」係指結構可維持所選範圍內之尺寸達一段選定時段之能力。於某些實施例中，該所選範圍可藉由結構執行所欲功能(諸如，使得氣體於選定壓力下以選定速率通過)之能力來確定。
如本文中所用，術語「室溫」係指在20℃至25℃範圍內之溫度。
預浸材疊層及複合部件
為形成複合部件，可鋪放複數層本文所揭示之可固化預浸材形成預浸材疊層，且接著固結及固化該疊層。固結及固化可在一個階段中或分開進行。
已發現具有表面開孔之預浸材(即，多孔預浸材)有利於在固結之前及/或期間自個別預浸材及其中包括含一或多層多孔預浸材之預浸材疊層移除氣體，且因而使得由其形成之複合材料中之孔隙體積相較於形成之不利用多孔預浸材所形成之複合材料變小。例如，開孔為氣體提供自多孔預浸材中之散逸路徑且使得氣體以相較於未經處理之預 浸材更大的容易度及更大的體積自預浸材移除。該等氣體可包括源自基質樹脂或經部分浸漬之預浸材之無樹脂區段中之氣體、或源自預浸材層之間之層間區域之氣體。特定言之，多孔預浸材可實現可能會在固結期間自樹脂組合物逸出之氣體之移除。
如本文中所用，術語「預浸材疊層」係指以堆疊配置方式彼此相鄰放置之複數層預浸材。於某些實施例中，於堆疊中之預浸材可以所選的定向彼此相對定位。於另一實施例中，預浸材可視需要藉由縫線材料縫接在一起以抑制其自所選定向相對移動。於額外的實施例中，「疊層」可包括經完全浸漬之預浸材、經部分浸漬之預浸材、及如本文中所述之多孔預浸材之任何組合。可藉由可包括(但不限於)手工疊層(hand layup)、自動化鋪帶疊層(automated tape layup)(ATL)、自動化纖維鋪放(automated fiber placement)(AFP)及長絲纏繞(filament winding)之技術製得疊層。
固結或壓實係指於加熱、抽真空、及加壓中之一或多者之作用下發生之製程，藉此基質樹脂流動，以置換空隙空間。例如，固結會導致(但不限於)樹脂流入預浸材中纖維之間之空隙空間、預浸材之間之空隙空間及類似者。
如本文中所用，術語「固化(cure/curing)」可包括聚合及/或交聯製程。可藉由包括(但不限於)加熱、暴露至紫外光、及暴露至輻射之方法進行固化。於其他實施例中，於多孔預浸材中之基質樹脂可經調配或經部分固化以展現所選黏著力(stickiness)或黏性(tack)。
在將複數層具有表面開孔之可固化預浸材用於預浸材疊層中時，疊層具有增強之可移除陷留於預浸材中及預浸材層之間之氣體(例如空氣)之能力。於預浸材疊層之固結/壓實期間，於預浸材中之開孔及不含樹脂區域為陷留於預浸材中及預浸材之間之氣體提供散逸之各種路徑，因而降低所得固結複合材料中之孔隙度。因此，於固化 後，已固化複合材料展現經改良之機械性能。例如，可以此方式獲得具有以複合材料總體積計小於1體積%之殘留孔隙度之已固化複合材料。
當開孔形成於可固化預浸材之兩個主表面中時，氣體可以進入一個表面且經由相對表面離開方式穿通預浸材。開孔亦容許抽真空可完全穿透預浸材之層壓堆疊。此外，開孔建立相鄰上方/下方跨過位置之通道以建立沿著兩相鄰預浸材層之界面之空氣通道。各種流動路徑可由預浸材之表面開孔、層間區域、及非浸漬(無樹脂)部分之任何組合建立。例如，來自相鄰預浸材之間之層間區域之氣體可經由預浸材一側上之開孔進入，且接著經由同一預浸材之無樹脂中間區段而散逸至外部。或者，氣體可自一個層間區域經由各預浸材相對側中之開孔而流動至下一個層間區域，且最終從預浸材疊層中流出去。此為相比無熱處理之標準產品的改良，因為於其中樹脂膜保持完整之標準產品中，空氣較難從層之間轉移且轉移至層核(ply core)中，而對於經熱處理之材料而言，歸因於一定數目之開孔，空氣轉移增強。該等各流動路徑大大地增強陷留氣體自預浸材疊層散逸之能力，且亦與相鄰上/下區域建立通道，以建立沿著兩相鄰層界面之通氣。
基質樹脂之黏度可經控制以在固結期間流動並填充預浸材中及之間之空隙空間。例如，於一個實施例中，可藉由樹脂調配物來控制基質樹脂之黏度以在無外加壓力下於施加熱後流動並填充空隙空間。於另一個實施例中，可藉由樹脂調配物來控制基質樹脂之黏度以在施加熱及外加壓力後且視需要於真空下流動並填充空隙空間。有益地，藉由容許於固結期間填充開孔及其他空隙空間，所得複合材料之孔隙度實質上降低或消除。
可藉由使用真空袋設置來進行預浸材疊層之壓實。於該設置中，可與工具接觸鋪放可固化預浸材疊層且接著藉由不滲透膜密封。 該工具可具有相對平坦表面、彎曲表面、或其他三維組態。於一個實施例中，諸如未經浸漬之玻璃纖維薄片之通氣層可鄰近疊層之至少一個水平表面定位以達成表面通氣。必要時，可進一步使用密封膠帶，以在工具與膜之間建立近似真空密封。為抑制樹脂在疊層外部流動，或為改良氣體流動，亦可鄰近疊層的邊緣放置一或多個壩。可將穿孔離型膜(例如穿孔聚酯膜)插於通氣層與預浸材疊層之間及可將固態離型膜(例如聚酯膜)插於預浸材疊層與工具之間以促進自該設置移除固結之複合材料。抽空封閉體積且緩慢加熱疊層以引起固結。藉由將真空袋設置置於烘箱或高壓釜中施用加熱。此外，可於存在壓力(例如，在高壓釜中)或不存在壓力(例如，於烘箱中)下進行加熱，以減低基質之黏度並引起允許基質樹脂流動的壓力差。在基質之黏度足夠低以促進壓實時，該樹脂流可填充於預浸材疊層中之空隙空間並置換該疊層中之氣體。因此，在相同高壓釜或烘箱中於提高更多之溫度下固化該疊層，以製得最終複合部件。
已發現當在上述真空袋設置中處理經熱處理之預浸材時，可實質上縮短固化之前於真空下之時間長(另稱為壓實週期)。此係如先前所述增強之預浸材移除空氣及氣體之能力之結果。
可使用本文所揭示之多孔預浸材製造複合夾層結構。於一個實施例中，如圖13中所顯示，由木材、發泡體、蜂窩構造物、或其他結構材料所組成之中心核130係夾在兩個預浸材疊層131、132之間，其中疊層中之部分或全部預浸材層包含表面開孔。由圖14圖解說明所得複合夾層結構。視情況，可將倍加層置於多孔預浸材層之間以建立延長之增強區域。另外，未經浸漬、或經部分浸漬之輕量條子稀洋紗(scrim)，諸如玻璃纖維、碳、熱塑性或其他編織或非編織材料，可在所選位置併入疊層中以促進氣體之移除或增強諸如損傷耐受性之機械性能。
當在預浸材疊層併有核結構時，亦可在預浸材疊層之固化之前使用黏著材料以將該核結合至預浸材材料。因諸如蜂窩結構之敞開中心核結構可能包含顯著量的氣體，故黏著層亦可經穿孔以促進氣體之移除。
本文所揭示熱處理可在疊層之前或期間在部件建置器(builder)上併入複合部件製造製程。任何預浸材層之熱處理可於預浸材疊層製程期間藉由在將預浸材材料或層鋪放之前、正進行鋪放時、或在已鋪放一個預浸材層之後但在鋪放隨後的下一層之前施加熱至預浸材材料或層而在原位進行。例如，該製程可包括：鋪放一個表面上覆蓋有離型紙或聚酯膜之預浸材層；使用受熱輥、熱空氣棍(hot air wand)、熱鐵等等進行熱處理，以形成表面開孔；移除該離型紙/聚酯膜；鋪放下一層預浸材層；及必要時重複直到形成所欲厚度之預浸材疊層。
實例
提供以下實例來證實所揭示之可固化預浸材之實施例之優點。論述該等實例以達說明目的而不應解釋為限制所揭示實施例之範疇。
實例1
藉由熱熔融製程使用預浸漬機器製得預浸材織物，其中將兩層由韌化環氧基樹脂Cycom 5320(購自Cytec Industries Inc.)形成之樹脂膜對壓至8-H緞紋編織碳纖維織物之頂表面及底表面，藉此該織物夾在兩層樹脂膜之間。各樹脂膜係形成於經聚矽氧塗覆之離型紙上且每層膜具有106gsm之面積單位重量。碳纖維織物具有(370)gsm之FAW及0.0146in之厚度。對層壓物施加熱及壓力以引起樹脂膜熔融並部分穿透該織物之厚度。在預浸漬之後以平滑聚酯膜更換離型紙中之一者以促進纏繞至輥上。於200℉(93℃)下在烘箱中加熱頂部具有離型紙且底部具有聚酯膜之經預浸漬之預浸材2至5分鐘。已發現該熱週期時間足以打開封閉氣穴而不會影響預浸材之機械或物理特性。圖15至17顯 示將離型紙移除之預浸材表面分別於1分鐘、4分鐘及7.5分鐘之加熱時間下之俯視圖。開孔與緞紋編織織物中之上方/下方跨過位置(即，向上/向下絲束部分)重合。由圖15至17可見，開孔之尺寸經時變大。於7.5分鐘後，於同一絲束中對準且鄰近相鄰絲束之上方/下方跨過位置之部分開孔觸及彼此，此點可自圖13之圖像看出。該等開孔對應於緞紋編織織物中之向上/向下絲束部分(如圖7中參考數字70所示)。應注意該等開孔僅形成於經熱處理之預浸材之離型紙側。
實例2
藉由使用圖12中所描繪之預浸漬系統製得預浸材織物。使用的織物為平織編織碳纖維織物，及施加至織物之相對側之樹脂膜係由Cycom 5320環氧基樹脂形成。各樹脂膜係形成於聚矽氧塗覆之離型紙上且具有55gsm之面積單位重量。該碳纖維織物具有190gsm之FAW及0.0083"之厚度。就部分浸漬而言，在第一輥隙處施加20psi；220℉(104℃)為加熱板處之溫度；及在第二輥隙處提供小於0.5in(12.7mm)之間隙以限制壓實力。圖18顯示移除離型紙之經熱處理之預浸材表面之俯視圖。於預浸材表面中之開孔與平織編織織物中之間隙重合。另外，應注意該等開孔係形成於經熱處理之預浸材之兩個主表面中。
實例3
如實例1中所述在無建立表面開孔之熱後處理下製得對照預浸材以供比較。圖19顯示所得之具有形成於連續樹脂膜下方之封閉氣泡之預浸材表面。該等氣泡對應於緞紋編織織物中之向上/向下絲束部分。因此，可看出，在固化之前不進行熱處理，來自氣穴之陷留空氣、及層之間無法散逸之空氣殘留在所得固化預浸材中，此歸因於連續樹脂膜限制自預浸材移除空氣之事實。
實例4
建構由15層如實例1中所述之5320/8HS預浸材材料所組成之12"×12"單片式板並固化。使用未經處理之5320/8HS預浸材材料建構相同板並於相同條件下固化以供比較。所得孔隙度自未經處理之1.31%減低至經熱處理之0.04%。圖20顯示由未經處理之材料所組成之板之截面，及圖21顯示由經熱處理之材料所組成之板之截面。
實例5
基於圖13所顯示組態，組裝蜂窩核夾層結構，其中將10層多孔預浸材層(201)置於蜂窩核(202)上方及將14層多孔預浸材層(203)置於蜂窩核下方。如實例1中所述，藉由利用Cycom 5320樹脂部分地浸漬緞紋編織碳纖維織物，接著進行熱處理以建立表面開孔，製得該等多孔預浸材層。經組裝之夾層結構經真空袋化，於室溫下固結及於烘箱(不是高壓釜)中固化。
除了預浸材層不經熱處理以建立表面開孔以外，以相同方式組裝、固結及固化標準蜂窩核夾層結構以供比較。
於固化產品之不同部分處，包括凸緣、傾斜部分、中心核，測量孔隙度且計算得平均孔隙度。藉由拋光板截面之目視顯微鏡法測量孔隙度。
發現相較於固化標準產品之2.0%孔隙度，藉由使用多孔預浸材獲得之固化產品包含平均約0.05%之孔隙度。
實例6
使用多孔預浸材層且基於圖13之組態組裝蜂窩核夾層結構。用於該結構之多孔預浸材層係由平織編織碳纖維織物及Cycom 5320樹脂所組成，及如實例2中所述藉由於預浸漬製程期間在原位加熱製得預浸材層中之開孔。隨後，經組裝之夾層結構經真空袋化，於室溫下固結及於烘箱(不是高壓釜)中固化。除了預浸材層不經熱處理以建立表面開孔以外，以相同方式組裝、固結及固化標準蜂窩核夾層結構以 供比較。
發現相較於固化標準產品之1.74%孔隙度，藉由使用多孔預浸材獲得之固化產品包含平均約0.18%孔隙度。
實例7
由5320-1/8HS預浸材製造複合板以判定固化之前於真空下之時間長(另稱為壓實週期)是否縮短，因而，縮短總固化時間。使用經熱處理之預浸材及未經處理之預浸材(作為對照組)，固化之前於真空下之時間係自0.5小時至16小時改變。
建構由15層如實例1中所述之5320-1/8HS經熱處理之預浸材材料所組成之12"×12"單片式板及使用兩種不同固化週期固化。使用未經處理之5320/8HS預浸材材料建構相同板且於相同的兩種固化週期下固化以供比較。第一固化週期係由在固化之前於真空下保持16小時所組成。第二固化週期係由在固化之前於真空下保持0.5小時所組成。
C-掃描用於判定固化板是否無孔隙度。C-掃描為針對複合材料之非破壞性檢測技術，其中超音波能量之短脈衝入射於樣本上。透射脈衝之測量值指示樣本的入射脈衝之衰減。空隙、層離、樹脂固化狀態、纖維體積分率、纖維/基質界面之條件及存在的任何外源性包含物(foreign inclusion)會影響脈衝之衰減。因此，c-掃描之確定板或最終部件中所存在孔隙的數量之能力係為工業所接受之品質控制方式。c-掃描之靈敏度可偵測低至諸如小於2%空隙之極低百分比之孔隙度。將該等板與已知孔隙度之參照板進行比較，以測定所檢測之樣本中所存在孔隙的數量。該等板證實顯示如藉由c-掃描測得準確度在0.00%至2.00%範圍內之差別性之能力。為與使用截面拋光表面的c-掃描作比較，亦對該等板進行破壞性測試及剖視以測定孔隙度%。所測試複合板之截面圖顯示於圖22至25中。
藉由於真空下保持16小時所得之孔隙度使得孔隙度自未經處理 之1.46%減低至經熱處理之0.02%。圖22顯示由未經熱處理之預浸材材料所組成之板之截面，及圖23顯示由經熱處理之材料所組成之板之截面。藉由於真空下保持0.5小時所得之孔隙度使得孔隙度自未經處理之2.53%減低至經熱處理之1.06%。圖24顯示由未經處理之材料所組成之板之截面，及圖25顯示由經熱處理之材料所組成之板之截面。
該等結果顯示可藉由使用經熱處理之預浸材實質上縮短固化之前於真空下之時間長。此係如先前所述經熱處理之預浸材移除空氣及氣體之能力之結果。
實例8
由5320-1/PW預浸材製得複合板以判定在固化之前於真空下之壓實時間長是否縮短，因而，縮短總固化時間。使用經熱處理之預浸材及未經處理之預浸材(作為對照組)二者，在固化之前於真空下之時間係自0.5小時至16小時改變。
建構由15層如實例1中所述之經熱處理之5320-1/PW預浸材材料所組成之12"×12"單片式板及使用兩種不同固化週期固化。使用未經處理之5320-1/PW預浸材材料建構相同板及於相同兩種固化週期下固化以供比較。第一固化週期係由在固化之前於真空下保持16小時所組成。第二固化週期係由在固化之前於真空下保持0.5小時所組成。如實例7中所述對所製得複合板進行測試，及所測試之複合板之截面圖顯示於圖26至29中。
藉由於真空下保持16小時所得之孔隙度使得孔隙度自未經處理之0.83%減低至經熱處理之0.23%。圖26顯示由未經熱處理之預浸材材料所組成之板之截面，及圖27顯示由經熱處理之材料所組成之板之截面。未顯示藉由於真空下保持0.5小時所得之孔隙度使得孔隙度減低，此指示在固化之前的0.5小時真空停留對於所測試PW基材料要移除空氣時間不充足。圖28顯示由未經處理之預浸材材料所組成之板之 截面，及圖29顯示由經熱處理之材料所組成之板之截面。
雖然前述說明已顯示、描述、及指出本發明教示之主要新穎特徵，但應瞭解可在不脫離本發明教示之範疇下由熟習此項技藝者做出呈所說明設備以及其用途之細部形式之各種省略、取代、及改變。因此，本發明教示之範疇不應受限於前述說明，而應由隨附申請專利範圍界定。
如本文中所用，術語「近似」、「約」及「實質上」表示仍執行所欲功能或達成所欲結果之接近所述量之量。例如，術語「近似」、「約」、及「實質上」可係指在小於所述量之10%、小於所述量之5%、小於所述量之1%、小於所述量之0.1%、及小於所述量之0.01%中之量。
20‧‧‧纖維絲束
21‧‧‧上層樹脂膜
22‧‧‧下層樹脂膜
23‧‧‧封閉氣穴
Tf‧‧‧織物之厚度

Claims (21)

  1. 一種可固化預浸材，其包括：編織織物，其具有兩個相對的面及如下織造圖樣：其中第一編織方向上之一或多根絲束浮在第二編織方向上之一或多根絲束上方，接著在第二編織方向上之一或多根絲束下方穿過；其中當第一編織方向上之第一絲束在第二編織方向上之第二絲束上方穿過接著在第二編織方向上之相鄰第三絲束下方穿過時，或當該第一絲束在第二編織方向上之第二絲束下方穿過接著在第二編織方向上之相鄰第三絲束上方穿過時，在該織物表面中界定一空穴，且該空穴位置係由在相鄰第二與第三絲束之間上升或下降之該第一絲束之部分所界定；可固化熱熔融樹脂膜，其覆蓋該織物之一或兩個面並部分穿透該織物之厚度，在該厚度方向留下實質上不含該樹脂膜之該織物之內區段；及於至少一層該等樹脂膜中之開孔陣列，各開孔暴露該織物表面中至少一部分該空穴及經組態以建立自該織物之內區段至該預浸材之至少一個外表面、或自該預浸材之至少一個外表面至該內區段、或自該預浸材之一個外表面至相對的外表面、或其組合之流體流動路徑。
  2. 一種可固化預浸材，其包括：編織織物，其具有兩個相對的面及如下織造圖樣：其中第一編織方向上之絲束在第二編織方向上之另一絲束上方穿過，接著在第二編織方向上之相鄰絲束下方穿過，且在相鄰絲束之間界定間隙；可固化熱熔融樹脂膜，其覆蓋該織物之一或兩個面且部分穿 透該織物之厚度，在該厚度方向留下實質上不含該樹脂膜之該織物之內區段；及於至少一層該等樹脂膜中之開孔陣列，各開孔暴露該織物中之間隙且經組態以建立自該織物之內區段至該預浸材之至少一個外表面、或自該預浸材之至少一個外表面至該內區段、或自該預浸材之一個外表面至相對的外表面、或其組合之流體流動路徑。
  3. 一種具有表面開孔陣列之可固化預浸材，其係藉由包括以下之方法形成：(a)利用可固化熱熔融樹脂部分地浸漬編織織物，使得連續樹脂膜覆蓋該織物之各面且部分穿透該織物之厚度，在該厚度方向留下實質上不含該樹脂之該織物之內區段，其中該編織織物具有兩個相對的面及如下織造圖樣：其中第一編織方向上之一或多根絲束浮在第二編織方向上之一或多根絲束上方，接著在第二編織方向上之一或多根絲束下方穿過，其中當該第一編織方向上之第一絲束在第二編織方向上之第二絲束上方穿過接著在第二編織方向上之相鄰第三絲束下方穿過時、或當該第一絲束在第二編織方向上之第二絲束下方穿過接著在相鄰第三絲束上方穿過時，在該織物之面中界定一空穴，及其中經部分浸漬之織物包括複數個封閉氣穴，各氣穴與該織物中之空穴重合；及(b)加熱該經部分浸漬之織物，使得該織物之至少一個面上之樹脂膜變為流態，及隨後，該樹脂膜之於氣穴上方之部分破損敞開，因而建立該樹脂膜中對應於該等氣穴之位置之開孔，其中該等開孔經組態以提供自該織物之內區段至該預浸材之 至少一個外表面、或自該預浸材之至少一個外表面至該內區段、或自該預浸材之一個外表面至相對的外表面、或其組合之流體流動路徑。
  4. 如請求項1之可固化預浸材，其中該編織織物之織造圖樣為緞紋編織或斜紋編織。
  5. 如請求項2之可固化預浸材，其中該編織織物之織造圖樣為平織編織。
  6. 如請求項5之可固化預浸材，其中該等開孔係穿透該預浸材之相對的外表面而形成。
  7. 如請求項1之可固化預浸材，其中該織造圖樣為緞紋編織，該等開孔係穿透該預浸材之一或兩個表面而形成。
  8. 如請求項1之可固化預浸材，其中該熱熔融樹脂膜在20℃至25℃範圍內之溫度下實質上為固態，及在低於該樹脂膜之初始固化溫度之提高之溫度下變為流態。
  9. 如請求項1之可固化預浸材，其中該熱熔融樹脂膜包含一或多種熱固性樹脂作為主要組分，且實質上不含任何有機溶劑。
  10. 如請求項1之可固化預浸材，其中該熱熔融樹脂膜包含一或多種環氧樹脂、固化劑、及至少一種熱塑性或彈性化合物。
  11. 如請求項1之可固化預浸材，其中各絲束包括複數根纖維長絲，該等纖維長絲包括選自以下之材料：玻璃、碳、芳族聚醯胺、聚乙烯(PE)、硼、石英、玄武岩、陶瓷、聚酯、聚-對-伸苯基-苯并雙噁唑(PBO)、及其組合。
  12. 一種用於製造具有表面開孔陣列之可固化複合材料之方法，該方法包括：(a)利用可固化熱熔融樹脂部分地浸漬編織織物，使得連續樹脂膜覆蓋該織物之各面且部分穿透該織物之厚度，在該厚度方 向留下實質上不含該樹脂之該織物之內區段，其中該編織織物具有兩個相對的面及如下織造圖樣：其中第一編織方向上之一或多根絲束在第二編織方向上之一或多根絲束上方穿過，接著在第二編織方向上之一或多根絲束下方穿過，其中當在該第一編織方向上之第一絲束穿過該第二編織方向上之第二絲束接著在第二編織方向上之相鄰第三絲束下方穿過時、或當該第一絲束在第二編織方向上之第二絲束下方穿過接著在相鄰第三絲束上方穿過時，於該織物之面上界定一空穴，及其中該經部分浸漬之織物包括複數個封閉氣穴，各氣穴與該織物表面中之空穴重合；及(b)加熱該經部分浸漬之織物，使得該織物之至少一個面上之樹脂膜變為流態，及隨後，該樹脂膜之於該等氣穴上方之部分破損敞開，因而建立該樹脂膜中對應於膨脹氣穴位置之開孔，其中該等開孔經組態以提供自該織物之內區段至該複合材料之至少一個外表面、或自該複合材料之至少一個外表面至該內區段、或自該複合材料之一個外表面至相對的表面、或其組合之流體流動路徑。
  13. 一種用於製造具有表面開孔陣列之可固化複合材料之方法，該方法包括：(a)利用可固化熱熔融樹脂部分地浸漬編織織物，使得連續樹脂膜覆蓋該織物之各面且部分穿透該織物之厚度，在該厚度方向留下實質上不含該樹脂之該織物之內區段，其中該編織織物具有兩個相對的面及如下織造圖樣：其中第一編織方向上之絲束在第二編織方向上之另一絲束上方穿過，接 著在第二編織方向上之相鄰絲束下方穿過，且在相鄰絲束之間界定間隙；及(b)加熱該經部分浸漬之織物，使得該織物之至少一個面上之樹脂膜變為流態，及隨後，該樹脂膜之於間隙上方之部分破損敞開，因而建立該樹脂膜中對應於該等間隙之位置之開孔，其中該等開孔經組態以提供自該織物之內區段至該複合材料之至少一個外表面、或自該複合材料之至少一個外表面至該內區段、或自該複合材料之一個外表面至相對的表面、或其組合之流體流動路徑。
  14. 如請求項12或13之方法，其中該樹脂膜之該外表面在加熱期間係由離型紙或聚酯膜覆蓋。
  15. 一種用於製造可固化複合部件之方法，該方法包括：鋪放複數個預浸材層以形成預浸材疊層，其中各預浸材層係依如請求項12之方法形成。
  16. 一種用於製造可固化複合部件之方法，該方法包括：鋪放複數個預浸材層以形成預浸材疊層，其中各預浸材層係依如請求項13之方法形成。
  17. 一種用於製造可固化複合部件之方法，該方法包括：依照如請求項12之方法形成寬複合材料；將該寬複合材料切割成預定尺寸之預浸材層；鋪放該等預浸材層以形成預浸材疊層，其中在切割該材料之前針對於該材料進行該加熱步驟。
  18. 一種用於製造可固化複合部件之方法，該方法包括：依照如請求項13之方法形成寬複合材料；將該寬複合材料切割成預定尺寸之預浸材層；鋪放該等預浸材層以形成預浸材疊層， 其中在切割該材料之前針對於該材料進行該加熱步驟。
  19. 一種用於製造複合部件之方法，其中總固化時間因固化之前之壓實時間縮短而導致縮短，該方法包括：鋪放複數層如請求項1之可固化預浸材以形成複合疊層；藉由以下使該複合疊層壓實以自其移除空氣及揮發物：(a)將真空袋密封於該複合疊層上方；(b)自該真空袋內部抽真空；(c)施加壓力於該真空袋外部；及(d)繼續抽真空及施用加壓達一段預定時間間隔；及於壓實之後固化該複合疊層。
  20. 一種用於製造複合部件之方法，其中總固化時間因固化之前之壓實時間縮短而導致縮短，該方法包括：鋪放複數層如請求項2之可固化預浸材以形成複合疊層；藉由以下使該複合疊層壓實以自其移除空氣及揮發物：(a)將真空袋密封於該複合疊層上方；(b)自該真空袋內部抽真空；(c)施加壓力於該真空袋外部；及(d)繼續抽真空及施用加壓達一段預定時間間隔；及於壓實之後固化該複合疊層。
  21. 一種用於製造複合部件之方法，其中總固化時間因固化之前之壓實時間縮短而導致縮短，該方法包括：鋪放複數層如請求項3之可固化預浸材以形成複合疊層；藉由以下使該複合疊層壓實以自其移除空氣及揮發物：(a)將真空袋密封於該複合疊層上方；(b)自該真空袋內部抽真空；(c)施加壓力於該真空袋外部；及(d)繼續抽真空及施用加壓達一段預定時間間隔；及於壓實之後固化該複合疊層。
TW102147661A 2012-12-21 2013-12-20 具有表面開孔之可固化預浸材及用於製造可固化複合材料、可固化複合部件及複合部件之方法 TWI643730B (zh)

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US20140174641A1 (en) 2014-06-26
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US20140174632A1 (en) 2014-06-26
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