阅读说明：本技术 一种热塑性复合材料机翼油箱盒段及其制造方法 (Thermoplastic composite material wing oil tank box section and manufacturing method thereof ) 是由 孙见卓 杜恒毅 周俊 潘杰 张星明 刘亚男 蓝元沛 王栋 刘传军 于 2021-08-16 设计创作，主要内容包括：一种热塑性复合材料机翼油箱盒段及其制造方法,涉及飞机油箱盒段设计技术领域,包括：壁板单元,所述壁板单元之间相对设置；梁单元,所述梁单元设置在所述壁板单元之间,用于支撑所述壁板单元；肋单元,所述肋单元沿所述壁板单元和所述梁单元内侧轮廓设置,用于加固所述壁板单元和所述梁单元；其中,所述壁板单元、所述梁单元和所述肋单元均采用热塑性复合材料。本发明采用热塑性焊接工艺进行连接,不使用紧固件对零件进行连接,不用钻孔,提高装配效率,减少零件缺陷风险；不使用衬套螺栓,降低制造成本,同时满足闪电防护要求；不使用加强铜网,减轻结构重量,同时满足闪电防护要求；不使用密封胶,满足密封要求,减少装配工序。(A thermoplastic composite material wing oil tank box section and a manufacturing method thereof relate to the technical field of design of airplane oil tank box sections and comprise the following steps: the wallboard units are oppositely arranged; the beam units are arranged between the wall plate units and used for supporting the wall plate units; a rib unit provided along inner profiles of the wall plate unit and the beam unit for reinforcing the wall plate unit and the beam unit; wherein the wall panel units, the beam units and the rib units are all made of thermoplastic composite materials. The invention adopts the thermoplastic welding process for connection, does not use a fastener to connect parts, does not need drilling, improves the assembly efficiency and reduces the risk of part defects; a lining bolt is not used, so that the manufacturing cost is reduced, and the lightning protection requirement is met; a reinforced copper mesh is not used, so that the structural weight is reduced, and the lightning protection requirement is met; and no sealant is used, so that the sealing requirement is met, and the assembly procedures are reduced.)

1. A thermoplastic composite wing tank box section comprising:

the wall plate units are oppositely arranged and used for bearing and transmitting pneumatic load;

the beam units are arranged between the wall plate units and used for supporting the wall plate units;

the rib units are arranged along the inner profiles of the wall plate units and the beam units and are used for supporting the wall plate units and forming a space box type structure with the beam units;

wherein the wall panel units, the beam units and the rib units are all made of thermoplastic composite materials.

2. A thermoplastic composite wing tank box according to claim 1,

the panel unit comprises a skin and a stringer, wherein the stringer is arranged on the inner side of the skin;

the beam units are respectively arranged on the left side and the right side of the wallboard unit and comprise beam edge strips and beam web plates, and the beam edge strips are respectively vertically arranged at the upper end and the lower end of each beam web plate;

the rib unit comprises a rib web and a rib cap, the rib web is arranged along the inner contour of the stringer and the web; the rib edge strip is disposed perpendicularly at the rib web edge.

3. The thermoplastic composite wing tank box of claim 2, wherein the stringer is Z-shaped in cross-section and includes a stringer web and a stringer tape;

the stringer webs are arranged perpendicular to the skin;

the stringer flanges are respectively and vertically arranged at two ends of the stringer web;

a plurality of stringers are co-directionally aligned along the interior side of the skin.

4. A thermoplastic composite wing tank box section according to claim 2, wherein the ribbing comprises a transverse ribbing and a longitudinal ribbing;

the transverse rib strip is arranged in parallel with the skin;

the longitudinal rib strips are arranged in parallel with the web.

5. The thermoplastic composite wing tank box section of claim 4, wherein the inner side of the skin is fixedly connected to the outer side of the stringer base, the inner side of the skin is fixedly connected to the outer side of the stringer, the inner side of the stringer base is fixedly connected to the outer side of the transverse rib, and the inner side of the web is fixedly connected to the outer side of the longitudinal rib by thermoplastic welding.

6. A thermoplastic composite wing tank box section according to claim 3, wherein the ends of the spar cap, the rib cap and the stringer cap are each provided with a bevel angle of 30 ° to 35 °.

7. The thermoplastic composite wing tank box section according to claim 1, wherein the outer side of the wallboard unit is further provided with a copper mesh for lightning stroke protection, and the density of the copper mesh is 60-70 g/m²。

8. A thermoplastic composite wing tank box according to claim 1, wherein the thermoplastic composite is a carbon fiber reinforced composite with a thermoplastic resin as a matrix.

9. A method of manufacturing a thermoplastic composite wing tank box for use in manufacturing a wing tank box according to any one of claims 1 to 8, the method comprising:

step 1: manufacturing skins of the beam unit and the wallboard unit based on an automatic wire laying in-situ process, and manufacturing stringers of the rib unit and the wallboard unit based on a compression molding process;

step 2: under the action of local heating and pressure, the inner surface of the covering is bonded with the interface of the bottom surface of the stringer, the interface of the inner surface of the covering is bonded with the outer surface of the beam edge strip, the interface of the inner surface of the stringer is bonded with the outer surface of the rib edge strip, and the interface of the inner surface of the beam web is bonded with the outer surface of the rib edge strip.

10. The method for manufacturing the thermoplastic composite material wing oil tank box section according to the claim 9, wherein the step 2 can adopt the induction welding mode, the electromagnetic compound is laid on the combination position of the surfaces of the parts to be welded, and the magnetic field is applied to heat the parts to 300-400 ℃ so as to complete the interface self-bonding.

Technical Field

The invention relates to the technical field of design of airplane oil tank sections, in particular to a thermoplastic composite material wing oil tank section and a manufacturing method thereof.

Background

The main box section of the large civil aircraft wing mainly acts to bear and transfer wing bending moment and shearing force caused by aerodynamic load. The main composition structure comprises an upper reinforced wall plate, a lower reinforced wall plate, a front beam, a rear beam and ribs arranged along the spanwise direction. The carbon fiber reinforced composite material has the properties of high specific strength, high specific stiffness, designability, fatigue resistance, corrosion resistance, less maintenance and the like, and is widely applied to the most advanced international large civil aircraft. At present, carbon fiber reinforced thermosetting resin matrix composite materials (hereinafter referred to as thermosetting composite materials) are widely adopted in the main structure of the wing box of the advanced large civil aircraft. In the main box section structure of a B787 airplane and an airbus A350xwb wing, the upper and lower wall plates, the front and rear beam structures are made of thermosetting composite materials, and the wing ribs are made of metal structures; in the tail box section, the wall plate, the beam and the rib structure are all made of thermosetting composite materials.

The existing thermosetting composite material wing box section has the following defects:

1. the wall plates are connected with the beams, the wall plates are connected with the ribs, the beams and the ribs and the like, and the wall plates are still connected by fasteners, so that the accessory procedures such as drilling, packaging and the like are brought, the assembly procedures are increased, the risk of introducing part defects is increased, and the assembly efficiency is reduced;

2. in the oil tank area of the main box section of the wing, all fasteners connected with the outside of the box section need to use a special bushing fastener, the fastener is expensive in manufacturing cost and is tens of times of common high-locking fasteners, and the assembly cost is greatly improved;

3. in order to keep the oil tank area in a sealed state, all possible passages between the oil tank and the outside need to be sealed, common sealing operations comprise joint face sealing, fillet sealing and the like, the assembly procedures are increased, and the assembly efficiency is reduced;

4. in order to meet the lightning protection requirement, the reinforcing copper mesh is laid on the wall plate in the fastener area, so that the structural weight is increased, and the deformation state of the wall plate after solidification is greatly influenced;

5. the thermosetting composite material has poor toughness and poor impact resistance.

Disclosure of Invention

In view of the above, the invention provides a thermoplastic composite material wing oil tank box section and a manufacturing method thereof, wherein a thermoplastic welding process is adopted for connection, fasteners are not used for connecting parts, drilling is not needed, the assembly efficiency is improved, and the risk of part defects is reduced; a lining bolt is not used, so that the manufacturing cost is reduced, and the lightning protection requirement is met; a reinforced copper mesh is not used, so that the structural weight is reduced, and the lightning protection requirement is met; and no sealant is used, so that the sealing requirement is met, and the assembly procedures are reduced.

In order to achieve the purpose, the invention adopts the technical scheme that:

according to a first aspect of the present invention there is provided a thermoplastic composite wing tank box section comprising:

the wall plate units are oppositely arranged and used for bearing and transmitting pneumatic load;

the beam units are arranged between the wall plate units and used for supporting the wall plate units;

the rib units are arranged along the inner profiles of the wall plate units and the beam units and are used for supporting the wall plate units and forming a space box type structure with the beam units;

wherein the wall panel units, the beam units and the rib units are all made of thermoplastic composite materials.

Further, the panel unit includes a skin and stringers, the stringers being disposed inboard of the skin;

the beam units are respectively arranged on the left side and the right side of the wallboard unit and comprise beam edge strips and beam web plates, and the beam edge strips are respectively vertically arranged at the upper end and the lower end of each beam web plate;

the rib unit comprises a rib web and rib flanges, the rib web is arranged along the inner profiles of the stringers and the web, and the rib flanges are vertically arranged at the edges of the rib web.

Further, the stringer is Z-shaped in cross section and comprises a stringer web and a stringer tape;

the stringer webs are arranged perpendicular to the skin;

the stringer flanges are respectively and vertically arranged at two ends of the stringer web;

a plurality of stringers are co-directionally aligned along the interior side of the skin.

Further, the rib strips comprise transverse rib strips and longitudinal rib strips;

the transverse rib strip is arranged in parallel with the skin;

the longitudinal rib strips are arranged in parallel with the web.

Further, the inner side of the skin is fixedly connected with the outer side of the bottom surface of the stringer, the inner side of the skin is fixedly connected with the outer side of the beam edge strip, the inner side of the bottom surface of the stringer is fixedly connected with the outer side of the transverse rib strip, and the inner side of the web plate is fixedly connected with the outer side of the longitudinal rib strip in a thermoplastic welding mode.

Further, the ends of the beam flange strips, the rib flange strips and the stringer flange strips are all provided with oblique angles, and the oblique angles are 30-35 degrees.

Furthermore, the outer side of the wallboard unit is also provided with a lightning protection plate for protecting against lightning strikeThe density of the copper mesh is 60-70 g/m²。

Further, the thermoplastic composite material is a carbon fiber reinforced composite material using a thermoplastic resin as a matrix.

According to a second aspect of the invention, there is provided a method of manufacturing a thermoplastic composite wing tank box, the method comprising:

step 1: manufacturing skins of the beam unit and the wallboard unit based on an automatic wire laying in-situ process, and manufacturing stringers of the rib unit and the wallboard unit based on a compression molding process;

step 2: under the action of local heating and pressure, the inner surface of the covering is bonded with the interface of the bottom surface of the stringer, the interface of the inner surface of the covering is bonded with the outer surface of the beam edge strip, the interface of the inner surface of the stringer is bonded with the outer surface of the rib edge strip, and the interface of the inner surface of the beam web is bonded with the outer surface of the rib edge strip.

Further, step 2 can adopt an induction welding mode, electromagnetic compounds are laid on the surface joint of the parts to be welded, and a magnetic field is applied to heat the parts to 300-400 ℃ so as to complete interface self-bonding.

Compared with the prior art, the thermoplastic composite material wing oil tank box section and the manufacturing method thereof have the following advantages:

1. the parts of the invention are all made of thermoplastic composite materials. The skin adopts an automatic wire laying in-situ forming process, the ribs are Z-shaped, a continuous compression molding process is adopted, the beams adopt the automatic wire laying in-situ forming process, and the ribs adopt the compression molding process;

2. the wall plate and the beam edge strip, the wall plate and the rib edge strip and the rib and the beam are connected by adopting a thermoplastic welding process;

3. the spar cap is not mechanically connected with the wall plate, so that drilling and bushing bolts are not needed, the assembly cost is improved, and the manufacturing cost is reduced;

4. because the wing oil tank is not penetrated through by a fastener at the position, a reinforced copper mesh is not required to be laid on the outer side of the wall plate at the position, the structural weight can be saved, and the lightning protection requirement can be met;

5. because there is not welding clearance between spar cap and the wallboard, need not to seal, improve assembly efficiency.

6. The edge of the beam edge strip and the edge of the rib edge strip are designed by adopting an oblique angle with extremely slow gradient, so that the local rigidity is slowly changed, and the debonding risk is reduced.

Drawings

The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the invention and not to limit the invention.

In the drawings:

FIG. 1 is a schematic overall view of a thermoplastic composite wing tank box in an embodiment of the invention;

FIG. 2 is a schematic flow chart of a method of manufacturing a thermoplastic composite wing tank box in an embodiment of the invention.

Wherein, 1-skin; 2-a web; 3-a beam edge strip; 4-rib webs; 5-a rib strip; 6-stringer; 7-skin and stringer weld interface; 8-stringer to rib fillet weld interface; 9-the beam flange strip and skin weld interface; 10-web and rib welding interface; 11-copper mesh; 12-chamfering the beam edge strip; 13-chamfering the stringer tape; and 14-chamfering rib edge strips.

Detailed Description

Reference will now be made in detail to the exemplary embodiments, examples of which are illustrated in the accompanying drawings. When the following description refers to the accompanying drawings, like numbers in different drawings represent the same or similar elements unless otherwise indicated. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with the present invention. Rather, they are merely examples of apparatus and methods consistent with certain aspects of the invention, as detailed in the appended claims.

The terms first, second and the like in the description and in the claims of the present invention are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the data so used is interchangeable under appropriate circumstances such that the embodiments of the invention described herein are, for example, capable of operation in sequences other than those illustrated or otherwise described herein. Furthermore, the terms "comprises," "comprising," and "having," and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, or apparatus that comprises a list of steps or elements is not necessarily limited to those steps or elements expressly listed, but may include other steps or elements not expressly listed or inherent to such process, method, article, or apparatus.

A plurality, including two or more.

And/or, it should be understood that, as used herein, the term "and/or" is merely one type of association that describes an associated object, meaning that three types of relationships may exist. For example, a and/or B, may represent: a exists alone, A and B exist simultaneously, and B exists alone.

A thermoplastic composite wing tank box section comprising:

the wall plate units are oppositely arranged and used for bearing and transmitting pneumatic load;

the beam units are arranged between the wall plate units and used for supporting the wall plate units;

the rib units are arranged along the inner profiles of the wall plate units and the beam units and are used for supporting the wall plate units and forming a space box type structure with the beam units;

wherein, the wallboard unit, the beam unit and the rib unit are all made of thermoplastic composite materials.

Preferably, the panel unit comprises a skin and stringers, the stringers being located inboard of the skin;

the beam units are respectively arranged at the left side and the right side of the wallboard unit and comprise beam edge strips and a beam web plate, and the beam edge strips are respectively and vertically arranged at the upper end and the lower end of the beam web plate;

the rib unit comprises a rib web and rib flanges, and the rib web is arranged along the inner profiles of the stringers and the web; the rib edge strips are arranged perpendicularly at the rib web edges.

Preferably, the stringer is Z-shaped in cross-section and includes a stringer web and a stringer tape;

the stringer web is perpendicular to the skin;

the stringer flanges are respectively vertically arranged at two ends of the stringer web;

a plurality of stringers are co-directionally aligned along the interior side of the skin.

Preferably, the rib strips comprise transverse rib strips and longitudinal rib strips;

the transverse rib strip is arranged in parallel with the skin;

the longitudinal ribs are arranged parallel to the web.

Preferably, the inner side of the skin is fixedly connected with the outer side of the bottom surface of the stringer, the inner side of the skin is fixedly connected with the outer side of the girder edge strip, the inner side of the bottom surface of the stringer is fixedly connected with the outer side of the transverse rib edge strip, and the inner side of the web plate is fixedly connected with the outer side of the longitudinal rib edge strip in a thermoplastic welding mode.

Preferably, the ends of the beam flanges, the rib flanges and the stringer flanges are provided with bevels, the bevels being from 30 to 35 °.

Preferably, the outer side of the wallboard unit is also provided with a copper net for protecting against lightning stroke, and the density of the copper net is 60-70 g/m²。

Preferably, the thermoplastic composite material is a carbon fiber reinforced composite material having a thermoplastic resin as a matrix.

A method of manufacturing a thermoplastic composite wing tank box section, comprising:

step 1: manufacturing skins of the beam unit and the wallboard unit based on an automatic wire laying in-situ process, and manufacturing stringers of the rib unit and the wallboard unit based on a compression molding process;

step 2: under the action of local heating and pressure, the inner surface of the covering is bonded with the interface of the bottom surface of the stringer, the interface of the inner surface of the covering is bonded with the outer surface of the beam edge strip, the interface of the inner surface of the stringer is bonded with the outer surface of the rib edge strip, and the interface of the inner surface of the beam web is bonded with the outer surface of the rib edge strip.

Preferably, step 2 can adopt an induction welding mode, electromagnetic compounds are laid on the surface joint of the parts to be welded, and a magnetic field is applied to heat the parts to 300-400 ℃ so as to complete interface self-bonding.

Example (b):

the specific scheme of the invention is shown in figure 1, the composite material wing box section adopts a double-beam multi-rib structure, and parts of each component are made of thermoplastic composite materials. The skin 1 adopts an automatic fiber-laying in-situ forming process, the stringers 6 adopt a Z-shaped structure and are suitable for a continuous compression molding process, the web plates 2 and the edge strips 3 adopt an automatic fiber-laying in-situ forming process, and the rib web plates 4 and the rib edge strips 5 adopt a compression molding process.

The two skins 1 are oppositely arranged, the stringers 6 are arranged on the inner sides of the skins 1 and are used for transmitting pneumatic loads transmitted by the skins 1 to the wing ribs in the form of loads of the multi-fulcrum beams, the Z-shaped stringers 6 are high in bending rigidity and structural efficiency, and compared with the I-shaped stringers with the same high bending rigidity, the manufacturing is simple; the two beam webs 2 are respectively fixed on two sides in the skin 1 through beam edge strips 3 to play a supporting role; the rib web 4 is arranged along the inner profiles of the stringers 6 and the web 2 and is fixed thereto by the rib flanges 5; meanwhile, the outer side of the skin 1 is also provided with a density of 60g/m²For protection against lightning strikes 11.

Compared with the traditional main box section of the wing made of the thermosetting composite material, the parts involved in the invention are made of the thermoplastic composite material, so that the parts can be repeatedly melted and solidified, and the interface between the parts can be self-bonded under the action of local heating and pressure. There are many processes for achieving heating and pressurizing of the interface between parts, which are collectively referred to as thermoplastic composite welding processes.

The invention adopts a thermoplastic welding process to connect a skin and stringer welding interface 7, a stringer and rib strip welding interface 8, a beam flange strip and skin welding interface 9 and a beam web and rib strip welding interface 10. By adopting thermoplastic welding connection, under the condition of meeting the strength requirement, the application of fasteners can be reduced or avoided on a large scale at the connection interface of each part, the drilling of composite materials is reduced, and the assembly process is simplified; after the fasteners are reduced to be connected, the use amount of the bolts along with the bushings is greatly reduced, the component cost can be greatly reduced, and meanwhile, the lightning protection risk is also greatly reduced. Meanwhile, the interfaces between the parts are greatly reduced due to the welding process, and only a few positions in the box section need additional sealing, so that the use of a sealant is greatly reduced, the assembly process is simplified, and the structural weight is reduced. Due to the large-scale reduction of the fasteners, the use of the reinforced copper mesh is greatly reduced, and the weight of the structure can be reduced; meanwhile, the thermoplastic composite material improves the shock resistance of the main box section of the wing and reduces the structural weight.

In addition, in order to increase the welding area, improve the bearing level of the connection area between parts and reduce stress concentration, the edge of the edge strip is designed to be inclined angle with extremely slow gradient so as to slowly change the local rigidity and reduce the debonding risk, wherein the beam edge strip inclined chamfer angle 12, the stringer edge strip inclined chamfer angle 13 and the rib edge strip inclined chamfer angle 14 are preferably 32.5 degrees.

As shown in fig. 2, a method for manufacturing a wing tank box section made of thermoplastic composite material comprises the following steps:

step 1: manufacturing skins of the beam unit and the wallboard unit based on an automatic wire laying in-situ process, and manufacturing stringers of the rib unit and the wallboard unit based on a compression molding process;

step 2: and laying an electromagnetic compound at the joint of the surfaces of the parts by adopting an induction welding mode, and applying a magnetic field to heat to 300-400 ℃ to complete interface self-bonding.

While the present invention has been described with reference to the embodiments shown in the drawings, the present invention is not limited to the embodiments, which are illustrative rather than restrictive, and it will be apparent to those skilled in the art that many more modifications and variations can be made without departing from the spirit of the invention and the scope of the appended claims.