Composite structure and method for molding composite structure

• US 10,195,789 B2
• Filed: 10/07/2015
• Issued: 02/05/2019
• Est. Priority Date: 12/15/2014
• Status: Active Grant

• Current Assignee: Mitsubishi Heavy Industries, Ltd.
• Original Assignee: Mitsubishi Heavy Industries, Ltd.
• Inventors: Abe, Toshio, Takagi, Kiyoka, Koyama, Takayuki, Kishimoto, Kazuaki, Saito, Koichi, Ishida, Takashi
• Primary Examiner(s): Daniels, Matthew J
• Assistant Examiner(s): Page, Hana C
• Application Number:
  US15/531,871
• Publication Number:
  US 20170266874A1
• Time in Patent Office: 1,217 Days
• Field of Search: 156242
• CPC Class Codes: B29C 65/4835 Heat curing adhesives
• CPC Class Codes: B29C 65/486 characterised by their physical form being non-liquid, e.g. in the form of granules or powders B29C65/50 takes precedence
• CPC Class Codes: B29C 65/5057 positioned between the surfaces to be joined B29C65/5035 takes precedence
• CPC Class Codes: B29C 65/5071 and being composed by one single element
• CPC Class Codes: B29C 66/00145 Vacuum, e.g. partial vacuum
• CPC Class Codes: B29C 66/112 Single lapped joints
• CPC Class Codes: B29C 66/1122 Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/131 Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
• CPC Class Codes: B29C 66/326 Shaping the burr, e.g. by the joining tool
• CPC Class Codes: B29C 66/5346 said single elements being substantially flat
• CPC Class Codes: B29C 66/53462 joining substantially flat covers and substantially flat bottoms to open ends of container bodies
• CPC Class Codes: B29C 66/54 Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
• CPC Class Codes: B29C 66/634 using an inflatable core
• CPC Class Codes: B29C 66/7212 characterised by the composition of the fibres
• CPC Class Codes: B29C 66/81455 being a fluid inflatable bag or bladder, a diaphragm or a vacuum bag for applying isostatic pressure inflatable element positioned between the joining tool and a backing-up part B29C66/82421
• CPC Class Codes: B29C 70/44 using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
• CPC Class Codes: B29D 99/0005 Producing noodles, i.e. composite gap fillers, characterised by their construction
• CPC Class Codes: B29D 99/0014 provided with ridges or ribs, e.g. joined ribs
• CPC Class Codes: B29D 99/0017 with filled hollow ridges
• CPC Class Codes: B29K 2307/04 Carbon
• CPC Class Codes: B29L 2024/003 : comprising corrugated cores
• CPC Class Codes: B29L 2031/3076 : Aircrafts blades, propellers B29L2031/08
• CPC Class Codes: B29L 2031/3082 : Fuselages
• CPC Class Codes: B29L 2031/3085 : Wings
• CPC Class Codes: B32B 2250/03 : 3 layers
• CPC Class Codes: B32B 2250/20 : All layers being fibrous or filamentary
• CPC Class Codes: B32B 2250/24 : All layers being polymeric
• CPC Class Codes: B32B 2250/40 : Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2260/023 : Two or more layers
• CPC Class Codes: B32B 2260/046 : Synthetic resin
• CPC Class Codes: B32B 2262/106 : Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2307/748 : Releasability
• CPC Class Codes: B32B 2603/00 : Vanes, blades, propellers, rotors with blades
• CPC Class Codes: B32B 2605/18 : Aircraft
• CPC Class Codes: B32B 27/08 : of synthetic resin
• CPC Class Codes: B32B 27/38 : comprising epoxy resins
• CPC Class Codes: B32B 3/28 : characterised by a layer comprising a deformed thin sheet , i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled B32B29/08 takes precedence
• CPC Class Codes: B32B 5/02 : characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: B32B 5/12 : 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
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 7/05 : the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection using interposed adhesives or bonding materials applied in spaced arrangements B32B7/14
• CPC Class Codes: B32B 7/14 : applied in spaced arrangements, e.g. in stripes
• CPC Class Codes: B64C 1/00 : Fuselages; Constructional features common to fuselages, wings, stabilising surfaces or the like
• CPC Class Codes: B64C 1/061 : Frames
• CPC Class Codes: B64C 1/12 : Construction or attachment of skin panels
• CPC Class Codes: B64C 2001/0072 : from composite materials
• CPC Class Codes: Y02T 50/40 : Weight reduction

Abstract

This structure is provided with a first composite material 11, a second composite material 12 joined to the first composite material 11 by a film adhesive 21 provided between the first composite material 11 and the second composite material 12, and a corner fillet part 13 provided on a corner part 15 formed by the first composite material 11 and the second composite material 12. The shape of the corner fillet part 13 is a design shape P designed in advance, and the corner fillet part 13 is formed by curing the film adhesive 21 after arranging the film adhesive 21 on the corner part 15 so as to fit into the design shape P.

Claims

1. A method for molding a composite structure comprising:

a film formation step of forming a film adhesive in a lump, wherein the film adhesive is intended to be used in order to join a first composite material and a second composite material together;

an arrangement step of arranging the film adhesive formed in a lump on a corner part formed by the first composite material and the second composite material; and

a curing step of curing the film adhesive to form a corner fillet part in the corner part,

wherein the film adhesive arranged on the corner part is formed in a lump by being bent in the shape of bellows.

2. The method for molding a composite structure according to claim 1,

wherein the film adhesive is continuous toward the corner part from between the first composite material and the second composite material, and

wherein the corner fillet part is formed with a surplus part of the film adhesive exposed from between the first composite material and the second composite material.

3. The method for molding a composite structure according to claim 1,

wherein the film adhesive includes

a first film adhesive arranged between the first composite material, and the second composite material, and

a second film adhesive provided separately from the first film adhesive to form the corner fillet part.

4. The method for molding a composite structure according to claim 1,

wherein a bagging film is arranged on the corner part in the curing step,

wherein the bagging film is arranged such that the shape of the corner fillet part becomes a design shape designed in advance, and

wherein the corner fillet part is formed in the design shape by curing the film adhesive after the shape of the bagging film.

5. The method for molding a composite structure according to claim 1, wherein the size of the film adhesive that forms the corner fillet part is adjusted such that a filling rate of the film adhesive with respect to a design shape of the corner fillet part designed in advance is between 50% to 200%, and wherein the filling rate is associated with flow of the film adhesive.