Fiber composite component assembly having at least two plate-shaped composite structures and processes for preparing same

• US 10,456,989 B2
• Filed: 12/22/2016
• Issued: 10/29/2019
• Est. Priority Date: 12/09/2011
• Status: Active Grant

• Current Assignee: Airbus Operations GmbH (Airbus SE)
• Original Assignee: Airbus Operations GmbH (Airbus SE)
• Inventors: Kruse, Thomas, Fideu, Paulin
• Primary Examiner(s): Tucker, Philip C
• Assistant Examiner(s): Slawski, Brian R
• Application Number:
  US15/388,593
• Publication Number:
  US 20170100884A1
• Time in Patent Office: 1,041 Days
• Field of Search: 156 60, 156 90, 156 91, 156 92, 156 93, 156250, 156252, 1562722, 1562755, 1562757, 1563071, 1563073, 264241, 264249, 264257, 264258, 264154, 264155, 264156, 2441296, 244131, 244133, 428 57, 428102, 428103, 428131, 428134, 428136, 428137, 428192, 428194, 4281951, 428198
• CPC Class Codes: B29C 65/48 using adhesives , i.e. using supplementary joining material; solvent bonding
• CPC Class Codes: B29C 65/564 hidden in the joint, e.g. dowels or Z-pins B29C65/603 takes precedence
• CPC Class Codes: B29C 65/62 Stitching
• CPC Class Codes: B29C 65/72 by combined operations or combined techniques, e.g. welding and stitching
• 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 66/21 said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
• CPC Class Codes: B29C 66/3452 Making complete joints by combining partial joints
• CPC Class Codes: B29C 66/43 Joining a relatively small portion of the surface of said articles B29C66/45 takes precedence
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/721 Fibre-reinforced materials B29C66/729 takes precedence
• CPC Class Codes: B29C 66/7212 characterised by the composition of the fibres
• CPC Class Codes: B29C 66/73752 the to-be-joined areas of both parts to be joined being uncured
• CPC Class Codes: B29C 66/73756 the to-be-joined areas of both parts to be joined being fully cured
• CPC Class Codes: B29C 66/73941 characterised by the materials of both parts being thermosets
• CPC Class Codes: B29C 70/845 by moulding material on a relative small portion of the preformed parts
• CPC Class Codes: B29K 2063/00 Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2307/04 Carbon
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer
• 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 2605/18 : Aircraft
• CPC Class Codes: B32B 3/02 : characterised by features of form at particular places, e.g. in edge regions non-uniform thickness B32B3/263
• CPC Class Codes: B32B 3/06 : for securing layers together; for attaching the product to another member, e.g. to a support , or to another product, e.g. groove/tongue, interlocking
• CPC Class Codes: B32B 37/02 : characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
• CPC Class Codes: B32B 5/06 : characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
• 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 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: Y10T 428/197 : with noncoplanar reinforcement
• CPC Class Codes: Y10T 428/24033 : including stitching and discrete fastener[s], coating or bond
• CPC Class Codes: Y10T 428/249923 : Including interlaminar mechanical fastener

Abstract

A method for producing a fiber composite component assembly having at least first and second plate-shaped composite structures made from synthetic resin embedded fibers, the at least first and second fiber composite components having a plurality of partial regions not containing synthetic resin is described. The method includes positioning the at least first and second fiber composite components, the partial regions having been brought to flush conformity with each other, bonding the at least first and second positioned fiber composite components by the adhesive layer arranged in between, placing mechanical reinforcement means through the partial regions, infusing the dry partial regions with synthetic resin, and curing the synthetic resin placed in the partial regions.

Claims

1. A method for producing a fiber composite component assembly having at least first and second plate-shaped composite structures made from synthetic resin embedded fibers, the at least first and second fiber composite components having a plurality of partial regions not containing synthetic resin in an initial state, the plurality of partial regions extending from a top surface to a bottom surface of the respective first and second fiber composite components, the method comprising:

positioning the at least first and second fiber composite components, the partial regions having been brought to flush conformity with each other,

bonding the at least first and second positioned fiber composite components by an adhesive layer arranged in between,

placing mechanical reinforcement means through the partial regions,

infusing the plurality of partial regions not containing synthetic resin in the initial state with synthetic resin, and

curing the synthetic resin placed in the plurality of partial regions not containing synthetic resin in the initial state.

2. The method of claim 1, wherein each of the plurality of partial regions not containing synthetic resin in the initial state is enclosed by a cured region of the fiber composite component.

3. The method of claim 1, wherein each of the plurality of partial regions is essentially rectangular or oval to round in shape.

4. The method of claim 1, wherein the mechanical reinforcement means are configured as pins to form a pin connection.

5. The method of claim 1, wherein the mechanical reinforcement means are configured as threads to form a sewn connection.

6. The method of claim 1, wherein the plurality of partial regions not containing synthetic resin in the initial state, are produced by inserting a filler during the production of the fiber composite components from fibers and synthetic resin.

7. A method for producing a fiber composite component assembly having at least first and second plate-shaped composite structures made from synthetic resin embedded fibers, the at least first and second fiber composite components having a plurality of partial regions not containing synthetic resin in an initial state, the method comprising:

positioning the at least first and second fiber composite components, the plurality of partial regions not containing synthetic resin having been brought to flush conformity with each other,

bonding the at least first and second positioned fiber composite components by an adhesive layer arranged in between,

placing mechanical reinforcement means through the plurality of partial regions not containing synthetic resin in the initial state,

infusing the plurality of partial regions not containing synthetic resin in the initial state with synthetic resin, and

curing the synthetic resin placed in the plurality of partial regions not containing synthetic resin in the initial state,

wherein the plurality of partial regions not containing synthetic resin in the initial state is produced by inserting a filler during the production of the fiber composite components from fibers and synthetic resin.

8. The method of claim 7, wherein each of the plurality of partial regions not containing synthetic resin in the initial state is enclosed by a cured region of the fiber composite component.

9. The method of claim 7, wherein each of the plurality of partial regions not containing synthetic resin in the initial state is essentially rectangular or oval to round in shape.

10. The method of claim 7, wherein the mechanical reinforcement means are configured as pins to form a pin connection.

11. The method of claim 7, wherein the mechanical reinforcement means are configured as threads to form a sewn connection.

12. The method of claim 7, wherein the plurality of partial regions not containing synthetic resin in the initial state is arranged in series with an edge spacing and a web spacing.

13. A method for producing a fiber composite component assembly having at least first and second plate-shaped composite structures made from synthetic resin embedded fibers, the at least first and second fiber composite components having a plurality of partial regions not containing synthetic resin in an initial state, the method comprising:

positioning the at least first and second fiber composite components, the plurality of partial regions not containing synthetic resin in the initial state having been brought to flush conformity with each other,

bonding the at least first and second positioned fiber composite components by an adhesive layer arranged in between,

placing mechanical reinforcement means through the plurality of partial regions not containing synthetic resin in the initial state,

infusing the plurality of partial regions not containing synthetic resin in the initial state with synthetic resin, and

curing the synthetic resin placed in the plurality of partial regions not containing synthetic resin in the initial state,

wherein the plurality of partial regions not containing synthetic resin in the initial state is arranged in series with an edge spacing and a web spacing.

14. The method of claim 13, wherein the plurality of partial regions not containing synthetic resin in the initial state, are produced by inserting a filler during the production of the fiber composite components from fibers and synthetic resin.

15. The method of claim 13, wherein each of the plurality of partial regions not containing synthetic resin in the initial state is enclosed by a cured region of the fiber composite component.

16. The method of claim 13, wherein each of the plurality of partial regions not containing synthetic resin in the initial state is essentially rectangular or oval to round in shape.

17. The method of claim 13, wherein the mechanical reinforcement means are configured as pins to form a pin connection.

18. The method of claim 13, wherein the mechanical reinforcement means are configured as threads to form a sewn connection.