Method of forming a layered composite assembly

• US 10,457,017 B2
• Filed: 12/08/2014
• Issued: 10/29/2019
• Est. Priority Date: 12/08/2014
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Humfeld, Keith Daniel, Hurley, Kelsi Marie
• Primary Examiner(s): Powers, Laura C
• Assistant Examiner(s): Rowe, Larissa E
• Application Number:
  US14/563,435
• Publication Number:
  US 20160159036A1
• Time in Patent Office: 1,786 Days
• Field of Search: 428223
• CPC Class Codes: B29C 65/02 by heating, with or without pressure
• CPC Class Codes: B29C 65/18 using heated tools
• CPC Class Codes: B29C 65/564 hidden in the joint, e.g. dowels or Z-pins B29C65/603 takes precedence
• 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 66/45 Joining of substantially the whole surface of the articles methods or apparatus for laminating B32B37/00
• CPC Class Codes: B29C 66/721 Fibre-reinforced materials B29C66/729 takes precedence
• CPC Class Codes: B29C 66/73752 the to-be-joined areas of both parts to be joined being uncured
• CPC Class Codes: B29C 66/73941 characterised by the materials of both parts being thermosets
• CPC Class Codes: B29C 66/83431 rollers, cylinders or drums cooperating with bands or belts
• CPC Class Codes: B29C 70/24 oriented in at least three directions forming a three dimensional structure
• CPC Class Codes: B29C 70/543 Fixing the position or configuration of fibrous reinforcements before or during moulding for non-woven fabrics D04H3/08
• CPC Class Codes: B32B 2250/20 All layers being fibrous or filamentary
• 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 2305/076 Prepregs
• CPC Class Codes: B32B 2305/34 Inserts
• CPC Class Codes: B32B 2311/005 Shape memory alloys
• CPC Class Codes: B32B 2605/18 Aircraft blades, propellers B32B2603/00
• CPC Class Codes: B32B 3/08 characterised by added members at particular parts layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18
• CPC Class Codes: B32B 37/18 : involving the assembly of discrete sheets or panels only
• 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 7/08 : by mechanical means
• CPC Class Codes: F16B 2200/77 : Use of a shape-memory material

Abstract

A layered composite assembly may include a plurality of composite fiber layers stacked onto one another. Each of the plurality of composite fiber layers may include a main body including a plurality of composite fibers. The main body may be pre-impregnated with at least one resin. Each composite fiber layer also includes a plurality of layer-securing pins secured to the main body. The layer-securing pins are configured to mechanically connect the main body to an adjacent composite fiber layer.

Claims

1. A composite fiber layer that couples to another composite fiber layer, the composite fiber layer comprising:

a main body including a plurality of composite fibers; and

a plurality of layer-securing pins secured to the main body, wherein the plurality of layer-securing pins are separate and distinct from one another, wherein the plurality of layer-securing pins are configured to mechanically connect the main body to the other composite fiber layer, wherein each of the plurality of layer-securing pins comprises;

an annular ring; and

a plurality of legs extending from the annular ring, wherein the annular ring is exposed through an outer surface of the main body, and wherein the plurality of legs extend into the main body, wherein the annular ring adhesively bonds via curing to another annular ring of the other composite fiber layer.

2. The composite fiber layer of claim 1, wherein the main body is pre-impregnated with at least one resin.

3. The composite fiber layer of claim 1, wherein the main body includes first and second opposed surfaces separated by a thickness, wherein each of the plurality of layer-securing pins extends through only one of the first or second opposed surfaces.

4. The composite fiber layer of claim 1, wherein each of the plurality of layer-securing pins comprises a linear structure.

5. The composite fiber layer of claim 1, wherein each of the plurality of layer-securing pins further comprises a linear exposed end extending outwardly from the main body.

6. The composite fiber layer of claim 1, wherein each of the plurality of layer-securing pins includes first and second portions that exhibit different coefficients of thermal expansion.

7. The composite fiber layer of claim 1, wherein each of the plurality of layer-securing pins is formed of a shape memory alloy.

8. The composite fiber layer of claim 7, wherein each of the plurality of layer-securing pins is curled at a first temperature, and wherein each of the plurality of layer-securing pins is configured to be straightened at a second temperature that differs from the first temperature.

9. The composite fiber layer of claim 1, wherein each of the plurality of legs is formed of a bimetallic material.

10. A layered composite assembly that couples to an adjacent composite layer, the layered composite assembly comprising:

a plurality of composite fiber layers stacked onto one another, each of the plurality of composite fiber layers comprising;

a main body including a plurality of composite fibers, wherein the main body is pre-impregnated with at least one resin; and

a plurality of layer-securing pins secured to the main body, wherein the plurality of layer-securing pins are separate and distinct from one another, wherein the plurality of layer-securing pins are configured to mechanically connect the main body to the adjacent composite fiber layer, wherein each of the plurality of layer-securing pins comprises;

(a) an annular ring; and

(b) a plurality of legs extending from the annular ring, wherein the annular ring is exposed through an outer surface of the main body, and wherein the plurality of legs extend into the main body, and wherein the annular ring is adhesively bonded via curing to another annular ring of the adjacent composite fiber layer.

11. The layered composite assembly of claim 10, further comprising at least one laminate layer secured around an outer one of the plurality of composite fiber layers.

12. The layered composite assembly of claim 10, wherein each of the plurality of layer-securing pins is formed of a shape memory alloy, wherein each of the plurality of layer-securing pins is formed in a curled shaped at a first temperature, wherein each of the plurality of layer-securing pins is cooled to a second temperature that differs from the first temperature, wherein each of the plurality of layer-securing pins is mechanically straightened at a second temperature, wherein each of the plurality of layer-securing pins is secured to the main body in a straightened orientation, and wherein each of the plurality of layer-securing pins transitions to a curled orientation to hook onto one or more of the plurality of composite fibers.

13. The layered composite assembly of claim 10, wherein each of the plurality of layer-securing pins includes an inner portion formed of a first metal and an outer portion formed of a second metal that is different than the first metal, wherein the first and second metals exhibit different coefficients of thermal expansion, wherein each of the plurality of layer-securing pins is curled at a first temperature, wherein each of the plurality of layer-securing pins is configured to be straightened at a second temperature that differs from the first temperature, wherein each of the plurality of layer-securing pins is secured to the main body in a straightened orientation, and wherein each of the plurality of layer-securing pins transitions to a curled orientation to hook onto one or more of the plurality of composite fibers.

14. A method of forming a layered composite assembly, the method comprising:

stacking a plurality of composite fiber layers, wherein each of the composite fiber layers includes a main body including a plurality of composite fibers that are pre-impregnated with at least one resin, and a plurality of layer-securing pins; and

mechanically connecting the plurality of layer-securing pins of each of the plurality of composite fiber layers with another of the plurality of composite fiber layers wherein the plurality of layer-securing pins are separate and distinct from one another, wherein the mechanically connecting operation comprises;

abutting exposed portions of rings of the plurality of layer-securing pins of the plurality of composite fiber layers together; and

adhesively bonding, via curing, the abutting exposed portions of the rings of the plurality of layer-securing pins of the plurality of composite fiber layers together.

15. The method of claim 14, wherein the mechanically connecting operation comprises:

exposing the plurality of composite fibers layers to a change in one or both of temperature or pressure; and

transitioning the plurality of layer-securing pins between straightened and curled orientations through the exposing operation.