Co-bonded joint with Z-pins

• US 20030066589A1
• Filed: 10/09/2001
• Published: 04/10/2003
• Est. Priority Date: 10/09/2001
• Status: Active Grant

• Current Assignee: Lockheed Martin Corporation (Martin Marietta Corporation)
• Original Assignee: Lockheed Martin Corporation (Martin Marietta Corporation)
• Inventors: Bersuch, Larry R., Benson, Ross A., Sheahen, Patrick D.
• Granted Patent: US 6,821,368 B2
• Time in Patent Office: Days
• US Class Current: 156/92
• 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 66/12441 being a single wall
• CPC Class Codes: B29C 66/43441 with two right angles, e.g. for making T-shaped pieces, H-shaped pieces
• 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 66/72141 Fibres of continuous length
• CPC Class Codes: B29C 66/7315 Mechanical properties
• 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 70/24 oriented in at least three directions forming a three dimensional structure
• 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: B29C 70/543 Fixing the position or configuration of fibrous reinforcements before or during moulding for non-woven fabrics D04H3/08
• CPC Class Codes: B29K 2077/00 Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2077/10 Aromatic polyamides [polyaramides] or derivatives thereof
• CPC Class Codes: B29K 2277/00 Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as reinforcement
• CPC Class Codes: B29K 2277/10 Aromatic polyamides [Polyaramides] or derivatives thereof
• CPC Class Codes: B29K 2309/08 Glass
• CPC Class Codes: B29K 2995/0089 Impact strength or toughness
• 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

Abstract

A method is provided for using a woven preform having a base and at least one leg extending from the base. The preform is used to assemble first and second composite laminate components formed from tape or fabric and a resin matrix. Z-pins are inserted into the first component prior to its being cured, forming a stubble extending above a surface of the first component. The uncured preform is placed on the surface of the first component, the stubble extending into the preform. The cured second component is attached to the preform. Over-wrap plies are optionally placed on the outer surfaces of preform. Adhesive is optionally placed between the preform and the first and second components. A vacuum bag and tooling are used while curing the preform to adhere the legs of the preform to the second component and the base of the preform to the first component.

Claims

1. A method of making a composite structure, the method comprising:

(a) locating at least two peel plies on the bonding surface of a component;

then

(b) inserting pins through the peel plies and into the component prior to curing of the component;

then

(c) curing the component;

then

(d) providing a woven preform having a base and two legs extending from the base, the legs defining a slot;

then

(e) placing the base of the preform against the bonding surface of the component, the pins extending into the base of the preform; and

(f) curing the preform to adhere the base of the preform to the component.

2. The method of claim 1, further comprising:

inserting a second component into the slot of the preform after step (e) and before step (f); and

completing step (f) with the second component in the slot.

3. The method of claim 1, further comprising:

inserting a rigid sizing tool into the slot of the preform after step (e) and before step (f);

completing step (f) with the sizing tool in the slot;

removing the sizing tool after step (f), the slot being sized for insertion of a second component; and

inserting the second component into the slot and adhering the second component to the preform.

4. A method of joining first and second composite components, the method comprising:

(a) inserting Z-pins into the first component prior to curing the first component, ends of the Z-pins extending above a bonding surface of the first component and forming a stubble;

(b) curing the first component;

(c) providing a woven preform having a base and two legs extending from the base, the legs defining a slot;

(d) placing the base of the preform against the bonding surface of the first component, the stubble extending into the base of the preform;

(e) inserting the second component into the slot of the preform; and

(f) curing the preform to adhere the base of the preform to the first component and the legs of the preform to the second component, joining the components with the preform.

5. The method of claim 4, further comprising:

in step (d), inserting adhesive between the base of the preform and the first component.

6. The method of claim 4, further comprising:

in step (e), inserting adhesive between the legs of the preform and the second component.

7. The method of claim 4, further comprising:

before step (a), locating at least two peel plies on the bonding surface of the first component and removing the peel plies after step (b) and before step (d).

8. The method of claim 4, further comprising:

before step (a), locating at least two peel plies on the bonding surface of the first component;

after step (b) and before step (d), removing at least one of the peel plies and trimming the stubble to a height equal to a height of the peel plies that remain on the bonding surface; and

removing the remaining peel plies after trimming the stubble but before step (d).

9. The method of claim 4, further comprising:

before step (a), locating at least two woven-fabric peel plies on the bonding surface of the first component and removing the peel plies after step (b) and before step (d).

10. The method of claim 4, wherein:

the peel plies are formed from nylon fibers.

11. The method of claim 4, wherein:

the peel plies are formed from glass fibers.

12. The method of claim 4, further comprising:

before step (a), locating an elastomeric spacer on the bonding surface of the first component;

after step (b) and before step (d), trimming the stubble to a height equal to a height of the spacer; and

removing the spacer after trimming the stubble but before step (d).

13. A method of joining first and a second composite components, the method comprising:

(a) inserting Z-pins into the first component prior to curing the first component, the Z-pins extending above a bonding surface of the first component and forming a stubble;

then

(b) curing the first component;

then

(c) providing a woven preform having a base and two legs extending from the base, the legs defining a slot;

then

(d) placing the base of the preform against the bonding surface of the first component, the stubble extending into the base of the preform;

then

(e) inserting a rigid sizing tool into the slot;

then

(f) curing the preform to adhere the preform to the first component and to shape the slot to a size of the tool;

then

(g) removing the tool and applying an adhesive into the slot;

then

(h) inserting the second component into the slot, the adhesive bonding the second component to the preform, the second component having a smaller width than the tool.

14. The method of claim 13, further comprising:

before step (a), locating at least two peel plies on the bonding surface of the first component and removing the peel plies after step (b) and before step (d).

15. The method of claim 13, further comprising:

before step (a), locating at least two woven-fabric peel plies on the bonding surface of the first component and removing the peel plies after step (b) and before step (d).

16. The method of claim 13, further comprising:

before step (a), locating an elastomeric spacer on the bonding surface of the first component and removing the spacer after step (b) and before step (d).

17. A method of joining a preform to a panel, the method comprising:

(a) inserting Z-pins into a composite panel prior to curing the panel, the Z-pins extending above a bonding surface of the panel and forming a stubble;

then

(b) curing the panel;

then

(c) providing a woven preform having a base and at least one leg that extends from the base, the preform being infused with uncured resin;

then

(d) placing the base of the preform against the bonding surface of the panel, the stubble extending into the base of the preform;

then

(e) curing the preform with each leg in a desired orientation.

18. The method of claim 17, further comprising:

(f) attaching a composite component to at least one leg.

19. The method of claim 17, further comprising:

before step (a), locating at least two peel plies on the bonding surface of the panel and removing the peel plies after step (b) and before step (d).

20. The method of claim 17, further comprising:

before step (a), locating at least two woven-fabric peel plies on the bonding surface of the panel and removing the peel plies after step (b) and before step (d).

21. The method of claim 17, further comprising:

before step (a), locating an elastomeric spacer on the bonding surface of the panel and removing the spacer after step (b) and before step (d).