Composite structural members and methods for forming the same

• US 20060236652A1
• Filed: 03/31/2005
• Published: 10/26/2006
• Est. Priority Date: 03/31/2005
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Kismarton, Max U.
• Granted Patent: US 7,721,495 B2
• Time in Patent Office: Days
• US Class Current: 52/782.100
• CPC Class Codes: B29C 65/08 using ultrasonic vibrations non-plastics element to plastics elements B29C65/645
• CPC Class Codes: B29C 65/562 using extra joining elements, i.e. which are not integral with the parts to be joined using plastic snap elements B29C65/58; using plastic rivets B29C65/601
• CPC Class Codes: B29C 65/564 hidden in the joint, e.g. dowels or Z-pins B29C65/603 takes precedence
• CPC Class Codes: B29C 65/72 by combined operations or combined techniques, e.g. welding and stitching
• CPC Class Codes: B29C 65/7808 in the form of holes or slots B29C65/7814 takes precedence; holding or clamping means cooperating with specially formed features of at least one of the parts to be joined B29C65/7844
• 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 66/1142 Single butt to butt joints
• CPC Class Codes: B29C 66/304 Joining through openings in an intermediate part of the article B29C66/3034 takes 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 66/71 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 66/742 to metals or their alloys
• CPC Class Codes: B29C 70/24 oriented in at least three directions forming a three dimensional structure
• CPC Class Codes: B29C 70/545 Perforating, cutting or machining during or after moulding
• CPC Class Codes: B29K 2063/00 Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2105/101 Oriented
• CPC Class Codes: B29K 2277/10 Aromatic polyamides [Polyaramides] or derivatives thereof
• CPC Class Codes: B29K 2283/00 Use of polymers having silicon, with or without sulfur, nitrogen, oxygen or carbon only, in the main chain, as reinforcement
• CPC Class Codes: B29K 2307/00 : Use of elements other than metals as reinforcement
• CPC Class Codes: B29K 2307/02 : Boron
• CPC Class Codes: B29K 2307/04 : Carbon
• CPC Class Codes: B29K 2309/04 : Carbides; Nitrides
• CPC Class Codes: B29K 2309/08 : Glass
• CPC Class Codes: B29K 2705/00 : Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
• 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 15/092 : comprising epoxy resins
• CPC Class Codes: B32B 15/20 : comprising aluminium or copper B32B15/016 and B32B15/017 take precedence
• CPC Class Codes: B32B 2250/05 : 5 or more layers
• CPC Class Codes: B32B 2250/40 : Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2262/106 : Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2307/54 : Yield strength; Tensile strength
• CPC Class Codes: B32B 2307/542 : Shear strength
• CPC Class Codes: B32B 2307/546 : Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/718 : Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2605/18 : Aircraft blades, propellers B32B2603/00
• CPC Class Codes: B32B 27/08 : of synthetic resin
• CPC Class Codes: B32B 27/18 : characterised by the use of special additives
• CPC Class Codes: B32B 27/38 : comprising epoxy resins
• CPC Class Codes: B32B 3/266 : characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• 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: E04C 3/29 : built-up from parts of different material, i.e. composite structures
• CPC Class Codes: Y02T 50/40 : Weight reduction
• CPC Class Codes: Y10T 428/24058 : including grain, strips, or filamentary elements in respective layers or components in angular relation
• CPC Class Codes: Y10T 428/24074 : Strand or strand-portions
• CPC Class Codes: Y10T 428/249942 : Fibers are aligned substantially parallel
• CPC Class Codes: Y10T 428/249945 : Carbon or carbonaceous fiber
• CPC Class Codes: Y10T 428/249946 : Glass fiber

Abstract

Composite structural members and methods for forming the same are disclosed. In one disclosed embodiment, a composite structural member includes a central structural portion comprised of a reinforced, polymer-based material and having a length, a first side and an opposing second side extending along the length. A first reinforcement member fixedly coupled to the first side and a second reinforcement member fixedly coupled to the second side.

Claims

1. A composite structural member, comprising:

a central structural portion comprised of a reinforced, polymer-based material and having a length, a first side and an opposing second side extending along the length;

a first reinforcement member fixedly coupled to the first side; and

a second reinforcement member fixedly coupled to the second side.

2. The composite structural member of claim 1, wherein the central structural portion includes a plurality of first apertures positioned in a predetermined pattern and extending through the central structural portion, further wherein the first reinforcement member and the second reinforcement member include a plurality of second apertures corresponding to the predetermined pattern;

the member further comprising a plurality of fasteners suitably sized to extend through the first and second apertures and operable to apply a compressive force to the member.

3. The composite structural member of claim 1, wherein at least one of the first reinforcement member and the second reinforcement member includes a plurality of z-pin members that are configured to extend into a respective first side and second side of the central structural portion.

4. The composite structural member of claim 2, wherein the fasteners include at least one of structural bolts having a corresponding nut portions, and deformable tension members.

5. The composite structural member of claim 2, wherein the fasteners include fasteners configured to impart a predetermined tension by including a shear portion that breaks during installation when the predetermined tension is achieved.

6. The composite structural member of claim 1, wherein the reinforced, polymer-based material comprises a polymer-based carbon-fiber material, and the first reinforcement member and the second reinforcement member are selected from a titanium and an aluminum alloy.

7. The composite structural member of claim 4, wherein the polymer-based carbon-fiber material includes a plurality of layers having a predetermined ply arrangement.

8. The composite structural member of claim 7, wherein the predetermined ply arrangement further comprises a first layer having fibers oriented at an angle α

with reference to a selected reference direction, a second layer having fibers oriented at an angle −

α

with respect to the reference direction, a third layer having fibers oriented at an angle β

with respect to the selected reference direction, and a fourth layer having fibers oriented at an angle −

β

with respect to the reference direction.

9. The composite structural member of claim 8, wherein the angle α

is approximately five degrees, and the angle β

is approximately sixty-five degrees.

10. The composite structural member of claim 8, wherein the central structural portion is further comprised of approximately 80% first and second layers.

11. The composite structural member of claim 1, further comprising a transverse attachment member coupled to one of the first reinforcement member and the second reinforcement member.

12. The composite structural member of claim 1, further comprising a longitudinal attachment member configured to extend outwardly from an end of the composite structural member.

13. The composite structural member of claim 1, further comprising an angled attachment member coupled to one of the first reinforcement member and the second reinforcement member and extending outwardly from an end of the composite structural member.

14. The composite structural member of claim 1, wherein the central structural portion includes a first portion and a second portion that abut at respective end portions to define an interface, further comprising a first splicing member positioned on the first reinforcement member, and a second splicing member positioned on the second reinforcement member, the first splicing member and the second splicing member configured to fixedly couple the first portion and the second portion.

15. A method of manufacturing a composite structural member, comprising:

forming a central structural portion from a reinforced, polymer-based material, the central structural portion having a length, a first side and an opposing second side extending along the length;

forming a first reinforcing member and a second reinforcing member from a suitable reinforcing material; and

fixedly coupling the first reinforcing member and the second reinforcing members to respective first and second sides of the central structural portion.

16. The method of claim 15, wherein forming a central structural portion further comprises forming the central structural portion from a fiber-reinforced polymer-based material having a predetermined ply arrangement.

17. The method of claim 16, wherein forming the central structural portion from a fiber-reinforced polymer-based material having a predetermined ply arrangement further comprises forming a first layer having fibers oriented at an angle α

with reference to a selected reference direction, forming a second layer with fibers oriented at an angle −

α

with respect to the reference direction, forming a third layer with fibers oriented at an angle β

with respect to the selected reference direction, and forming a fourth layer with fibers oriented at an angle −

β

with respect to the reference direction.

18. The method of claim 17, wherein the angle α

is approximately five degrees, and the angle β

is approximately sixty-five degrees, further wherein forming the central structural portion further comprises embedding the first, second, third and fourth layers in an epoxy resin.

19. The method of claim 15, wherein forming a first reinforcing member and a second reinforcing member further comprises forming the first reinforcing member and the second reinforcing member from one of an aluminum and a titanium alloy.

20. An aerospace vehicle, comprising:

a fuselage;

wing assemblies and an empennage operatively coupled to the fuselage; and

a composite structural member positioned in at least one of the wing assemblies, the fuselage and the empennage, the composite structural member further comprising;

a central structural portion comprised of a reinforced, polymer-based material and having a length, a first side and an opposing second side extending along the length;

a first reinforcement member fixedly coupled to the first side; and

a second reinforcement member fixedly coupled to the second side.