METHOD AND APPARATUS FOR JOINING COMPOSITE STRUCTURAL MEMBERS AND STRUCTURAL MEMBERS MADE THEREBY

• US 20100116938A1
• Filed: 11/13/2008
• Published: 05/13/2010
• Est. Priority Date: 11/13/2008
• Status: Abandoned Application

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Nelson, Charles J., Meyer, Robert G., Kennedy, Thomas J., VanVoast, Peter J., Holland, Justin L., Phung, Thang D., Warren, Joseph F., Day, Dan D., Ransom, Richard A., Kline, William T., Perla, Luis A., Groth, Curtis M., Hu, Charles Y., Lund, Erik, Butler, Geoffrey A.
• Application Number:
  US12/270,682
• Publication Number:
  US 20100116938A1
• Time in Patent Office: Days
• US Class Current: 244/131
• CPC Class Codes: B29C 65/18 using heated tools
• CPC Class Codes: B29C 65/26 Hot fluid
• CPC Class Codes: B29C 65/4835 Heat curing adhesives
• CPC Class Codes: B29C 65/5042 covering both elements to be joined
• CPC Class Codes: B29C 65/505 and placed in a recess formed in the parts to be joined, e.g. in order to obtain a continuous surface
• CPC Class Codes: B29C 65/5071 and being composed by one single element
• CPC Class Codes: B29C 65/5085 and comprising grooves, e.g. being E-shaped, H-shaped
• 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 66/1162 Single bevel to bevel joints, e.g. mitre joints
• CPC Class Codes: B29C 66/128 Stepped joint cross-sections
• CPC Class Codes: B29C 66/14 the joint having the same thickness as the thickness of the parts to be joined B29C66/1142 takes precedence
• CPC Class Codes: B29C 66/5241 for forming coaxial connections, i.e. the profiled elements to be joined forming a zero angle relative to each other
• CPC Class Codes: B29C 66/5243 for forming corner connections, e.g. for making window frames or V-shaped pieces welded corner joints for window frames E06B3/9604
• CPC Class Codes: B29C 66/63 Internally supporting the article during joining B29C66/49 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 66/723 being multi-layered B29C66/7292, B29C66/72941 take precedence
• 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 66/81811 : of the welding jaws
• CPC Class Codes: B29C 66/81821 : of the welding jaws
• CPC Class Codes: B29C 66/8432 : Machines for making separate joints at the same time mounted in parallel or in series
• CPC Class Codes: B29C 66/9121 : by measuring the temperature
• CPC Class Codes: B29C 66/91411 : of the parts to be joined, e.g. the joining process taking the temperature of the parts to be joined into account
• CPC Class Codes: B29C 66/91645 : by steps
• CPC Class Codes: B29C 66/9241 : by controlling or regulating the pressure, the force or the mechanical power
• CPC Class Codes: B29C 66/961 : involving a feedback loop mechanism, e.g. comparison with a desired value
• 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 70/544 : Details of vacuum bags, e.g. materials or shape
• CPC Class Codes: B29K 2063/00 : Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2105/06 : containing reinforcements, fillers or inserts
• CPC Class Codes: B29K 2307/04 : Carbon
• CPC Class Codes: Y02T 50/40 : Weight reduction
• CPC Class Codes: Y10T 156/10 : Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 29/49622 : Vehicular structural member making

Abstract

A composite structural member includes first and second composite sections spliced together by an overlapping composite splice member.

Claims

1. A composite structural member, comprising:

a first composite section;

a second composite section; and

,

a composite splice member at least partially overlapping and splicing together the first and second composite sections.

2. The composite structure of claim 1, wherein the first and second composite sections each have a cross section selected from the group consisting of:

a C shape,

a Z shape,

a J shape,

a T shape

an I shape, and

a hat shape.

3. The composite structure of claim 2, wherein the splice member includes a substantially V-shaped longitudinal section extending traverse to the cross section of the splice member.

4. The composite structure of claim 1, wherein:

the first and second composite sections extend in differing directions forming an angle, and

the composite splice member includes first and second portions respectively overlapping and joined to the first and second composite sections.

5. The composite structure of claim 1, wherein the composite splice member forms a substantially V-shaped joint between the first and second composite sections.

6. The composite structure of claim 5, wherein the substantially V-shape joint includes:

a first scarf joint between the composite splice member and the first composite section, and

a second scarf joint between the composite splice member and the second composite section.

7. The composite structure of claim 1, wherein:

the first and second composite sections form one of a continuous spar, a continuous beam, a continuous stringer, or a continuous frame for an aircraft, and

the splice member is bonded to the first and second composite sections.

8. An aircraft comprising an airframe including the composite structural member of claim 1.

9. A method of manufacturing the airframe of claim 8, the method comprising assembling the composite structural member into a wing assembly, the wing assembly forming a component of the airframe.

10. A method of manufacturing the aircraft of claim 8, comprising assembling the aircraft with at least one composite structural member according to claim 1.

11. The composite structure of claim 1, wherein the first and second composite sections form a continuous part selected from the group consisting of—

a spar,

a beam,

a stringer, and

a frame.

12. The composite structure of claim 11, wherein the continuous part has a cross section selected from the group consisting of:

a C shape,

a Z shape,

a J shape,

a T shape,

an I shape, and

a hat shape.

13. A method of producing a composite structural member, comprising:

forming a first composite section;

forming a second composite section;

forming a composite splice member; and

,

bonding the composite splice member to the first and second composite sections to form a splice joint between the first and second composite sections.

14. The method of claim 13, wherein:

forming the first composite section includes forming a first layup of composite materials and curing the first layup,

forming the second composite section includes forming a second layup of composite materials and curing the second layup,

forming the composite splice member includes forming a third layup of composite materials, and

bonding the splice member includes placing the third layup on the first and second composite sections and then curing the third layup.

15. The method of claim 13, wherein bonding the splice member includes using a press to locally apply heat and pressure to the joint.

16. The method of claim 14, wherein:

forming the first layup includes forming a first ramp along an edge of the first layup,

forming the second layup includes forming a first second ramp along an edge of the second layup, and

forming the third layup includes forming third and fourth ramps respectively overlapping the first and second ramps when the third layup has been placed on the first and second composite sections.

17. The method of claim 13, wherein bonding the splice member includes:

providing a mandrel,

placing the joint over the mandrel,

placing a vacuum bag over the joint, and

using the bag to apply pressure to the joint.

18. The method of claim 13 wherein bonding the splice member includes:

using a pressurized bladder to apply pressure to the joint, and

applying heat to the joint while pressure is being applied to the joint by the bladder.

19. The method of claim 18, wherein using the bladder to apply pressure is performed within a press.

20. A composite structural member made by the method of claim 13.

21. A composite structural member produced by the method of claim 13 wherein each of the first and second composite sections has a cross section selected from the group consisting of:

a C shape,

a Z shape,

a J shape,

a T shape,

an I shape, and

a hat shape.

22. The method of claim 13, wherein the composite structural member is one selected from the group consisting of—

a spar,

a beam,

a stringer, and

a frame.

23. Apparatus for curing composite parts, comprising:

a first platform and a second platform relatively movable between an open position and a closed position;

a tool against which a part may be pressed, the tool being supported by the first platform;

at least a first bladder adapted to be pressurized and supported by the second platform for pressing the part against the tool; and

,

means for heating the tool.

24. The apparatus of claim 23, wherein each of the first and second platforms is portable.

25. The apparatus of claim 23, further comprising:

first means for mounting the tool on the first platform for linear movement substantially horizontally toward and away from the part; and

,

second means for mounting the first bladder on the second platform for liner movement toward and away from the part.

26. The apparatus of claim 23, further comprising:

a frame removably mounted on the second platform, and

wherein the first bladder is attached to the frame and removable from the second platform along with the frame.

27. The apparatus of claim 23, wherein the heating means includes:

a first heating system mounted on the first platform for heating the tool, and

a second heating system mounted on the second platform for heating the part.

28. The apparatus of claim 27, wherein the first heating system includes:

a heat source,

a blower,

ducting coupled with the blower and the heat source for carrying a heated medium, and

nozzles coupled with the ducting for directing the heated medium onto the tool.

29. The apparatus of claim 23, wherein the means for heating the tool includes insulation surrounding the bladder.

30. The apparatus of claim 28, wherein:

the ducting includes a return medium duct for carrying heated medium away from the tool, and

the first heating system further includes

a source of cool medium, and

a valve coupled with the return medium duct and with the source of cool medium for selectively delivering cool medium to the tool to cool the part.

31. The apparatus of claim 28, wherein the medium is one of:

air, and

oil.

32. Apparatus for splicing elongate composite sections of a composite structural member, comprising:

a bonding machine for bonding a composite splice member onto a joint between adjacent ends of two composite sections; and

jigs on opposite sides of the bonding machine for supporting the composite sections in end-to-end relationship.

33. The apparatus of claim 32, wherein the bonding machine includes a mandrel and alignment pins connecting the mandrel with the composite sections for maintaining the ends of the composite sections in a desired alignment within the bonding machine.

34. The apparatus of claim 32, wherein the jigs are arranged to support the composite sections along their lengths and maintain the composite sections in a desired alignment as the splice member is bonded onto the joint between the composite sections.

35. The apparatus of claim 32, wherein the bonding machine includes:

means for applying heat to the joint for curing the splice member, and

means for holding the composite sections against movement during curing.

36. The apparatus of claim 35, wherein the means for holding the composite sections includes a pair of plates spanning the joint and clamping the adjacent ends of the composite sections together.

37. A method of joining two elongate composite sections, comprising:

supporting the composite sections in aligned, end-to-end relationship;

placing adjoining ends of the composite sections within a press;

forming a joint between the composite sections by placing an uncured splice member over the adjoining ends of the composite sections;

closing the press; and

,

bonding the splice member to the ends of the composite sections by using the press to locally apply heat and pressure to the joint.

38. The method of claim 37, wherein supporting the composite sections includes:

positioning jigs on opposite sides of the press, and

holding the composite sections in the jigs as the splice member is being bonded to the ends of the composite sections.

39. The method of claim 38, wherein bonding the splice member includes:

placing a vacuum bag over the splice member, and

applying pressure to the splice member by evacuating the vacuum bag.

40. The method of claim 37, wherein bonding the splice member includes:

positioning a pressure bladder in the press over the splice member and the vacuum bag, and

applying pressure to the splice member by pressurizing the bladder.

41. The method of claim 37, wherein:

forming a joint includes placing the splice member and the ends of the composite sections on a mandrel, and

applying heat to the joint includes directing a hot medium onto the mandrel.

42. The method of claim 41, wherein applying heat to the joint includes:

recirculating the medium directed over the mandrel, and

heating the medium as it is re-circulated.

43. The method of claim 37, wherein the composite sections form one of:

a floor beam,

a spar,

a frame, and

a stringer.

44. A heated tool assembly for forming a part, comprising:

a first tool and a second tool between which a part may be formed; and

,

means for heating the first tool, including

a heater for heating a medium,

a blower for blowing the heated medium,

a plurality of nozzles for directing the heated medium over the first tool,

a plenum coupled between the blower and the nozzles.

45. The heated tool assembly of claim 44, wherein the plenum includes a manifold having a medium inlet and a plurality of medium outlets spatially arranged to direct medium to differing zones on the first tool.

46. The heated tool assembly of claim 44, wherein each of the nozzles includes a perforated element through which heated medium may flow onto the first tool.

47. The heated tool assembly of claim 44, wherein:

the first tool is a mandrel having a substantially hollow side, and

the nozzles extend into the hollow side of the mandrel.

48. The heated tool assembly of claim 44, wherein the second tool includes:

a tool surface for forming the part and,

thermal insulation for reducing the escape of heat through the tool surface.

49. A method of joining composite sections to produce a continuous wing spar, comprising:

forming a first cured composite spar section;

forming a second cured composite spar section;

holding the first and second spar sections in aligned, end-to-end relationship;

placing an uncured composite splice member over a joint between the ends of the aligned spar sections;

placing the ends of the aligned spar sections and the splice member in a press;

applying a vacuum bag over the splice member;

closing the press;

applying a vacuum to the vacuum bag;

applying pressure to the splice member using a pressure bladder to force the splice member against a tool;

heating the tool and the splice member to cure the splice member;

opening the press after the splice member has been cured; and

,

removing the continuous wing spar from the press.

50. A method of joining composite sections to produce a continuous composite stringer, comprising:

forming a first cured composite stringer section;

forming a second cured composite stringer section;

holding the first and second stringer sections in aligned, end-to-end relationship;

placing an uncured composite splice member over a joint between the ends of the aligned stringer sections;

placing the ends of the aligned stringer sections and the splice member in a press;

applying a vacuum bag over the splice member;

closing the press;

applying a vacuum to the vacuum bag;

applying pressure to the splice member using a pressure bladder to force the splice member against a tool;

heating the tool and the splice member to cure the splice member;

opening the press after the splice member has been cured; and

,

removing the continuous composite stringer from the press.

51. Apparatus for splicing composite frame sections to form a continuous composite frame, comprising:

a tool tower;

a tool;

means for removably mounting the tool on the tool tower;

a modular heating and cooling system on the tool tower for heating and cooling the tool;

a pressure tower;

a pressure bladder on the pressure tower;

means for pressurizing the pressure bladder to apply pressure to a splice joint between the ends of the frame sections;

means for mounting the tool tower and the pressure tower for movement toward and away from each other;

a locking system for locking the tool tower and the pressure tower together during a splicing operation; and

,

jigs for supporting the frame sections in aligned, end-to-end relationship and for holding the splice joint between the tool and the pressure bladder.