Molded-In Insert and Method for Fiber Reinforced Thermoplastic Composite Structure

• US 20130022391A1
• Filed: 07/22/2011
• Published: 01/24/2013
• Est. Priority Date: 07/22/2011
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Fisher, Edward McMurray Jr., Carter, Brian Allen
• Granted Patent: US 9,180,631 B2
• Time in Patent Office: Days
• US Class Current: 403/265
• CPC Class Codes: B29C 2043/181 encapsulated
• CPC Class Codes: B29C 39/10 incorporating preformed parts or layers, e.g. casting around inserts or for coating articles coating a surface by casting in general B05D1/30, B29C39/126 takes precedence
• CPC Class Codes: B29C 43/18 incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles B29C43/206 takes precedence
• CPC Class Codes: B29C 45/14311 using means for bonding the coating to the articles B29C45/14795 takes precedence
• CPC Class Codes: B29C 45/14631 Coating reinforcements fibre reinforcements B29C45/0005
• CPC Class Codes: B29C 70/682 Preformed parts characterised by their structure, e.g. form
• CPC Class Codes: B29C 70/683 Pretreatment of the preformed part, e.g. insert
• CPC Class Codes: B29K 2101/12 Thermoplastic materials
• CPC Class Codes: B29K 2105/06 containing reinforcements, fillers or inserts
• CPC Class Codes: B29K 2105/20 Inserts
• CPC Class Codes: F16B 37/122 Threaded inserts, e.g. "rampa bolts"
• CPC Class Codes: Y10T 403/47 Molded joint

Abstract

In an embodiment of the disclosure, there is provided a molded-in insert for high strength retention in a fiber reinforced thermoplastic composite structure. The insert has a cylindrical body and at least one circumferential groove formed in the cylindrical body, the groove having a substantially concave configuration, having a groove radius of 0.025 inch or greater, and having the groove radius greater than or equal to a groove depth.

Claims

1. A molded-in insert for high strength retention in a fiber reinforced thermoplastic composite structure, the molded-in insert comprising:

a cylindrical body; and

,

at least one circumferential groove formed in the cylindrical body, the groove having a substantially concave configuration, having a groove radius of 0.025 inch or greater, and having the groove radius greater than or equal to a groove depth.

2. The insert of claim 1, wherein the at least one circumferential groove has a groove width greater than the groove depth.

3. The insert of claim 1, wherein when the molded-in insert is molded in a fiber reinforced thermoplastic composite structure, reinforcing fibers from the fiber reinforced thermoplastic composite structure flow into and fully fill the at least one circumferential groove in order to form a high strength mechanical locking mechanism that secures the molded-in insert in place in the fiber reinforced thermoplastic composite structure.

4. The insert of claim 3, wherein the molded-in insert is molded in the fiber reinforced thermoplastic composite structure via a molding process selected from a group comprising compression molding, resin transfer molding, injection molding, blow molding, transfer molding, reaction injection molding, casting, and investment casting.

5. The insert of claim 1, wherein the at least one circumferential groove is formed in an exterior surface of the cylindrical body.

6. The insert of claim 1, wherein the at least one circumferential groove is formed in an interior surface of the cylindrical body.

7. The insert of claim 1, wherein the cylindrical body has two or more circumferential grooves formed in an exterior surface of the cylindrical body.

8. The insert of claim 1, wherein the cylindrical body has two or more circumferential grooves formed in an interior surface of the cylindrical body.

9. The insert of claim 1, wherein the cylindrical body has a first circumferential groove formed in an exterior surface of the cylindrical body and a second circumferential groove formed in an interior surface of the cylindrical body.

10. The insert of claim 1, wherein the molded-in insert is made of a machinable material selected from a group comprising a metal material, a ceramic material, and a composite material.

11. A composite part with a molded-in insert, the composite part comprising:

a fiber reinforced thermoplastic composite structure comprised of a fiber reinforced thermoplastic composite material;

a molded-in insert secured in the fiber reinforced thermoplastic composite structure, the molded-in insert comprising;

a cylindrical body; and

,

at least one circumferential groove formed in the cylindrical body, the groove having a substantially concave configuration, having a groove radius of 0.025 inch or greater, and having the groove radius greater than or equal to a groove depth.

12. The composite part of claim 11, wherein the at least one circumferential groove has a groove width greater than the groove depth.

13. The composite part of claim 11, wherein the at least one circumferential groove is formed in an exterior surface of the cylindrical body.

14. The composite part of claim 11, wherein the at least one circumferential groove is formed in an interior surface of the cylindrical body.

15. The composite part of claim 11, wherein the cylindrical body has a first circumferential groove formed in an exterior surface of the cylindrical body and a second circumferential groove formed in an interior surface of the cylindrical body.

16. The composite part of claim 11, wherein the composite part is used in a transport vehicle selected from a group comprising an aircraft, an aerospace vehicle, a space launch vehicle, a rocket, a satellite, a rotorcraft, a watercraft, a boat, a train, an automobile, a truck, and a bus.

17. A method of retaining a molded-in insert in a fiber reinforced thermoplastic composite material and forming a high strength mechanical locking mechanism, the method comprising:

fixing a molded-in insert in a mold cavity, the insert comprising;

a cylindrical body; and

,

at least one circumferential groove formed in the cylindrical body, the groove having a substantially concave configuration, having a groove radius of 0.025 inch or greater, and having the groove radius greater than or equal to a groove depth;

introducing a fiber reinforced thermoplastic composite material into the mold cavity and around the molded-in insert;

enclosing the mold cavity;

heating and compressing the fiber reinforced thermoplastic composite material in the mold cavity to consolidate the fiber reinforced thermoplastic composite material around the molded-in insert, such that reinforcing fibers from the fiber reinforced thermoplastic composite material flow into and fully fill the at least one circumferential groove in order to form a high strength mechanical locking mechanism that retains the molded-in insert in place in the fiber reinforced thermoplastic composite material and forms a consolidated fiber reinforced thermoplastic composite structure with the molded-in insert;

cooling the consolidated fiber reinforced thermoplastic composite structure with the molded-in insert; and

,

removing the consolidated fiber reinforced thermoplastic composite structure with the molded-in insert from the mold cavity.

18. The method of claim 17, further comprising prior to fixing the molded-in insert in the mold cavity, treating a surface of the at least one circumferential groove of the molded-in insert to promote bonding of the fiber reinforced thermoplastic composite material to the surface of the at least one circumferential groove.

19. The method of claim 18, wherein treating the surface of the at least one circumferential groove comprises one or more surface preparation treatments selected from a group comprising solvent wiping, abrading, grit blasting, sanding, sandblasting, chemical cleaning, chemical etching, sol gel treatment, primer treatment, and adhesive treatment.

20. The method of claim 17, wherein the molded-in insert is consolidated with the fiber reinforced thermoplastic composite material via a molding process selected from a group comprising compression molding, resin transfer molding, injection molding, blow molding, transfer molding, reaction injection molding, casting, and investment casting.

21. The method of claim 17, wherein the method minimizes or eliminates formation of void areas of no reinforcement and minimizes or eliminates cutting of fibers in the fiber reinforced thermoplastic composite material.

22. The method of claim 17, wherein the at least one circumferential groove is formed in an exterior surface of the cylindrical body.

23. The method of claim 17, wherein the at least one circumferential groove is formed in an interior surface of the cylindrical body.

24. The method of claim 17, wherein the cylindrical body has a first circumferential groove formed in an exterior surface of the cylindrical body and a second circumferential groove formed in an interior surface of the cylindrical body.