METHOD OF FORMING A LAYERED COMPOSITE ASSEMBLY

• US 20160159036A1
• Filed: 12/08/2014
• Published: 06/09/2016
• 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
• Granted Patent: US 10,457,017 B2
• Time in Patent Office: Days
• 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 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 configured to mechanically connect the main body to another 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, wherein the linear exposed end is configured to penetrate into another composite fiber layer.

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 8, 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 is configured to transition to a curled orientation to hook onto one or more of the plurality of composite fibers and one or more composite fibers of an adjacent composite fiber layer.

10. The composite fiber layer of claim 1, 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.

11. The composite fiber layer of claim 10, wherein each of the plurality of legs is formed of a bimetallic material.

12. The composite fiber layer of claim 10, wherein the annular ring is configured to abut into and bond to another annular ring of another composite fiber layer.

13. A layered composite assembly, 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 configured to mechanically connect the main body to an adjacent composite fiber layer.

14. The layered composite assembly of claim 13, further comprising at least one laminate layer secured around an outer one of the plurality of composite fiber layers.

15. The layered composite assembly of claim 13, 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 shape 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 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 and one or more composite fibers of the adjacent composite fiber layer.

16. The layered composite assembly of claim 13, wherein each of the plurality of layer-securing pins includes an inner portion formed of a first material and an outer portion formed of a second material that is different than the first material, 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 and one or more carbon fibers of the adjacent composite fiber layer.

17. The layered composite assembly of claim 13, 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, and wherein the annular ring abuts into and is bonded to another annular ring of the adjacent composite fiber layer.

18. 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 plurality of composite fibers that are pre-impregnated with at least one resin and a plurality of layer-securing pins;

curing the plurality of composite fiber layers to form the layered composite assembly; 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 through one or both of the stacking and curing operations.

19. The method of claim 18, wherein one or both of the curing and the mechanically connecting operations 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.

20. The method of claim 18, wherein one or both of the mechanically connecting and the curing operations comprises:

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

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