Method of making delamination resistant composites

• US 4,786,343 A
• Filed: 05/10/1985
• Issued: 11/22/1988
• Est. Priority Date: 05/10/1985
• Status: Expired due to Term

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Hertzberg, Paul E.
• Primary Examiner(s): Dawson, Robert A.
• Application Number:
  US06/732,753
• Time in Patent Office: 1,292 Days
• Field of Search: 29/526 A, 29/526 R, 112/262.1, 112/423, 112/440, 156/91, 156/92, 156/93, 156/330, 244/119, 244/123, 244/126, 244/129.1, 244/131, 244/132, 244/133, 428/102, 428/120, 428/408, 428/902
• US Class Current: 156/93
• CPC Class Codes: B29C 65/48 using adhesives , i.e. using supplementary joining material; solvent bonding
• CPC Class Codes: B29C 65/4835 Heat curing adhesives
• CPC Class Codes: B29C 65/601 using extra riveting elements, i.e. the rivets being non-integral with the parts to be joined
• CPC Class Codes: B29C 65/72 by combined operations or combined techniques, e.g. welding and stitching
• CPC Class Codes: B29C 66/112 Single lapped joints
• CPC Class Codes: B29C 66/131 Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
• CPC Class Codes: B29C 66/474 said single elements being substantially non-flat
• 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 70/30 Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
• CPC Class Codes: B29D 99/0003 Producing profiled members, e.g. beams
• CPC Class Codes: B29D 99/0014 provided with ridges or ribs, e.g. joined ribs
• CPC Class Codes: B29K 2101/10 Thermosetting resins
• CPC Class Codes: B29K 2105/06 containing reinforcements, fillers or inserts
• CPC Class Codes: B29K 2105/24 crosslinked or vulcanised
• CPC Class Codes: C08J 5/124 using adhesives based on a macromolecular component
• CPC Class Codes: Y10T 428/24033 including stitching and discrete fastener[s], coating or bond
• CPC Class Codes: Y10T 428/30 Self-sustaining carbon mass or layer with impregnant or other layer

Abstract

Fiber reinforced resin composites formed by elements joined by a high shear strength, high fracture toughness adhesive are disclosed. The elements are created in easily produceable cross-sectional shapes such as flat, C-shaped, Z-shaped or T-shaped. When joined, the elements form delamination resistant fiber reinforced resin composites having more complex shapes. The strength of the junctions between a pair of elements, such as a panel and its associated reinforcing members, can be enhanced by fasteners, such as rivets, if desired.

Claims

1. A method of making a delamination resistant fiber reinforced resin composite comprising the steps of:

forming a fiber reinforced resin composite panel from a plurality of plies and a resin matrix;

forming a fiber reinforced resin composite reinforcing member from a plurality of plies and a resin matrix; and

,

bonding said fiber reinforced resin composite panel to said fiber reinforced resin composite reinforcing member with a high shear strength, high toughness, thermosetting resin adhesive layer, said thermosetting resin being different from the resin used to form said resin matrix of said fiber reinforced resin composite panel and said fiber reinforced resin composite reinforcing member.

2. The method claimed in claim 1, wherein the resin used to form said fiber reinforced resin composite panel is cured prior to said fiber reinforced resin composite panel being bonded to said fiber reinforced resin composite reinforcing element by said high shear strength, high toughness, thermosetting resin adhesive layer.

3. The method claimed in claim 2, wherein the resin used to form said fiber reinforced resin composite reinforcing member is cured prior to said panel being bonded to said fiber reinforced resin composite reinforcing member by said high shear strength, high toughness, thermosetting resin adhesive layer.

4. The method claimed in claim 1, wherein the resin used to form said fiber reinforced resin composite reinforcing member is cured prior to said panel being bonded to said fiber reinforced resin composite reinforcing member by said high shear strength, high toughness, thermosetting resin adhesive layer.

5. The method claimed in claim 1, wherein the resin used to form said fiber reinforced resin composite panel, the resin used to form said fiber reinforced resin composite reinforcing member and said high shear strength, high toughness, thermosetting resin adhesive layer are all cured simultaneously.

6. The method claimed in claim 1, including the step of crossply stitching the plies of said fiber reinforced resin composite panel to enhance the delamination resistance of said fiber reinforced resin composite panel.

7. The method claimed in claim 6, wherein the resin used to form said fiber reinforced resin composite panel is cured prior to said fiber reinforced resin composite panel being bonded to said fiber reinforced resin composite reinforcing element by said high shear strength, high toughness, thermosetting resin adhesive layer.

8. The method claimed in claim 7, wherein the resin used to form said fiber reinforced resin composite reinforcing member is cured prior to said panel being bonded to said fiber reinforced resin composite reinforcing member by said high shear strength, high toughness, thermosetting resin adhesive layer.

9. The method claimed in claim 6, wherein the resin used to form said fiber reinforced resin composite reinforcing member is cured prior to said panel being bonded to said fiber reinforced resin composite reinforcing member by said high shear strength, high toughness, thermosetting resin adhesive layer.

10. The method claimed in claim 6, wherein the resin used to form said fiber reinforced resin composite panel, the resin used to form said fiber reinforced resin composite reinforcing member and said high shear strength, high toughness, thermosetting resin adhesive layer are all cured simultaneously.

11. The method claimed in claim 6, including the step of crossply stitching the plies of said fiber reinforced resin composite reinforcing member in order to enhance the delamination resistance of said fiber reinforced resin composite reinforcing member.

12. The method claimed in claim 11, wherein the resin used to form said fiber reinforced resin composite panel is cured prior to said fiber reinforced resin composite panel being bonded to said fiber reinforced resin composite reinforcing element by said high shear strength, high toughness, thermosetting resin adhesive layer.

13. The method claimed in claim 12, wherein the resin used to form said fiber reinforced resin composite reinforcing member is cured prior to said panel being bonded to said fiber reinforced resin composite reinforcing member by said high shear strength, high toughness, thermosetting resin adhesive layer.

14. The method claimed in claim 11, wherein the resin used to form said fiber reinforced resin composite reinforcing member is cured prior to said panel being bonded to said fiber reinforced resin composite reinforcing member by said high shear strength, high toughness, thermosetting resin adhesive layer.

15. The method claimed in claim 11, wherein the resin used to form said fiber reinforced resin composite panel, the resin used to form said fiber reinforced resin composite reinforcing member and said high shear strength, high toughness, thermosetting resin adhesive layer are all cured simultaneously.

16. The method claimed in claim 1, wherein said fiber reinforced resin composite reinforcing member is formed of at least two elements, said two elements being juxtaposed along at least one surface and including a further high shear strength, high toughness, thermosetting resin adhesive layer located between said juxtaposed surfaces for attaching said juxtaposed surfaces together.

17. The method claimed in claim 16, wherein the resin used to form said fiber reinforced resin composite panel is cured prior to said fiber reinforced resin composite panel being bonded to said fiber reinforced resin composite reinforcing element by said high shear strength, high toughness, thermosetting resin adhesive layer.

18. The method claimed in claim 17, wherein the resins used to form said at least two elements used to form said fiber reinforced resin composite reinforcing member are cured prior to said elements being bonded together and to said panel by said high shear strength, high toughness, thermosetting resin adhesive layers.

19. The method claimed in claim 16, wherein the resins used to form said at least two elements used to form said fiber reinforced resin composite reinforcing member are cured prior to said elements being bonded together and to said panel by said high shear strength, high toughness, thermosetting resin adhesive layers.

20. The method claimed in claim 16, wherein the resin used to form said fiber reinforced resin composite panel, the resin used to form said at least two elements used to form said fiber reinforced resin composite reinforcing member and said high shear strength, high toughness, thermosetting resin adhesive layers are all cured simultaneously.

21. The method claimed in claim 16, including the step of cross-ply stitching the plies of said fiber reinforced resin composite panel to enhance the delamination resistance of said fiber reinforced resin composite panel.

22. The method claimed in claim 21, wherein the resin used to form said fiber reinforced resin composite panel is cured prior to said fiber reinforced resin composite panel being bonded to said fiber reinforced resin composite reinforcing element by said high shear strength, high toughness, thermosetting resin adhesive layer.

23. The method claimed in claim 22, wherein the resins used to form said at least two elements used to form said fiber reinforced resin composite reinforcing member are cured prior to said elements being bonded together and to said panel by said high shear strength, high toughness, thermosetting resin adhesive layers.

24. The method claimed in claim 21, wherein the resins used to form said at least two elements used to form said fiber reinforced resin composite reinforcing member are cured prior to said elements being bonded together and to said panel by said high shear strength, high toughness, thermosetting resin adhesive layers.

25. The method claimed in claim 21, wherein the resin used to form said fiber reinforced resin composite panel, the resin used to form said at least two elements used to form said fiber reinforced resin composite reinforcing member and said high shear strength, high toughness, thermosetting resin adhesive layers are all cured simultaneously.

26. The method claimed in claim 21, including the step of cross-ply stitching the plies of said at least two elements used to form said fiber reinforced resin composite reinforcing member in order to enhance the delamination resistance of said elements.

27. The method claimed in claim 26, wherein the resin used to form said fiber reinforced resin composite panel is cured prior to said fiber reinforced resin composite panel being bonded to said fiber reinforced resin composite reinforcing element by said high shear strength, high toughness, thermosetting resin adhesive layer.

28. The method claimed in claim 27, wherein the resins used to form said at least two elements used to form said fiber reinforced resin composite reinforcing member are cured prior to said elements being bonded together and to said panel by said high shear strength, high toughness, thermosetting resin adhesive layers.

29. The method claimed in claim 26, wherein the resins used to form said at least two elements used to form said fiber reinforced resin composite reinforcing member are cured prior to said elements being bonded together and to said panel by said high shear strength, high toughness, thermosetting resin adhesive layers.

30. The method claimed in claim 26, wherein the resin used to form said fiber reinforced resin composite panel, the resin used to form said at least two elements used to form said fiber reinforced resin composite reinforcing member and said high shear strength, high toughness, thermosetting resin adhesive layers are all cured simultaneously.