Closed composite sections with bonded scarf joints

• US 5,281,454 A
• Filed: 08/16/1991
• Issued: 01/25/1994
• Est. Priority Date: 08/16/1991
• Status: Expired due to Term

• Current Assignee: Kaiser Compositek, Inc. (BAE Systems Plc)
• Original Assignee: Kaiser Aerospace & Electronics Corporation
• Inventors: Hanson, Brad A.
• Primary Examiner(s): Thomas, Alexander S.
• Application Number:
  US07/745,750
• Time in Patent Office: 893 Days
• Field of Search: 428/60, 428/57, 428/36.9, 428/36.91, 428/36.3, 156/304.5, 156/304.2, 138/155, 138/154
• US Class Current: 428/36.3
• 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 66/116 Single bevelled joints, i.e. one of the parts to be joined being bevelled in the joint area
• CPC Class Codes: B29C 66/1162 Single bevel to bevel joints, e.g. mitre joints
• CPC Class Codes: B29C 66/12822 comprising at least three overlap joint-segments
• CPC Class Codes: B29C 66/12842 comprising at least three butt joint-segments
• 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 66/5221 for forming coaxial connections, i.e. the tubular articles to be joined forming a zero angle relative to each other
• CPC Class Codes: B29C 66/5344 said single elements being substantially annular, i.e. of finite length, e.g. joining flanges to tube ends B29C66/5346 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 66/72141 Fibres of continuous length
• CPC Class Codes: B29C 66/742 to metals or their alloys
• CPC Class Codes: B29K 2063/00 Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2307/04 Carbon
• CPC Class Codes: B29L 2023/22 Tubes or pipes, i.e. rigid bent tubes not for use as pipe couplings B29L2023/004
• CPC Class Codes: F16L 13/103 Adhesive joints for hoses F16L33/34
• CPC Class Codes: F16L 47/24 for joints between metal and plastics pipes
• CPC Class Codes: Y10T 428/1369 Fiber or fibers wound around each other or into a self-sustaining shape [e.g., yarn, braid, fibers shaped around a core, etc.]
• CPC Class Codes: Y10T 428/139 Open-ended, self-supporting conduit, cylinder, or tube-type article
• CPC Class Codes: Y10T 428/1393 : Multilayer [continuous layer]
• CPC Class Codes: Y10T 428/19 : Sheets or webs edge spliced or joined
• CPC Class Codes: Y10T 428/195 : Beveled, stepped, or skived in thickness

Abstract

A novel joint for connecting a closed composite adherend utilizes complementary scarf surfaces on the adherends and then bonds the adherends together. The angle of the scarf is determined by the materials used and the expected loads. Preferably, constant stiffness is achieved through the joint. In alternative embodiments, lap joint areas are included to create localized stress free zones. A method of creating the scarf surfaces utilizes a wrapping technique in which the edges of a lamina of composite material are prepared so as to provide a desired edge termination which permits each layer to be bonded to the adjacent adherend.

Claims

1. A bonded joint connecting two substantially tubular adherends comprising:

a. a substantially tapered scarf surface on the first adherend including a first tapered portion, a level portion and a second tapered portion;

b. a substantially tapered scarf surface on the second adherend in a complementary opposing relationship to said scarf surface of the first adherend including a mating first tapered portion, a level portion and a second tapered portion, complementary to said scarf surface on the first adherend; and

c. an adhesive layer interposed between said scarf surfaces bonding the adherends into a unitary structure of substantially constant thickness across the area of the bond, whereby said adhesive layer transfers applied loads from one adherend to the other, and whereby the joint between the two adherends includes an area that is resistant to creep of said adhesive layer.

2. The bonded joint of claim 1, above wherein the first adherend is of metal, the second adherend is of a composite material and the exterior surface of the second adherend is bonded to an interior surface of the first adherend.

3. The bonded joint of claim 1, above wherein the first adherend is of metal, the second adherend is of a composite material and the exterior surface of the first adherend is bonded to an interior surface of the second adherend.

4. The bonded joint of claim 1, above where at least one of the adherends is a multilayer composite of fibers and plastic matrix and wherein each layer has an incremental edge in adhesive contact with the other adherend.

5. The bonded joint of claim 4, above, wherein each incremental edge extends around the perimeter of the adherend.

6. The bonded joint of claim 4, above, wherein each layer is a part of a continuous layer which has been wound to form the tubular adherend and said incremental edge extends in a spiral around the perimeter of the adherend.

7. The bonded joint of claim 4, above, wherein each layer is part of a continuous layer which has been wound to form the tubular adherend and the incremental edges of some layers extends around the periphery of the adherend and incremental edges of other layers extend in a continuous spiral.

8. The bonded joint of claim 7, above, wherein the incremental edges of the innermost and outermost layers extend completely about the perimeter of the adherend and the incremental edges of the remaining layers extend in a continuous spiral.

9. A bonded joint connecting two substantially tubular adherends comprising:

a. a substantially tapered scarf surface on the first adherend including a first tapered portion, a first level portion, a second tapered portion, a second level portion and a third tapered portion;

b. a substantially tapered scarf surface on the second adherend in a complementary opposing relationship to said scarf surface of the first adherend including a mating first tapered portion, a first level portion, a second tapered portion, a second level portion and a third tapered portion, complementary to said scarf surface on the first adherend; and

c. an adhesive layer interposed between said scarf surfaced bonding the adherends into a unitary structure of substantially constant thickness across the area of the bond,

whereby said adhesive layer transfers applied loads from one adherend to the other, and whereby the joint between the two adherends includes areas that are resistant to creep of said adhesive layer.

10. A bonded joint for connecting two substantially tubular adherends comprising:

a. a first substantially tapered scarf surface on the exterior of a first adherend;

b. a second substantially tapered scarf surface on the interior of the first adherend convergingly meeting said first scarf surface;

c. an opposing, diverging pair of substantially tapered scarf surfaces between the exterior and interior surfaces of the second adherend, said pair of scarf surfaces being complementary to said scarf surfaces of the first adherend;

d. an adhesive layer interposed between opposing scarf surfaces bonding the adherends into a unitary structure of substantially constant thickness across the area of the bond, whereby said adhesive layer transfers applied loads from one adherend to the other.

11. The bonded joint of claim 10, above wherein the first adherend is of metal, the second adherend is of a composite material and said scarf surfaces of the first adherend are bonded to interior surfaces intermediate the outer and inner surfaces of the second adherend.

12. The bonded joint of claim 10, above, wherein said substantially tapered scarf surfaces on the first adherend include a first tapered portion, a level portion and a second tapered portion, and said substantially tapered scarf surfaces on the second adherend include a mating first tapered portion, a level portion and a second tapered portion, complementary to said scarf surfaces on the first adherend, whereby the joint between the two adherends includes areas that are resistant to creep of said adhesive layer.

13. The bonded scarf joint of claim 12, above wherein the second adherend is a multilayer composite of a plurality of fiber layers wound to form a closed tube and wherein each layer terminates in an incremental edge portion that bonds to a portion of the adjacent surface of the second adherend.

14. The bonded scarf joint of claim 13, above, wherein the incremental edge portions adjacent a level portion extend sufficiently to bond to the adjoining tapered portion.

15. A bonded joint for connecting two substantially tubular adherends comprising:

a. a first substantially tapered scarf surface on the exterior of a first adherend;

b. a second substantially tapered scarf surface on the interior of the first adherend convergingly meeting said first scarf surface;

said substantially tapered scarf surfaces on the first adherend including a first tapered portion, a first level portion, a second tapered portion, a second level portion and a third tapered portion;

c. an opposing, diverging pair of substantially tapered scarf surfaces between the exterior and interior surfaces of the second adherend, said pair of scarf surfaces being complementary to said scarf surfaces of the first adherend;

said substantially tapered scarf surfaces on the second adherend each including a mating first tapered portion, a first level portion, a second tapered portion, a second level portion and a third tapered portion, complementary to said scarf surfaces on the first adherend; and

d. an adhesive layer interposed between opposing scarf surfaces bonding the adherends into a unitary structure of substantially constant thickness across the area of the bond,

whereby said adhesive layer transfers applied loads from one adherend to the other, whereby the joint between the two adherends includes areas that are resistant to creep of said adhesive layer.

16. The bonded scarf joint of claim 15, above wherein the second adherend is a multilayer composite of a plurality of fiber layers wound to form a closed tube and wherein each layer terminates in an incremental edge portion that bonds to a portion of the adjacent surface of the second adherend.

17. The bonded scarf joint of claim 15, above wherein the second adherend is a multilayer composite of a plurality of fiber layers wound to form a closed tube and wherein each layer terminates in an incremental edge portion that bonds to a portion of the adjacent surface of the second adherend, and wherein the incremental edge portions adjacent level portions extend sufficiently to bond to the adjoining tapered portions.