Reinforced joint for composite structures and method of joining composite parts

• US 5,667,859 A
• Filed: 02/03/1995
• Issued: 09/16/1997
• Est. Priority Date: 04/30/1993
• Status: Expired due to Term

• Current Assignee: Foster-Miller Incorporated (Thermo Fisher Scientific Incorporated)
• Original Assignee: Foster-Miller Incorporated (Thermo Fisher Scientific Incorporated)
• Inventors: Magee, Constance Lee, Boyce, Joseph Santin, Freitas, Glenn Alexander
• Primary Examiner(s): Michl, Paul R.
• Assistant Examiner(s): Shelborne, Kathryne E.
• Application Number:
  US08/383,087
• Time in Patent Office: 956 Days
• Field of Search: 428/248.1, 428/105, 428/282, 428/357, 428/364, 428/224, 428/398, 428/404, 428/408, 428/297, 428/298, 428/299, 428/301, 156/89, 156/92, 156/93, 156/304.3, 156/304.5, 156/304.6, 264/29.1, 228/120, 228/121, 228/151, 228/193, 228/194, 228/208, 228/263.19, 228/263.21
• US Class Current: 428/59
• CPC Class Codes: B29C 65/564 hidden in the joint, e.g. dowels or Z-pins B29C65/603 takes precedence
• CPC Class Codes: B29C 66/112 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 66/71 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 66/81455 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 70/543 Fixing the position or configuration of fibrous reinforcements before or during moulding for non-woven fabrics D04H3/08
• 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: C04B 2237/12 Metallic interlayers
• CPC Class Codes: C04B 2237/363 Carbon
• CPC Class Codes: C04B 2237/40 Metallic
• CPC Class Codes: C04B 2237/567 made of metal
• CPC Class Codes: C04B 2237/568 made of non-oxide ceramics
• CPC Class Codes: C04B 2237/592 whereby the interlayer is not continuous, e.g. not the whole surface of the smallest substrate is covered by the interlayer
• CPC Class Codes: C04B 2237/82 Two substrates not completely covering each other, e.g. two plates in a staggered position
• CPC Class Codes: C04B 2237/86 Joining of two substrates at their largest surfaces, one surface being complete joined and covered, the other surface not, e.g. a small plate joined at it's largest surface on top of a larger plate
• CPC Class Codes: C04B 37/006 consisting of metals or metal salts
• CPC Class Codes: C04B 37/008 by means of an interlayer consisting of an organic adhesive, e.g. phenol resin or pitch
• CPC Class Codes: Y10T 428/193 : Double faced corrugated sheets or webs connected
• CPC Class Codes: Y10T 428/24995 : Two or more layers
• CPC Class Codes: Y10T 428/2975 : Tubular or cellular
• CPC Class Codes: Y10T 428/2993 : Silicic or refractory material containing [e.g., tungsten oxide, glass, cement, etc.]
• CPC Class Codes: Y10T 428/30 : Self-sustaining carbon mass or layer with impregnant or other layer

Abstract

A method of joining composite parts including disposing reinforcing elements through the thickness of two composite adherends to be joined, at least a number of the reinforcing elements extending from the joint surface of each adherend; assembling the adherends so the joint surface of one faces the joint surface of the other defining a joint region therebetween, wherein the extending reinforcing elements are interstitially disposed in the joint region; and disposing an adherent within the joint region about the interstitially disposed reinforcing elements and the joint surface for providing an improved and reinforced joint.

Claims

1. A joined composite part structure comprising:

a pair of composite members, each comprising layers of plies of fiber arrays in a resin matrix, and each including a plurality of discrete, extrinsic reinforcing fibers disposed transversely through the thickness thereof, at least a number of said reinforcing fibers extending from the joint surface of each said member;

a joint region between said composite members bounded by the joint surface of each said composite member and including said discrete transversely extending reinforcing fibers interstitially disposed therein; and

an adhesive disposed about said extending interstitially disposed reinforcing fibers between said joint surfaces within the joint region.

2. The structure of claim 1 in which said adhesive is a brazing material.

3. The structure of claim 1 in which said adhesive is a prepeg material.

4. A joined composite part structure comprising:

a pair of composite members, each comprising layers of plies of fiber arrays in a resin matrix, one said member including a plurality of discrete, extrinsic reinforcing fibers disposed transversely through the thickness and extending from the joint surface thereof;

a joint region between said members bounded by the joint surface of each said member and including the extending reinforcing fibers of said one member disposed against the joint surface of the other said member; and

an adhesive disposed in said joint region and about said extending reinforcing fibers and between said joint surfaces.

5. A joined composite part structure comprising:

a pair of composite members, each comprising layers of plies of fiber arrays in a resin matrix, and each including a plurality of discrete, extrinsic reinforcing fibers disposed transversely through the thickness thereof, at least a number of said reinforcing fibers exposed at the joint surface of each said member;

a joint region between said members bounded by the joint surface of each said member and including said exposed reinforcing fibers; and

an adhesive about said exposed reinforcing fibers between said joint surfaces within the joint region.

6. A joined composite part structure comprising:

a pair of cured composite members each including longitudinally extending fibers in a hardened resin matrix and a plurality of extrinsic, discrete reinforcing fibers disposed through the thickness thereof transverse to the longitudinally extending fibers, at least a number of said reinforcing fibers extending from the joint surface of each said member;

a joint region between said members bounded by the joint surface of each said member, said joint region including said discrete extending reinforcing fibers interstitially disposed therein; and

an adhesive about said extending interstitially disposed reinforcing fibers between said joint surfaces and within the joint region.

7. The structure of claim 6 in which said adhesive is a brazing material.

8. The structure of claim 6 in which said adhesive is a prepeg material.