Composite structural members and methods for forming the same

• US 7,721,495 B2
• Filed: 03/31/2005
• Issued: 05/25/2010
• Est. Priority Date: 03/31/2005
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Kismarton, Max U.
• Primary Examiner(s): Chilcot, Jr.; Richard E
• Assistant Examiner(s): Wendell; Mark R
• Application Number:
  US11/096,743
• Publication Number:
  US 20060236652A1
• Time in Patent Office: 1,881 Days
• Field of Search: 521/261, 523/091.6, 525/78, 525/926, 248/188.2, 428/298.1, 428/299.1, 428/299.4, 428/105, 428/107, 428/109, 244/123, 244/119, 244/133, 442/218, 442/268, 442/269, 442/271, 442/277, 442/278
• US Class Current: 52/309.16
• CPC Class Codes: B29C 65/08 using ultrasonic vibrations non-plastics element to plastics elements B29C65/645
• CPC Class Codes: B29C 65/562 using extra joining elements, i.e. which are not integral with the parts to be joined using plastic snap elements B29C65/58; using plastic rivets B29C65/601
• CPC Class Codes: B29C 65/564 hidden in the joint, e.g. dowels or Z-pins B29C65/603 takes precedence
• CPC Class Codes: B29C 65/72 by combined operations or combined techniques, e.g. welding and stitching
• CPC Class Codes: B29C 65/7808 in the form of holes or slots B29C65/7814 takes precedence; holding or clamping means cooperating with specially formed features of at least one of the parts to be joined B29C65/7844
• 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 66/1142 Single butt to butt joints
• CPC Class Codes: B29C 66/304 Joining through openings in an intermediate part of the article B29C66/3034 takes 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 66/71 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: B29C 70/24 oriented in at least three directions forming a three dimensional structure
• CPC Class Codes: B29C 70/545 Perforating, cutting or machining during or after moulding
• CPC Class Codes: B29K 2063/00 Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2105/101 Oriented
• CPC Class Codes: B29K 2277/10 Aromatic polyamides [Polyaramides] or derivatives thereof
• CPC Class Codes: B29K 2283/00 Use of polymers having silicon, with or without sulfur, nitrogen, oxygen or carbon only, in the main chain, as reinforcement
• CPC Class Codes: B29K 2307/00 : Use of elements other than metals as reinforcement
• CPC Class Codes: B29K 2307/02 : Boron
• CPC Class Codes: B29K 2307/04 : Carbon
• CPC Class Codes: B29K 2309/04 : Carbides; Nitrides
• CPC Class Codes: B29K 2309/08 : Glass
• CPC Class Codes: B29K 2705/00 : Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
• CPC Class Codes: B29L 2031/3076 : Aircrafts blades, propellers B29L2031/08
• CPC Class Codes: B29L 2031/3082 : Fuselages
• CPC Class Codes: B29L 2031/3085 : Wings
• CPC Class Codes: B32B 15/092 : comprising epoxy resins
• CPC Class Codes: B32B 15/20 : comprising aluminium or copper B32B15/016 and B32B15/017 take precedence
• CPC Class Codes: B32B 2250/05 : 5 or more layers
• CPC Class Codes: B32B 2250/40 : Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2262/106 : Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2307/54 : Yield strength; Tensile strength
• CPC Class Codes: B32B 2307/542 : Shear strength
• CPC Class Codes: B32B 2307/546 : Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/718 : Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2605/18 : Aircraft blades, propellers B32B2603/00
• CPC Class Codes: B32B 27/08 : of synthetic resin
• CPC Class Codes: B32B 27/18 : characterised by the use of special additives
• CPC Class Codes: B32B 27/38 : comprising epoxy resins
• CPC Class Codes: B32B 3/266 : characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 5/12 : characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
• CPC Class Codes: E04C 3/29 : built-up from parts of different material, i.e. composite structures
• CPC Class Codes: Y02T 50/40 : Weight reduction
• CPC Class Codes: Y10T 428/24058 : including grain, strips, or filamentary elements in respective layers or components in angular relation
• CPC Class Codes: Y10T 428/24074 : Strand or strand-portions
• CPC Class Codes: Y10T 428/249942 : Fibers are aligned substantially parallel
• CPC Class Codes: Y10T 428/249945 : Carbon or carbonaceous fiber
• CPC Class Codes: Y10T 428/249946 : Glass fiber

Abstract

Composite structural members and methods for forming the same are disclosed. In one disclosed embodiment, a composite structural member includes a central structural portion comprised of a reinforced, polymer-based material and having a length, a first side and an opposing second side extending along the length. A first reinforcement member fixedly coupled to the first side and a second reinforcement member fixedly coupled to the second side.

Claims

1. An article comprising a composite beam sandwiched between first and second reinforcement plates, the beam including a first ply of reinforcing fibers with a fiber orientation of +5 degrees and a second ply of reinforcing fibers with a fiber orientation of −

5 degrees.

2. The article of claim 1, wherein at least one of the first and second reinforcement plates includes a plurality of z-pin members that are configured to extend into a respective first side and second side of the beam.

3. The article of claim 1, wherein the plies extend in an x-y plane, wherein holes are drilled through the beam in a z-direction;

and wherein fasteners extend through the holes to clamp the plates to the beam.

4. The article of claim 3, wherein the fasteners include fasteners configured to impart a predetermined tension by including a shear portion that breaks during installation when the predetermined tension is achieved.

5. The article of claim 1 further comprising a transverse attachment member positioned between the beam and at least one of the first and second reinforcement plates, wherein the transverse attachment member includes apertures to couple the beam to an external structural portion.

6. The article of claim 1, further comprising a longitudinal attachment member configured to extend outwardly from an end of the beam.

7. The article of claim 1, further comprising an angled attachment member coupled to one of the first and second reinforcement plates and extending outwardly from an end of the beam.

8. The article of claim 1, wherein the beam includes a first portion and a second portion that abut at respective end portions to define an interface, further comprising a first splicing member positioned on the first reinforcement plate, and a second splicing member positioned on the second reinforcement plate, the first splicing member and the second splicing member configured to fixedly couple the first portion and the second portion.

9. The article of claim 1, wherein the article is an aircraft keel beam.

10. The article of claim 1, wherein the beam further includes third and fourth plies of reinforcing fibers with fiber orientations of +65 degrees and −

65 degrees, respectively.

11. The article of claim 10, wherein 80% of all fibers in the beam are in the first and second plies.

12. The article of claim 1, wherein the composite beam includes high modulus carbon fibers in a resin.

13. The article of claim 1, wherein the plates are metal plates.

14. An aerospace vehicle, comprising:

a fuselage;

wing assemblies and an empennage operatively coupled to the fuselage; and

an article of claim 1 positioned in at least one of the wing assemblies, the fuselage and the empennage.