Method and apparatus for reinforcing composite structures

• US 8,398,027 B2
• Filed: 09/17/2007
• Issued: 03/19/2013
• Est. Priority Date: 09/17/2007
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Wood, Jeffrey H.
• Primary Examiner(s): Lee, Benjamin P
• Application Number:
  US11/856,271
• Publication Number:
  US 20100065688A1
• Time in Patent Office: 2,010 Days
• Field of Search: 244/131, 244/1.R, 244/117.R, 244/119, 244/120, 244/123.1, 244/129.1, 244/132, 411/258, 411/378, 411/427, 411/429, 403/267, 403/270
• US Class Current: 244/131
• CPC Class Codes: B29C 65/483 Reactive adhesives, e.g. chemically curing adhesives
• 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 66/54 Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
• 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 66/72525 comprising honeycomb cores
• CPC Class Codes: B29K 2063/00 Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2105/06 containing reinforcements, fillers or inserts
• CPC Class Codes: B29K 2307/00 Use of elements other than metals as reinforcement
• CPC Class Codes: B29K 2307/04 Carbon
• CPC Class Codes: B29L 2031/608 Honeycomb structures
• CPC Class Codes: B29L 2031/727 Fastening elements bolts B29L2001/002; nuts B29L2001/005; screws B29L2001/007; slide fasteners B29L2005/00; buttons for haberdashery B29L2019/00
• CPC Class Codes: F16B 33/006 Non-metallic fasteners using screw-thread
• CPC Class Codes: Y10T 403/472 including mechanical interlock
• CPC Class Codes: Y10T 403/553 Laterally inserted section

Abstract

A computer implemented method and apparatus for creating a structural joint for an aircraft. A first composite component and a second composite component are co-joined to form the structural joint for the aircraft. A hole through the first composite component and the second composite component is created. A composite shear pin is placed through the hole. A composite collar is bonded to the composite shear pin with an adhesive.

Claims

1. A method for bonding a structural joint for an aircraft, the method comprising:

bonding a first composite component and a second composite component to form a bonded structural joint for the aircraft, such that the bonded structural joint comprises an outer splice plate, and an inner splice plate;

creating a first channel through the first composite component-and a second channel through the second composite component, such that the first channel and the second channel, respectively, each pass through the outer splice plate and the inner splice plate;

placing an adhesive on an interior surface of the first and the second channel respectively;

thereafter, placing a first and a second composite shear pin into the first and the second channel, respectively, such that a head of the first and of the second shear pin, respectively, seats adjacent to the outer splice plate, and such that the first and the second shear pin each mitigate separation of the first and the second composite component due to shear forces; and

bonding, using an adhesive bonding process, a first and a second composite collar to the first and the second composite shear pin, respectively, such that the first and the second composite collar are configured respectively, with a surface adjacent to the inner splice plate.

2. The method of claim 1, such that bonding the first composite component and the second composite component comprises:

co-curing the first composite component to the second composite component.

3. The method of claim 1, such that bonding the first composite component and the second composite component comprises:

co-bonding the first composite component to the second composite component.

4. The method of claim 1, such that the first and the second composite collar are each configured with a respective mechanical feature that retains adhesive.

5. The method of claim 4, wherein the mechanical feature is a set of non-threaded internal annular grooves.

6. The method of claim 1, wherein at least one composite collar is a male collar composite plug.

7. The method of claim 1, wherein the adhesive bonding process cures at a room temperature.

8. The method of claim 1, wherein placing the first and the second composite shear pin into the first and the second channel, respectively, occurs such that the adhesive closes gaps between the first and the second shear pin and the first and the second channel respectively.

9. The method of claim 1, wherein at least one composite shear pin is non-threaded, and positioning the at least one composite shear pin into at least one channel avoids torquing the shear pin.

10. A method for joining composite components, the method comprising:

co-joining a first composite component and a second composite component to form a bonded structural joint, such that the bonded structural joint comprises an outer splice plate, and an inner splice plate;

forming a first channel through the first composite component-and a second channel through the second composite component, such that the first and the second channel, respectively, each pass through the outer splice plate and the inner splice plate;

placing an adhesive on an interior surface of the first and the second channel respectively;

thereafter, positioning a first and a second composite shear pin in the first and the second channel respectively, such that a head of the first shear pin and a head of the second shear pin each seats adjacent to the outer splice plate, and such that the first and the second shear pin each mitigate separation of the first and the second composite component due to shear forces; and

bonding a first and a second composite collar to the first and the second composite shear pin, respectively, such that the first and the second composite collar are configured respectively, with a flush surface adjacent to the inner splice plate.

11. The method of claim 10, wherein the step of bonding further comprises:

applying adhesive in a space between the first and the second composite collar and the first and the second composite shear pin, respectively, to form an applied adhesive; and

curing the applied adhesive.

12. The method of claim 10, wherein the first composite component and the second composite component are part of a structure selected from one of an aircraft, a submarine, a spacecraft, a power plant, a building, and an automobile.

13. The method of claim 10, wherein positioning the first and the second composite shear pin in the first and the second channel respectively, avoids torquing either composite shear pin.

14. The method of claim 10, wherein at least one composite collar is a male collar composite plug.

15. A joint comprising:

a first composite component;

an inner splice plate;

a second composite component co-joined to the first composite component, such that an outer splice plate covers an outer portion of the first composite component and an outer portion of the second composite component, and wherein a first channel through the first composite component and a second channel through the second composite component are present and pass through the outer splice plate, and each channel being configured, respectively, with a counter bored area, being located at an end of the first and an end of the second channel respectively, nearest the outer splice plate;

a first shear pin and a second shear pin, each respectively having a first end configured to prevent the first end from passing through the first and second channel respectively, and configured such that the first end, of the first shear pin and of the second shear pin, respectively, seats in the first and the second counter bored area respectively, and the first and the second shear pin each comprise a second end having a first mechanical feature configured to retain adhesive, such that the first and the second shear pin each mitigate separation of the first and the second composite component due to shear forces;

a first and a second collar, each having a respective second mechanical feature configured to retain adhesive; and

an adhesive located between the first mechanical feature and the second mechanical feature respectively, wherein the adhesive bonds the first and the second shear pin to the first and the second collar, respectively.

16. The joint of claim 15, wherein the second mechanical feature does not mechanically engage the first mechanical feature.

17. The joint of claim 15, wherein the joint is located in a structure selected from one of an aircraft, a submarine, a spacecraft, a power plant, a building, and an automobile.

18. The joint of claim 15 wherein at least one collar further comprises an opening that provides an exit for excess adhesive.

19. The joint of claim 15 wherein the pin and the collar comprise composite materials.

20. The joint of claim 15, wherein at least one collar is a male collar plug.