Molded-in insert and method for fiber reinforced thermoplastic composite structure

• US 9,180,631 B2
• Filed: 07/22/2011
• Issued: 11/10/2015
• Est. Priority Date: 07/22/2011
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Fisher, Edward McMurray Jr., Carter, Brian Allen
• Primary Examiner(s): Lan, Yan
• Application Number:
  US13/189,478
• Publication Number:
  US 20130022391A1
• Time in Patent Office: 1,572 Days
• Field of Search: 428/35.3, 428/36.9, 428/35.8, 403/265, 411/82, 411/180
• US Class Current: 1/1
• CPC Class Codes: B29C 2043/181 encapsulated
• CPC Class Codes: B29C 39/10 incorporating preformed parts or layers, e.g. casting around inserts or for coating articles coating a surface by casting in general B05D1/30, B29C39/126 takes precedence
• CPC Class Codes: B29C 43/18 incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles B29C43/206 takes precedence
• CPC Class Codes: B29C 45/14311 using means for bonding the coating to the articles B29C45/14795 takes precedence
• CPC Class Codes: B29C 45/14631 Coating reinforcements fibre reinforcements B29C45/0005
• CPC Class Codes: B29C 70/682 Preformed parts characterised by their structure, e.g. form
• CPC Class Codes: B29C 70/683 Pretreatment of the preformed part, e.g. insert
• CPC Class Codes: B29K 2101/12 Thermoplastic materials
• CPC Class Codes: B29K 2105/06 containing reinforcements, fillers or inserts
• CPC Class Codes: B29K 2105/20 Inserts
• CPC Class Codes: F16B 37/122 Threaded inserts, e.g. "rampa bolts"
• CPC Class Codes: Y10T 403/47 Molded joint

Abstract

In an embodiment of the disclosure, there is provided a molded-in insert for high strength retention in a fiber reinforced thermoplastic composite structure. The insert has a cylindrical body and at least one circumferential groove formed in the cylindrical body, the groove having a substantially concave configuration, having a groove radius of 0.025 inch or greater, and having the groove radius greater than or equal to a groove depth.

Claims

1. A molded-in insert for high strength retention in a fiber reinforced thermoplastic composite structure, the molded-in insert comprising:

a cylindrical body having first and second circumferential substantially flat surfaces of identical width and diameter; and

,

at least one circumferential groove extending between the first and second circumferential substantially flat surfaces formed in the cylindrical body to obtain the molded-in insert, the groove having a substantially concave configuration, having a groove radius of 0.025 inch or greater, where the groove radius is constant, and having the groove radius greater than or equal to a groove depth and having a groove width greater than the groove depth, wherein the groove is configured to be filled with fiber reinforced thermoplastic composite material and is configured to mold in place within or to the fiber reinforced thermoplastic composite structure.

2. The insert of claim 1, wherein when the molded-in insert is molded in the fiber reinforced thermoplastic composite structure, reinforcing fibers from the fiber reinforced thermoplastic composite structure flow into and fully fill the at least one circumferential groove in order to form a high strength mechanical locking mechanism that secures the molded-in insert in place in the fiber reinforced thermoplastic composite structure.

3. The insert of claim 2, wherein the molded-in insert is molded in the fiber reinforced thermoplastic composite structure via a molding process selected from a group comprising compression molding, resin transfer molding, injection molding, blow molding, transfer molding, reaction injection molding, casting, and investment casting.

4. The insert of claim 1, wherein the at least one circumferential groove is formed in an exterior surface of the cylindrical body.

5. The insert of claim 1, wherein the at least one circumferential groove is formed in an interior surface of the cylindrical body.

6. The insert of claim 1, wherein the cylindrical body has two or more circumferential grooves formed in an exterior surface of the cylindrical body.

7. The insert of claim 1, wherein the cylindrical body has two or more circumferential grooves formed in an interior surface of the cylindrical body.

8. The insert of claim 1, wherein the cylindrical body has a first circumferential groove formed in an exterior surface of the cylindrical body and a second circumferential groove formed in an interior surface of the cylindrical body.

9. The insert of claim 1, wherein the molded-in insert is made of a machinable material selected from a group comprising a metal material, a ceramic material, and a composite material.

10. The insert of claim 3, wherein the at least one circumferential groove is formed in an exterior surface of the cylindrical body.

11. The insert of claim 3, wherein the at least one circumferential groove is formed in an interior surface of the cylindrical body.

12. The insert of claim 3, wherein the cylindrical body has two or more circumferential grooves formed in an exterior surface of the cylindrical body.

13. The insert of claim 3, wherein the cylindrical body has two or more circumferential grooves formed in an interior surface of the cylindrical body.

14. The insert of claim 3, wherein the cylindrical body has a first circumferential groove formed in an exterior surface of the cylindrical body and a second circumferential groove formed in an interior surface of the cylindrical body.

15. The insert of claim 3, wherein the molded-in insert is made of a machinable material selected from a group comprising a metal material, a ceramic material, and a composite material.

16. The insert of claim 9, wherein the at least one circumferential groove is formed in an exterior surface of the cylindrical body.

17. The insert of claim 9, wherein the at least one circumferential groove is formed in an interior surface of the cylindrical body.

18. The insert of claim 9, wherein the cylindrical body has two or more circumferential grooves formed in an exterior surface of the cylindrical body.

19. The insert of claim 9, wherein the cylindrical body has two or more circumferential grooves formed in an interior surface of the cylindrical body.

20. The insert of claim 9, wherein the cylindrical body has a first circumferential groove formed in an exterior surface of the cylindrical body and a second circumferential groove formed in an interior surface of the cylindrical body.