Patent · US10875256B2 · B2 · US

Method of making joint for structure

(11) Publication number

US10875256B2

(21) Application number

15/866,943

(22) Filing date

2018-01-10

(30) Priority date

2013-10-03

(43) Publication date

2020-12-29

(45) Date of grant

2020-12-29

(51) IPC

B29C 65/00; B29C 70/08; B29C 70/86; B32B 27/08; B32B 27/20; B32B 7/06; B64C 1/06; B64C 1/12

(52) CPC

B29C Shaping or joining of plastics; shaping of material in a plastic state, not otherwise provided for; after-treatment of the shaped products, e.g. repairing: 66/43441, 66/4344, 66/496, 66/524, 66/721, 66/7212, 66/73115, 66/73117, 66/73756, 66/73941, 66/91411, 66/91935, 70/086, 70/86
B29D Producing particular articles from plastics or from substances in a plastic state: 99/0005
B29K Indexing scheme associated with subclasses B29B, B29C or B29D, relating to moulding materials or to materials for {moulds, } reinforcements, fillers or preformed parts, e.g. inserts: 2307/04, 2309/08
B29L Indexing scheme associated with subclass B29C, relating to particular articles: 2031/3076, 2031/3082, 2031/3085
B32B Layered products, i.e. products built-up of strata of flat or non-flat, e.g. cellular or honeycomb, form: 2262/101, 2262/106, 2605/18, 27/08, 27/20, 7/06
B64C Aeroplanes; helicopters: 1/064, 1/12, 2001/0072
Y02T Climate change mitigation technologies related to transportation: 50/40
Y10T Technical subjects covered by former us classification: 428/24529, 428/249952

(73) Assignee

Boeing Co

(72) Inventors

Gabriel Z. Forston; Christopher G. Harris; Joshua P. Tyndall; Hyukbong Kwon; Carolyn Schmidt

(54) Title

Method of making joint for structure

(57) Abstract

A method of making a joint for a structure comprises forming a thermoplastic filler, applying an uncured first thermoset layer into direct contact with the thermoplastic filler, applying an uncured second thermoset layer into direct contact with the thermoplastic filler, and applying an uncured third thermoset layer into direct contact with the thermoplastic filler. The method additionally comprises curing the uncured first thermoset layer, the uncured second thermoset layer, and the uncured third thermoset layer at a temperature below a melting temperature of the thermoplastic material to form a cured first thermoset layer, a cured second thermoset layer, and a cured third thermoset layer and bonding together the cured first thermoset layer, the cured second thermoset layer, the cured third thermoset layer, and the thermoplastic filler.

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Claims (20)

A method for making a joint for a structure, comprising: forming a thermoplastic filler, having a length and made from a thermoplastic material; applying an uncured first thermoset layer into direct contact with the thermoplastic filler along the length of the thermoplastic filler, the uncured first thermoset layer comprising a first fibrous material embedded in a first thermoset matrix; applying an uncured second thermoset layer into direct contact with the thermoplastic filler along the length of the thermoplastic filler and into contact with the uncured first thermoset layer, the uncured second thermoset layer comprising a second fibrous material embedded in a second thermoset matrix; applying an uncured third thermoset layer into direct contact with the thermoplastic filler along the length of the thermoplastic filler and into contact with the uncured first and second thermoset layers, the uncured third thermoset layer comprising a third fibrous material, embedded in a third thermoset matrix; and while the uncured first, second, and third thermoset layers are applied into direct contact with the thermoplastic filler and while the uncured second thermoset layer contacts the uncured first thermoset layer and the uncured third thermoset layer, curing the uncured first thermoset layer, the uncured second thermoset layer, and the uncured third thermoset layer at a temperature below a melting temperature of the thermoplastic material to form a cured first thermoset layer, a cured second thermoset layer, and a cured third thermoset layer and bond together the cured first thermoset layer, the cured second thermoset layer, the cured third thermoset layer, and the thermoplastic filler.
The method of claim 1, wherein forming the thermoplastic filler comprises compression molding the thermoplastic material.
The method of claim 1, wherein forming the thermoplastic filler comprises extruding the thermoplastic material.
The method of claim 1, wherein forming the thermoplastic filler comprises forming at least one concave surface in the thermoplastic filler, and wherein applying the uncured first thermoset layer onto the thermoplastic filler comprises bending the uncured first thermoset layer along the at least one concave surface, and curing the uncured first thermoset layer comprises curing the uncured first thermoset layer while bent along the at least one concave surface.
The method of claim 1, wherein forming the thermoplastic filler comprises embedding unidirectional reinforcement fibers into the thermoplastic material.
The method of claim 1, wherein forming the thermoplastic filler comprises forming the thermoplastic filler with an asymmetrical geometry.
A method for making a joint for a structure, comprising: forming a thermoplastic filler, having a length and made from a thermoplastic material; applying an uncured first thermoset layer into direct contact with the thermoplastic filler along the length of the thermoplastic filler, the uncured first thermoset layer comprising a first fibrous material embedded in a first thermoset matrix; applying an uncured second thermoset layer into direct contact with the thermoplastic filler along the length of the thermoplastic filler and into contact with the uncured first thermoset layer, the uncured second thermoset layer comprising a second fibrous material embedded in a second thermoset matrix; applying an uncured third thermoset layer into direct contact with the thermoplastic filler along the length of the thermoplastic filler and into contact with the uncured first and second thermoset layers, the uncured third thermoset layer comprising a third fibrous material, embedded in a third thermoset matrix; and while the uncured first, second, and third thermoset layers are applied into direct contact with the thermoplastic filler and while the uncured second thermoset layer contacts the uncured first thermoset layer and the uncured third thermoset layer, curing the uncured first thermoset layer, the uncured second thermoset layer, and the uncured third thermoset layer to form a cured first thermoset layer, a cured second thermoset layer, and a cured third thermoset layer and bond together the cured first thermoset layer, the cured second thermoset layer, the cured third thermoset layer, and the thermoplastic filler without melting the thermoplastic filler.
The method of claim 7, wherein forming the thermoplastic filler comprises compression molding the thermoplastic material.
The method of claim 7, wherein forming the thermoplastic filler comprises extruding the thermoplastic material.
The method of claim 7, wherein forming the thermoplastic filler comprises forming the thermoplastic filler with an asymmetrical geometry.
The method of claim 7, wherein forming the thermoplastic filler comprises forming a flat surface on the thermoplastic filler.
The method of claim 7, wherein forming the thermoplastic filler comprises embedding reinforcement fibers into the thermoplastic material.
The method of claim 7, wherein forming the thermoplastic filler comprises forming the thermoplastic filler to be approximately equal in length to at least one of: the uncured first thermoset layer along a region of the uncured first thermoset layer to be bonded to the thermoplastic filler or the uncured second thermoset layer along a region of the uncured second thermoset layer to be bonded to the thermoplastic filler.
The method of claim 7, wherein forming the thermoplastic filler comprises forming the thermoplastic filler to be different in length from at least one of: the uncured first thermoset layer along a region of the uncured first thermoset layer to be bonded to the thermoplastic filler or the uncured second thermoset layer along a region of the uncured second thermoset layer to be bonded to the thermoplastic filler.
The method of claim 7, wherein forming the thermoplastic filler comprises forming at least one concave surface in the thermoplastic filler, and wherein applying the uncured first thermoset layer onto the thermoplastic filler comprises bending the uncured first thermoset layer along the at least one concave surface and curing the uncured first thermoset layer comprises curing the uncured first thermoset layer while bent along the at least one concave surface.
The method of claim 7, wherein a melting temperature of the thermoplastic material of the thermoplastic filler is between about 450° F. and about 650° F.
A method for forming a joint, the method comprising steps of: forming a thermoplastic filler, having a length and comprising a thermoplastic material and unidirectional reinforcement fibers; applying an uncured first thermoset layer into direct contact with the thermoplastic filler along the length of the thermoplastic filler, wherein the uncured first thermoset layer comprises a first fibrous material, embedded in a first thermoset matrix; applying an uncured second thermoset layer into direct contact with the thermoplastic filler along the length of the thermoplastic filler, wherein the uncured second thermoset layer comprises a second fibrous material, embedded in a second thermoset matrix; applying an uncured third thermoset layer into direct contact with the thermoplastic filler along the length of the thermoplastic filler, wherein: the uncured third thermoset layer comprises a third fibrous material, embedded in a third thermoset matrix, the uncured second thermoset layer is coupled to the uncured first thermoset layer and the uncured third thermoset layer to form the joint, and a gap is defined between the uncured first thermoset layer, the uncured second thermoset layer, and the uncured third thermoset layer; positioning the thermoplastic filler within the gap, wherein: the thermoplastic material of the thermoplastic filler has a melting temperature that is greater than a cure temperature of each of the first thermoset matrix and the second thermoset matrix, the melting temperature of the thermoplastic material of the thermoplastic filler is between about 450° F. and about 750° F., and the thermoplastic filler supports and maintains a first shape of a portion of the uncured first thermoset layer and a second shape of a portion of the uncured second thermoset layer; and while the uncured first thermoset layer, the uncured second thermoset layer, and the uncured third thermoset layer are applied into direct contact with the thermoplastic filler, curing the uncured first thermoset layer, the uncured second thermoset layer, and the uncured third thermoset layer without melting the thermoplastic material of the thermoplastic filler.
The method of claim 17, wherein the step of forming the thermoplastic filler comprises forming at least one concave surface in the thermoplastic filler; and the first shape of the portion of the uncured first thermoset layer is a concave shape.
The method of claim 17, wherein forming the thermoplastic filler comprises forming the thermoplastic filler with an asymmetrical geometry.
The method of claim 17, wherein applying the uncured first thermoset layer comprises shaping the portion of the uncured first thermoset layer, using the thermoplastic filler, into the first shape that is complementary to a shape of a first portion of the thermoplastic filler by applying the portion of the uncured first thermoset layer into direct contact with the first portion of the thermoplastic filler and wherein applying the uncured second thermoset layer comprises shaping the portion of the uncured second thermoset layer, using the thermoplastic filler, into the second shape that is complementary to a shape of a second portion of the thermoplastic filler by applying the portion of the uncured second thermoset layer into direct contact with the second portion of the thermoplastic filler.

Description

This disclosure relates generally to complex structures made from thermoset materials, and more particularly to the formation of joints adjoining layers of thermoset materials.

Today, many complex structures, such as aircraft, spacecraft, automobiles, and the like, are made from composite materials. Composite materials typically include fibrous materials embedded in a matrix made from thermoset materials. Uncured thermoset materials are arranged in a desired manner and then cured to harden the matrix. Like complex structures made from more traditional materials, such as metal, complex structures made from composite materials include a significantly large number of interconnected components. The interconnected components of complex structures are connected together at joints. The joints of conventional complex structures are traditionally formed using fasteners and weldments. However, the joints of some complex structures formed from composite materials are formed using adhesives and co-curing of thermoset materials.

To improve the characteristics of joints between components made from composite materials, the components incorporate bends at the joints, which introduce gaps within the joints. Often, the gaps are filled with thermoset materials that cure concurrently with the thermoset materials forming the components. Because uncured thermoset materials are flexible and pliable, before and during curing, maintaining such materials in place can be difficult. Additionally, after curing, thermoset joint fillers are susceptible to cracking due to thermal and mechanical static and fatigue loads.

Citations (19)

US4331495A
US4966802A
US4789594A
US5487941A
US5800657A
US5919543A
US5833786A
US6709538B2
US6562436B2
US7205066B1
US7732033B2
US20070175575A1
US20090065977A1
EP2052846A1
US20090317587A1
US8540833B2
WO2010144007A1
US20120074265A1
US20130171895A1

Record as JSON

{
  "publication_number": "US10875256B2",
  "country": "US",
  "kind": "B2",
  "title": "Method of making joint for structure",
  "abstract": "A method of making a joint for a structure comprises forming a thermoplastic filler, applying an uncured first thermoset layer into direct contact with the thermoplastic filler, applying an uncured second thermoset layer into direct contact with the thermoplastic filler, and applying an uncured third thermoset layer into direct contact with the thermoplastic filler. The method additionally comprises curing the uncured first thermoset layer, the uncured second thermoset layer, and the uncured third thermoset layer at a temperature below a melting temperature of the thermoplastic material to form a cured first thermoset layer, a cured second thermoset layer, and a cured third thermoset layer and bonding together the cured first thermoset layer, the cured second thermoset layer, the cured third thermoset layer, and the thermoplastic filler.",
  "claims": [
    "1. A method for making a joint for a structure, comprising: forming a thermoplastic filler, having a length and made from a thermoplastic material; applying an uncured first thermoset layer into direct contact with the thermoplastic filler along the length of the thermoplastic filler, the uncured first thermoset layer comprising a first fibrous material embedded in a first thermoset matrix; applying an uncured second thermoset layer into direct contact with the thermoplastic filler along the length of the thermoplastic filler and into contact with the uncured first thermoset layer, the uncured second thermoset layer comprising a second fibrous material embedded in a second thermoset matrix; applying an uncured third thermoset layer into direct contact with the thermoplastic filler along the length of the thermoplastic filler and into contact with the uncured first and second thermoset layers, the uncured third thermoset layer comprising a third fibrous material, embedded in a third thermoset matrix; and while the uncured first, second, and third thermoset layers are applied into direct contact with the thermoplastic filler and while the uncured second thermoset layer contacts the uncured first thermoset layer and the uncured third thermoset layer, curing the uncured first thermoset layer, the uncured second thermoset layer, and the uncured third thermoset layer at a temperature below a melting temperature of the thermoplastic material to form a cured first thermoset layer, a cured second thermoset layer, and a cured third thermoset layer and bond together the cured first thermoset layer, the cured second thermoset layer, the cured third thermoset layer, and the thermoplastic filler.",
    "2. The method of claim 1, wherein forming the thermoplastic filler comprises compression molding the thermoplastic material.",
    "3. The method of claim 1, wherein forming the thermoplastic filler comprises extruding the thermoplastic material.",
    "4. The method of claim 1, wherein forming the thermoplastic filler comprises forming at least one concave surface in the thermoplastic filler, and wherein applying the uncured first thermoset layer onto the thermoplastic filler comprises bending the uncured first thermoset layer along the at least one concave surface, and curing the uncured first thermoset layer comprises curing the uncured first thermoset layer while bent along the at least one concave surface.",
    "5. The method of claim 1, wherein forming the thermoplastic filler comprises embedding unidirectional reinforcement fibers into the thermoplastic material.",
    "6. The method of claim 1, wherein forming the thermoplastic filler comprises forming the thermoplastic filler with an asymmetrical geometry.",
    "7. A method for making a joint for a structure, comprising: forming a thermoplastic filler, having a length and made from a thermoplastic material; applying an uncured first thermoset layer into direct contact with the thermoplastic filler along the length of the thermoplastic filler, the uncured first thermoset layer comprising a first fibrous material embedded in a first thermoset matrix; applying an uncured second thermoset layer into direct contact with the thermoplastic filler along the length of the thermoplastic filler and into contact with the uncured first thermoset layer, the uncured second thermoset layer comprising a second fibrous material embedded in a second thermoset matrix; applying an uncured third thermoset layer into direct contact with the thermoplastic filler along the length of the thermoplastic filler and into contact with the uncured first and second thermoset layers, the uncured third thermoset layer comprising a third fibrous material, embedded in a third thermoset matrix; and while the uncured first, second, and third thermoset layers are applied into direct contact with the thermoplastic filler and while the uncured second thermoset layer contacts the uncured first thermoset layer and the uncured third thermoset layer, curing the uncured first thermoset layer, the uncured second thermoset layer, and the uncured third thermoset layer to form a cured first thermoset layer, a cured second thermoset layer, and a cured third thermoset layer and bond together the cured first thermoset layer, the cured second thermoset layer, the cured third thermoset layer, and the thermoplastic filler without melting the thermoplastic filler.",
    "8. The method of claim 7, wherein forming the thermoplastic filler comprises compression molding the thermoplastic material.",
    "9. The method of claim 7, wherein forming the thermoplastic filler comprises extruding the thermoplastic material.",
    "10. The method of claim 7, wherein forming the thermoplastic filler comprises forming the thermoplastic filler with an asymmetrical geometry.",
    "11. The method of claim 7, wherein forming the thermoplastic filler comprises forming a flat surface on the thermoplastic filler.",
    "12. The method of claim 7, wherein forming the thermoplastic filler comprises embedding reinforcement fibers into the thermoplastic material.",
    "13. The method of claim 7, wherein forming the thermoplastic filler comprises forming the thermoplastic filler to be approximately equal in length to at least one of: the uncured first thermoset layer along a region of the uncured first thermoset layer to be bonded to the thermoplastic filler or the uncured second thermoset layer along a region of the uncured second thermoset layer to be bonded to the thermoplastic filler.",
    "14. The method of claim 7, wherein forming the thermoplastic filler comprises forming the thermoplastic filler to be different in length from at least one of: the uncured first thermoset layer along a region of the uncured first thermoset layer to be bonded to the thermoplastic filler or the uncured second thermoset layer along a region of the uncured second thermoset layer to be bonded to the thermoplastic filler.",
    "15. The method of claim 7, wherein forming the thermoplastic filler comprises forming at least one concave surface in the thermoplastic filler, and wherein applying the uncured first thermoset layer onto the thermoplastic filler comprises bending the uncured first thermoset layer along the at least one concave surface and curing the uncured first thermoset layer comprises curing the uncured first thermoset layer while bent along the at least one concave surface.",
    "16. The method of claim 7, wherein a melting temperature of the thermoplastic material of the thermoplastic filler is between about 450° F. and about 650° F.",
    "17. A method for forming a joint, the method comprising steps of: forming a thermoplastic filler, having a length and comprising a thermoplastic material and unidirectional reinforcement fibers; applying an uncured first thermoset layer into direct contact with the thermoplastic filler along the length of the thermoplastic filler, wherein the uncured first thermoset layer comprises a first fibrous material, embedded in a first thermoset matrix; applying an uncured second thermoset layer into direct contact with the thermoplastic filler along the length of the thermoplastic filler, wherein the uncured second thermoset layer comprises a second fibrous material, embedded in a second thermoset matrix; applying an uncured third thermoset layer into direct contact with the thermoplastic filler along the length of the thermoplastic filler, wherein: the uncured third thermoset layer comprises a third fibrous material, embedded in a third thermoset matrix, the uncured second thermoset layer is coupled to the uncured first thermoset layer and the uncured third thermoset layer to form the joint, and a gap is defined between the uncured first thermoset layer, the uncured second thermoset layer, and the uncured third thermoset layer; positioning the thermoplastic filler within the gap, wherein: the thermoplastic material of the thermoplastic filler has a melting temperature that is greater than a cure temperature of each of the first thermoset matrix and the second thermoset matrix, the melting temperature of the thermoplastic material of the thermoplastic filler is between about 450° F. and about 750° F., and the thermoplastic filler supports and maintains a first shape of a portion of the uncured first thermoset layer and a second shape of a portion of the uncured second thermoset layer; and while the uncured first thermoset layer, the uncured second thermoset layer, and the uncured third thermoset layer are applied into direct contact with the thermoplastic filler, curing the uncured first thermoset layer, the uncured second thermoset layer, and the uncured third thermoset layer without melting the thermoplastic material of the thermoplastic filler.",
    "18. The method of claim 17, wherein the step of forming the thermoplastic filler comprises forming at least one concave surface in the thermoplastic filler; and the first shape of the portion of the uncured first thermoset layer is a concave shape.",
    "19. The method of claim 17, wherein forming the thermoplastic filler comprises forming the thermoplastic filler with an asymmetrical geometry.",
    "20. The method of claim 17, wherein applying the uncured first thermoset layer comprises shaping the portion of the uncured first thermoset layer, using the thermoplastic filler, into the first shape that is complementary to a shape of a first portion of the thermoplastic filler by applying the portion of the uncured first thermoset layer into direct contact with the first portion of the thermoplastic filler and wherein applying the uncured second thermoset layer comprises shaping the portion of the uncured second thermoset layer, using the thermoplastic filler, into the second shape that is complementary to a shape of a second portion of the thermoplastic filler by applying the portion of the uncured second thermoset layer into direct contact with the second portion of the thermoplastic filler."
  ],
  "description_excerpt": "This disclosure relates generally to complex structures made from thermoset materials, and more particularly to the formation of joints adjoining layers of thermoset materials.\n\nToday, many complex structures, such as aircraft, spacecraft, automobiles, and the like, are made from composite materials. Composite materials typically include fibrous materials embedded in a matrix made from thermoset materials. Uncured thermoset materials are arranged in a desired manner and then cured to harden the matrix. Like complex structures made from more traditional materials, such as metal, complex structures made from composite materials include a significantly large number of interconnected components. The interconnected components of complex structures are connected together at joints. The joints of conventional complex structures are traditionally formed using fasteners and weldments. However, the joints of some complex structures formed from composite materials are formed using adhesives and co-curing of thermoset materials.\n\nTo improve the characteristics of joints between components made from composite materials, the components incorporate bends at the joints, which introduce gaps within the joints. Often, the gaps are filled with thermoset materials that cure concurrently with the thermoset materials forming the components. Because uncured thermoset materials are flexible and pliable, before and during curing, maintaining such materials in place can be difficult. Additionally, after curing, thermoset joint fillers are susceptible to cracking due to thermal and mechanical static and fatigue loads.",
  "cpc": [
    "B29C 66/43441",
    "B29C 66/4344",
    "B29C 66/496",
    "B29C 66/524",
    "B29C 66/721",
    "B29C 66/7212",
    "B29C 66/73115",
    "B29C 66/73117",
    "B29C 66/73756",
    "B29C 66/73941",
    "B29C 66/91411",
    "B29C 66/91935",
    "B29C 70/086",
    "B29C 70/86",
    "B29D 99/0005",
    "B29K 2307/04",
    "B29K 2309/08",
    "B29L 2031/3076",
    "B29L 2031/3082",
    "B29L 2031/3085",
    "B32B 2262/101",
    "B32B 2262/106",
    "B32B 2605/18",
    "B32B 27/08",
    "B32B 27/20",
    "B32B 7/06",
    "B64C 1/064",
    "B64C 1/12",
    "B64C 2001/0072",
    "Y02T 50/40",
    "Y10T 428/24529",
    "Y10T 428/249952"
  ],
  "ipc": [
    "B29C 65/00",
    "B29C 70/08",
    "B29C 70/86",
    "B32B 27/08",
    "B32B 27/20",
    "B32B 7/06",
    "B64C 1/06",
    "B64C 1/12"
  ],
  "assignees": [
    "Boeing Co"
  ],
  "inventors": [
    "Gabriel Z. Forston",
    "Christopher G. Harris",
    "Joshua P. Tyndall",
    "Hyukbong Kwon",
    "Carolyn Schmidt"
  ],
  "filing_date": "2018-01-10",
  "publication_date": "2020-12-29",
  "grant_date": "2020-12-29",
  "priority_date": "2013-10-03",
  "application_number": "US-201815866943-A",
  "family_id": "52777167",
  "cited_by_count": 1,
  "citations": [
    "US4331495A",
    "US4966802A",
    "US4789594A",
    "US5487941A",
    "US5800657A",
    "US5919543A",
    "US5833786A",
    "US6709538B2",
    "US6562436B2",
    "US7205066B1",
    "US7732033B2",
    "US20070175575A1",
    "US20090065977A1",
    "EP2052846A1",
    "US20090317587A1",
    "US8540833B2",
    "WO2010144007A1",
    "US20120074265A1",
    "US20130171895A1"
  ]
}

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