Patent · US9358764B2 · B2 · US

System and method of joining components

(11) Publication number

US9358764B2

(21) Application number

14/183,006

(22) Filing date

2014-02-18

(30) Priority date

2013-12-17

(43) Publication date

2016-06-07

(45) Date of grant

2016-06-07

(51) IPC

B32B 37/02; B32B 37/15; B32B 37/18; B32B 41/00; B64F 5/00; B64F 5/10; B29C 65/00; B29C 65/02; B29C 65/48; B29C 65/50

(52) CPC

B32B Layered products, i.e. products built-up of strata of flat or non-flat, e.g. cellular or honeycomb, form: 37/15, 37/02, 37/18, 41/00
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: 65/02, 65/4815, 65/5021, 65/5057, 65/5078, 66/02241, 66/112, 66/131, 66/3494, 66/43441, 66/474, 66/524, 66/71, 66/721, 66/72141, 66/72143, 66/73117, 66/73755, 66/7392, 66/73921, 66/7394, 66/73941, 66/81455, 66/82423, 66/8322, 66/83221, 66/91411, 66/919
B33Y Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering: 80/00
Y10T Technical subjects covered by former us classification: 156/10

(73) Assignee

Boeing Co

(72) Inventors

Charles R. Prebil; James R. Fox

(54) Title

System and method of joining components

(57) Abstract

A method of forming a structural assembly may include providing a first component and a second component to be joined together. The method may additionally include scanning a contour of a first mating surface of the first component and scanning a contour of a second mating surface of the second component. The method may further include producing a thermoplastic element having opposing first and second element surfaces substantially matching a contour of the first mating surface and the second mating surface.

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Claims (20)

A method of joining components, comprising the steps of: providing a first component having a first mating surface, the first mating surface having a first contour; providing a second component having a second mating surface to be joined to the first mating surface, the second mating surface having a second contour; and scanning at least one of the first mating surface and the second mating surface to respectively determine the first contour and the second contour; additively manufacturing, based on the scanning, a unitary solid thermoplastic element directly onto at least one of the first component and the second component prior to assembly with a remaining one of the first component and the second component, the thermoplastic element having at least one of a first element surface and a second element surface respectively substantially matching the first contour and the second contour.
The method of claim 1, wherein: the first contour of the first mating surface has a mismatch with the second contour of the second mating surface.
The method of claim 1, wherein the step of additively manufacturing the thermoplastic element comprises: additively manufacturing a thermoplastic sheet having at least one of a first sheet surface and a second sheet surface substantially matching the first contour and the second contour.
The method of claim 1, wherein the step of additively manufacturing the thermoplastic element comprises: producing the thermoplastic element with at least one of opposing first and second element surfaces substantially matching a respective contour of a first thermoplastic film and a second thermoplastic film respectively applied to the first mating surface and the second mating surface.
The method of claim 1, wherein the first mating surface includes a first radius surface, the step of additively manufacturing the thermoplastic element comprises: additively manufacturing a thermoplastic radius filler having at least one of a radius filler side surface and a radius filler base surface substantially matching a respective contour of the first radius surface and the second mating surface.
The method of claim 5, wherein the step of additively manufacturing the thermoplastic element comprises: integrally forming a thermoplastic sheet with the thermoplastic radius filler; and the thermoplastic sheet having at least one of a first sheet surface and a second sheet surface substantially matching the first contour and the second contour.
The method of claim 1, wherein the step of scanning includes: scanning using a digital scanner, a camera, a coordinate-measuring machine, or any combination thereof.
The method of claim 1, wherein the step of additively manufacturing the thermoplastic element directly onto at least one of the first component and the second component comprises: additively manufacturing the thermoplastic element directly onto at least one of a first thermoplastic film of the first component or a second thermoplastic film of the second component.
The method of claim 1, further comprising the step of: assembling the first component and the second component with the thermoplastic element sandwiched therebetween; and fusing together the thermoplastic element, a first thermoplastic film, and a second thermoplastic film to form a thermoplastic joint joining the first component to the second component.
The method of claim 9, wherein the step of fusing comprises: heating at least one of the thermoplastic element, the first thermoplastic film, and/or the second thermoplastic film to at least a glass transition temperature thereof.
The method of claim 9, wherein the thermoplastic element includes a thermoplastic sheet, the step of fusing includes: compressing a thermoplastic sheet sandwiched between the first component and the second component.
The method of claim 9, wherein the step of additively manufacturing the thermoplastic element includes: additively manufacturing the thermoplastic element from material having a glass transition temperature that is lower than a melt temperature of the first component and/or the second component.
The method of claim 9, wherein the step of additively manufacturing the thermoplastic element includes: additively manufacturing the thermoplastic element from material that is substantially similar to the material of the first thermoplastic film and/or the second thermoplastic film.
The method of claim 1, wherein: the first component and/or the second component is formed of a thermoset material or a thermoplastic material.
The method of claim 1, wherein the step of providing the first component and the second component comprises: forming the first component and/or the second component by co-consolidating a thermoplastic film with a stack of plies of thermoplastic prepreg.
The method of claim 1, wherein the step of providing the first component and the second component comprises: forming the first component and/or the second component by co-curing a thermoplastic film with a stack of plies of thermoset prepreg.
The method of claim 1, wherein the step of additively manufacturing comprises one of: three-dimensional printing, stereolithography, and direct digital manufacturing.
A method of joining components, comprising the steps of: providing a first component having a first thermoplastic film applied to a first mating surface; providing a second component having a second thermoplastic film applied to a second mating surface; scanning the first thermoplastic film and the second thermoplastic film to determine a contour thereof; additively manufacturing, based on the scanning, a unitary solid thermoplastic element directly onto at least one of the first thermoplastic film and the second thermoplastic film prior to assembly with a remaining one of the first component and the second component, the thermoplastic sheet being formed from material that is substantially similar to the first thermoplastic film and/or the second thermoplastic film, the thermoplastic sheet having at least one of a first sheet surface and a second sheet surface respectively matching the contour of the first mating surface and the second mating surface; assembling the first component and the second component with the thermoplastic sheet sandwiched therebetween; applying heat and compactive pressure to the thermoplastic sheet, the first thermoplastic film, and/or the second thermoplastic film; and fusing together the thermoplastic sheet, the first thermoplastic film, and the second thermoplastic film to join the first component to the second component to form a structural assembly.
The method of claim 18, wherein the step of additively manufacturing comprises one of: three-dimensional printing, stereolithography, and direct digital manufacturing.
A method of joining components, comprising the steps of: providing a first component having a first thermoplastic film applied to a first mating surface, the first mating surface including a first radius surface; providing a second component having a second thermoplastic film applied to a second mating surface; scanning the first thermoplastic film and the second thermoplastic film to determine a contour thereof; additively manufacturing, based on the scanning, a unitary solid thermoplastic radius filler directly onto the second mating surface prior to assembly with the first component, the radius filler having a radius filler side surface substantially matching a contour of the first radius surface; assembling the first component and the second component with the thermoplastic radius filler sandwiched therebetween; applying heat and compactive pressure to the thermoplastic radius filler, the first thermoplastic film, and/or the second thermoplastic film; and fusing together the first thermoplastic film, the second thermoplastic film, and/or the thermoplastic radius filler to join the first component to the second component to form a structural assembly.

Description

The present disclosure relates generally to processes for joining structural components and, more particularly, to processes for joining components using thermoplastic films.

Composite materials and components are used in ever-increasing amounts in a wide variety of applications. For example, commercial aircraft are incorporating increasing amounts of composite materials into primary structure and secondary structure due to the favorable mechanical properties of composite materials. Such favorable mechanical properties may allow for a reduction in weight and an increase in payload capacity and fuel efficiency of an aircraft. In addition, the use of composite materials may extend the service life of the aircraft.

Laminated composite components may be joined together using several techniques. For example, composite components may be joined using mechanical fasteners which may require drilling fastener holes in the components using specialized drill bits. Following the drilling of the fasteners holes, disassembly of the composite components may be required to allow for de-burring and/or inspection of each fastener hole, followed by re-assembly of the composite components. Mechanical fasteners may be installed in the fastener holes and the fasteners may be tightened to a predetermined torque value. As may be appreciated, the use of mechanical fasteners for joining composite components may require multiple steps resulting in a time-consuming and labor-intensive process.

Composite components may also be joined together without mechanical fasteners by bonding the components together using an adhesive.

Citations (12)

US5264059A
US6174392B1
US20030154801A1
US20040236454A1
US7208057B2
US20090154775A1
US20120148789A1
US20110139932A1
WO2012156525A1
US20140079903A1
US20130344291A1
US20140216638A1

Record as JSON

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  "publication_number": "US9358764B2",
  "country": "US",
  "kind": "B2",
  "title": "System and method of joining components",
  "abstract": "A method of forming a structural assembly may include providing a first component and a second component to be joined together. The method may additionally include scanning a contour of a first mating surface of the first component and scanning a contour of a second mating surface of the second component. The method may further include producing a thermoplastic element having opposing first and second element surfaces substantially matching a contour of the first mating surface and the second mating surface.",
  "claims": [
    "1. A method of joining components, comprising the steps of: providing a first component having a first mating surface, the first mating surface having a first contour; providing a second component having a second mating surface to be joined to the first mating surface, the second mating surface having a second contour; and scanning at least one of the first mating surface and the second mating surface to respectively determine the first contour and the second contour; additively manufacturing, based on the scanning, a unitary solid thermoplastic element directly onto at least one of the first component and the second component prior to assembly with a remaining one of the first component and the second component, the thermoplastic element having at least one of a first element surface and a second element surface respectively substantially matching the first contour and the second contour.",
    "2. The method of claim 1, wherein: the first contour of the first mating surface has a mismatch with the second contour of the second mating surface.",
    "3. The method of claim 1, wherein the step of additively manufacturing the thermoplastic element comprises: additively manufacturing a thermoplastic sheet having at least one of a first sheet surface and a second sheet surface substantially matching the first contour and the second contour.",
    "4. The method of claim 1, wherein the step of additively manufacturing the thermoplastic element comprises: producing the thermoplastic element with at least one of opposing first and second element surfaces substantially matching a respective contour of a first thermoplastic film and a second thermoplastic film respectively applied to the first mating surface and the second mating surface.",
    "5. The method of claim 1, wherein the first mating surface includes a first radius surface, the step of additively manufacturing the thermoplastic element comprises: additively manufacturing a thermoplastic radius filler having at least one of a radius filler side surface and a radius filler base surface substantially matching a respective contour of the first radius surface and the second mating surface.",
    "6. The method of claim 5, wherein the step of additively manufacturing the thermoplastic element comprises: integrally forming a thermoplastic sheet with the thermoplastic radius filler; and the thermoplastic sheet having at least one of a first sheet surface and a second sheet surface substantially matching the first contour and the second contour.",
    "7. The method of claim 1, wherein the step of scanning includes: scanning using a digital scanner, a camera, a coordinate-measuring machine, or any combination thereof.",
    "8. The method of claim 1, wherein the step of additively manufacturing the thermoplastic element directly onto at least one of the first component and the second component comprises: additively manufacturing the thermoplastic element directly onto at least one of a first thermoplastic film of the first component or a second thermoplastic film of the second component.",
    "9. The method of claim 1, further comprising the step of: assembling the first component and the second component with the thermoplastic element sandwiched therebetween; and fusing together the thermoplastic element, a first thermoplastic film, and a second thermoplastic film to form a thermoplastic joint joining the first component to the second component.",
    "10. The method of claim 9, wherein the step of fusing comprises: heating at least one of the thermoplastic element, the first thermoplastic film, and/or the second thermoplastic film to at least a glass transition temperature thereof.",
    "11. The method of claim 9, wherein the thermoplastic element includes a thermoplastic sheet, the step of fusing includes: compressing a thermoplastic sheet sandwiched between the first component and the second component.",
    "12. The method of claim 9, wherein the step of additively manufacturing the thermoplastic element includes: additively manufacturing the thermoplastic element from material having a glass transition temperature that is lower than a melt temperature of the first component and/or the second component.",
    "13. The method of claim 9, wherein the step of additively manufacturing the thermoplastic element includes: additively manufacturing the thermoplastic element from material that is substantially similar to the material of the first thermoplastic film and/or the second thermoplastic film.",
    "14. The method of claim 1, wherein: the first component and/or the second component is formed of a thermoset material or a thermoplastic material.",
    "15. The method of claim 1, wherein the step of providing the first component and the second component comprises: forming the first component and/or the second component by co-consolidating a thermoplastic film with a stack of plies of thermoplastic prepreg.",
    "16. The method of claim 1, wherein the step of providing the first component and the second component comprises: forming the first component and/or the second component by co-curing a thermoplastic film with a stack of plies of thermoset prepreg.",
    "17. The method of claim 1, wherein the step of additively manufacturing comprises one of: three-dimensional printing, stereolithography, and direct digital manufacturing.",
    "18. A method of joining components, comprising the steps of: providing a first component having a first thermoplastic film applied to a first mating surface; providing a second component having a second thermoplastic film applied to a second mating surface; scanning the first thermoplastic film and the second thermoplastic film to determine a contour thereof; additively manufacturing, based on the scanning, a unitary solid thermoplastic element directly onto at least one of the first thermoplastic film and the second thermoplastic film prior to assembly with a remaining one of the first component and the second component, the thermoplastic sheet being formed from material that is substantially similar to the first thermoplastic film and/or the second thermoplastic film, the thermoplastic sheet having at least one of a first sheet surface and a second sheet surface respectively matching the contour of the first mating surface and the second mating surface; assembling the first component and the second component with the thermoplastic sheet sandwiched therebetween; applying heat and compactive pressure to the thermoplastic sheet, the first thermoplastic film, and/or the second thermoplastic film; and fusing together the thermoplastic sheet, the first thermoplastic film, and the second thermoplastic film to join the first component to the second component to form a structural assembly.",
    "19. The method of claim 18, wherein the step of additively manufacturing comprises one of: three-dimensional printing, stereolithography, and direct digital manufacturing.",
    "20. A method of joining components, comprising the steps of: providing a first component having a first thermoplastic film applied to a first mating surface, the first mating surface including a first radius surface; providing a second component having a second thermoplastic film applied to a second mating surface; scanning the first thermoplastic film and the second thermoplastic film to determine a contour thereof; additively manufacturing, based on the scanning, a unitary solid thermoplastic radius filler directly onto the second mating surface prior to assembly with the first component, the radius filler having a radius filler side surface substantially matching a contour of the first radius surface; assembling the first component and the second component with the thermoplastic radius filler sandwiched therebetween; applying heat and compactive pressure to the thermoplastic radius filler, the first thermoplastic film, and/or the second thermoplastic film; and fusing together the first thermoplastic film, the second thermoplastic film, and/or the thermoplastic radius filler to join the first component to the second component to form a structural assembly."
  ],
  "description_excerpt": "The present disclosure relates generally to processes for joining structural components and, more particularly, to processes for joining components using thermoplastic films.\n\nComposite materials and components are used in ever-increasing amounts in a wide variety of applications. For example, commercial aircraft are incorporating increasing amounts of composite materials into primary structure and secondary structure due to the favorable mechanical properties of composite materials. Such favorable mechanical properties may allow for a reduction in weight and an increase in payload capacity and fuel efficiency of an aircraft. In addition, the use of composite materials may extend the service life of the aircraft.\n\nLaminated composite components may be joined together using several techniques. For example, composite components may be joined using mechanical fasteners which may require drilling fastener holes in the components using specialized drill bits. Following the drilling of the fasteners holes, disassembly of the composite components may be required to allow for de-burring and/or inspection of each fastener hole, followed by re-assembly of the composite components. Mechanical fasteners may be installed in the fastener holes and the fasteners may be tightened to a predetermined torque value. As may be appreciated, the use of mechanical fasteners for joining composite components may require multiple steps resulting in a time-consuming and labor-intensive process.\n\nComposite components may also be joined together without mechanical fasteners by bonding the components together using an adhesive.",
  "cpc": [
    "B32B 37/15",
    "B29C 65/02",
    "B29C 65/4815",
    "B29C 65/5021",
    "B29C 65/5057",
    "B29C 65/5078",
    "B29C 66/02241",
    "B29C 66/112",
    "B29C 66/131",
    "B29C 66/3494",
    "B29C 66/43441",
    "B29C 66/474",
    "B29C 66/524",
    "B29C 66/71",
    "B29C 66/721",
    "B29C 66/72141",
    "B29C 66/72143",
    "B29C 66/73117",
    "B29C 66/73755",
    "B29C 66/7392",
    "B29C 66/73921",
    "B29C 66/7394",
    "B29C 66/73941",
    "B29C 66/81455",
    "B29C 66/82423",
    "B29C 66/8322",
    "B29C 66/83221",
    "B29C 66/91411",
    "B29C 66/919",
    "B32B 37/02",
    "B32B 37/18",
    "B32B 41/00",
    "B33Y 80/00",
    "Y10T 156/10"
  ],
  "ipc": [
    "B32B 37/02",
    "B32B 37/15",
    "B32B 37/18",
    "B32B 41/00",
    "B64F 5/00",
    "B64F 5/10",
    "B29C 65/00",
    "B29C 65/02",
    "B29C 65/48",
    "B29C 65/50"
  ],
  "assignees": [
    "Boeing Co"
  ],
  "inventors": [
    "Charles R. Prebil",
    "James R. Fox"
  ],
  "filing_date": "2014-02-18",
  "publication_date": "2016-06-07",
  "grant_date": "2016-06-07",
  "priority_date": "2013-12-17",
  "application_number": "US-201414183006-A",
  "family_id": "51897099",
  "cited_by_count": 25,
  "citations": [
    "US5264059A",
    "US6174392B1",
    "US20030154801A1",
    "US20040236454A1",
    "US7208057B2",
    "US20090154775A1",
    "US20120148789A1",
    "US20110139932A1",
    "WO2012156525A1",
    "US20140079903A1",
    "US20130344291A1",
    "US20140216638A1"
  ]
}

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