CA2070830A1 - Composite material - Google Patents

Composite material

Info

Publication number
CA2070830A1
CA2070830A1 CA002070830A CA2070830A CA2070830A1 CA 2070830 A1 CA2070830 A1 CA 2070830A1 CA 002070830 A CA002070830 A CA 002070830A CA 2070830 A CA2070830 A CA 2070830A CA 2070830 A1 CA2070830 A1 CA 2070830A1
Authority
CA
Canada
Prior art keywords
composite material
fastener
layers
vacuum bag
stacks
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
CA002070830A
Other languages
French (fr)
Inventor
Robert S. Wilson
Mark A. Braniff
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Short Brothers PLC
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of CA2070830A1 publication Critical patent/CA2070830A1/en
Abandoned legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/562—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits using extra joining elements, i.e. which are not integral with the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/02—Bending or folding
    • B29C53/04—Bending or folding of plates or sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/483—Reactive adhesives, e.g. chemically curing adhesives
    • B29C65/4835—Heat curing adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5064—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like of particular form, e.g. being C-shaped, T-shaped
    • B29C65/5071—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like of particular form, e.g. being C-shaped, T-shaped and being composed by one single element
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5064—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like of particular form, e.g. being C-shaped, T-shaped
    • B29C65/5078—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like of particular form, e.g. being C-shaped, T-shaped and being composed by several elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5064—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like of particular form, e.g. being C-shaped, T-shaped
    • B29C65/5085—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like of particular form, e.g. being C-shaped, T-shaped and comprising grooves, e.g. being E-shaped, H-shaped
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/562—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits using extra joining elements, i.e. which are not integral with the parts to be joined
    • B29C65/564—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits using extra joining elements, i.e. which are not integral with the parts to be joined hidden in the joint, e.g. dowels or Z-pins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/72—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by combined operations or combined techniques, e.g. welding and stitching
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/434—Joining substantially flat articles for forming corner connections, fork connections or cross connections
    • B29C66/4342—Joining substantially flat articles for forming corner connections, e.g. for making V-shaped pieces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/434—Joining substantially flat articles for forming corner connections, fork connections or cross connections
    • B29C66/4344—Joining substantially flat articles for forming fork connections, e.g. for making Y-shaped pieces
    • B29C66/43441—Joining substantially flat articles for forming fork connections, e.g. for making Y-shaped pieces with two right angles, e.g. for making T-shaped pieces, H-shaped pieces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
    • B29C66/474—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially non-flat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/52—Joining tubular articles, bars or profiled elements
    • B29C66/524—Joining profiled elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8145—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/81455—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the constructional aspects of the pressing elements, e.g. of the welding jaws or clamps being a fluid inflatable bag or bladder, a diaphragm or a vacuum bag for applying isostatic pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/832—Reciprocating joining or pressing tools
    • B29C66/8322—Joining or pressing tools reciprocating along one axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91411—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature of the parts to be joined, e.g. the joining process taking the temperature of the parts to be joined into account
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9141—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature
    • B29C66/91441—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature the temperature being non-constant over time
    • B29C66/91443—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the temperature the temperature being non-constant over time following a temperature-time profile
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/919—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges
    • B29C66/9192—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams
    • B29C66/91951—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux characterised by specific temperature, heat or thermal flux values or ranges in explicit relation to another variable, e.g. temperature diagrams in explicit relation to time, e.g. temperature-time diagrams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
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    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
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    • B29L2031/3076—Aircrafts
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B15/00—Nails; Staples
    • F16B15/0015—Staples

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Textile Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Moulding By Coating Moulds (AREA)
  • Adhesives Or Adhesive Processes (AREA)
  • Laminated Bodies (AREA)

Abstract

2070830 9108892 PCTABS00005 A composite material is manufactured from two spaced stacks (2 and 4) of intermediate fabric material. Each stack consists of a plurality of layers of material placed together face to face. Each layer is formed by embedding high strength fibres having a high modulus of elasticity in a resin matrix. The stacks (2 and 4) are removed from a release film (6), and a film of adhesive is applied to the lower surface of the side portion (8) of the stack (2) and the upper surface of the side portion (10) of the stack (4). These side portions (8 and 10) are placed in overlapping relationship, and are then crimp fastened together by a plurality of fasteners (12). Further layers (14 and 16) of intermediate fabric material are placed over the side portions (8 and 10) to cover the fasteners (12). The crimp fastened stacks (2 and 4) are placed in a mould tool comprising a base plate (18) and a top mould plate (20). A vacuum bag (22) is placed over the top mould plate (20), and an air tight seal is made between the vacuum bag (22) and the base plate (18) by means of a peripheral sealer tape (24). The space inside the vacuum bag (22) is evacuated by withdrawing air through a passage (34) at one edge of the vacuum bag (22). The fastened stacks (2 and 4) are compressed by bringing together the plates (18 and 20), and the mould tool and vacuum bag assembly is then heated in an autoclave to cure the stacks (2 and 4) while they remain under pressure to form the required composite material. After the curing operation has been completed, the mould tool and vacuum bag assembly is removed from the autoclave, the vacuum bag (22) is removed, the mould plates (18 and 20) are separated, and the cured composite material is removed.

Description

2 PCl/GB90/01903
3 1 ~ ? ~
- 1- 2(~70~330 A CO~POSITE ~ATERIAL

.. . . ..
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The present invention relates to a method of manufacturing a composite material, such as for example a composite material particularly suitable for forming the outer surface ~aterial of an aircraft.
.
The term "material" includes any suitable component o:r structure, such as for example a laminate joint, depending on the application of the invention.

A previously proposed composite material has been manu~'actured by embedding high strength f ibres having a high modulùs o~' elasticity within a homogenous matrix.
In one example of such a material, the fibres are made of carbon, aramid or boron, and the matrix can be formed of material sùch as an epoxy, bismalemide or polyimide .
resin.

The flbres are supplied in a uni-directional,.woven.or fibrous mat format which i5 pre-impregnated with slightly cured resin to form an intermediate.fabric material. ..
This intermediate fabric material is flexi~le and tacky, and the positions of the fibre filaments therein are.not flxed. Layers of these intermediate fabric materials are assembled one upon the.other.~in~a mould,lan,d.then. .,f~.
compressed and heated. The heating action accelerates the curing of the resin, and the combination.of.the .~-~heating ~nd compression joins together t~e~.intermediate fabric materials to form~the~c,omposite~.~aterial i -l;r ~
. . .
It is an aim of the invention to provide.an~improved..--..

. ~ . . . . ..
' ' ' ~ ' ~ " ~ , ' . ' ' ~07 ~83 ~ - 2 -method of manufacturing a composite material.

According to the present invention there is provided a method of manufacturing a composite material comprising placing together face to face a pluralit:y of layers of intermediate fabric material, each layer comprising high strength fibres having a high modulus of elasticity in a tacky homogeneous 'resin matrix, fastening together said layers at spaced locations thereon, and then compressing and heating the layer assembly to cure the resin.

One form of fastening together said layers is by the technique of crimp fastening. In the specification, by "crimp fastening" i's meant a process in which each leg of a fastener is forced'through at least two overlapping layers by direct pressure when the ~astener is either stationary or subject to mechanical rotation. When each leg of a fastener'protrudes through the overlapping layers to a required distance it is ëither crimped or punched in a controlled manner to produce a clamping or fastening action. Crimp fasteners may have any suitable number of legs, such as' for ~example'one, two or three legs as illustrated in ~igure 8''of the drawings, or may be of-a'spiral or hèiical`configura'tion as iilustrated in Figure 9'of the dr'awings. 'The fastener is made of any - suitable'm'aterial',i'sùch as for example'met`àl or plastics ~material,;càpa~le of''being''crimpèd or'punchèd to produce the réquirèd;clamping';or'fastèning action.
"~ r ,~
If desired;-thè~f~stëners may be covered by additional ' ~layeris~''ôf;intérmédi ~ ë'~fabri'c~matér'iaï'befiore the`
assembly'''is-heated"t3n'd"compress'ëd;

Embo'd'iménts of thè'~in'vèntlontwill~now'bè`'déscribed by way ' _ 3 _ 2Q7~30 of example with reference to the accompanying dirawings in ; which:- .
4 Figs. la, lb and lc are diagrammatic il:Lustrations of three stages in the manufacture of a composite material;

Fig. 2 is a perspective~.view showing.one stage in the preparation of,the Fomposite materiali Fig. 3 is a sectional elevation O~r the composite material in a mould tool;

Fig. 4 is a detailed sectional elevation of part of the composite material located.in a mould tool; .

Fig. 5 is a perspective view showing one stage in the preparation of a fur~her.composite material;
.... . .
.. . . . . . . ......... .. . .
Figs..6 and 7 are diagrammatic illustrations of two examples of.crimp fasteners for use in the preparaition of .,. ,the.composite..material; , -.,i . .~i;-. : : ..
.. ., _ . .. .. .
.. .. .... . .
r,,~,Figs 8,and 9.are.diagrammatic.illustrations of fu~ther .,,examples;.,of,,crimp fasteners,for,use in.~.the.preparation of the~composite-~materia~ ?~ 3:

Fiy."lo is.ja.diagram .of an.Joperationalicycle of.,the.
invent,~io-n;~ .S ~ 5~ J'r ' '` - '' ''`~' -`'i ;~ ` ' ~ ' '' Fig.,~ll is,a-,diagrammatic.;illustration of examples of skin stiffening configurations~which~are..suitable.for the ,crimp fastening~ethod,of~the~invention; ~r~
~ ~?~t -~ ~3 ~ ~q ~!'.'!'-t ~t~ ; s ~ ~r i~ r... ..
,~,.;,Fig..,l2~i~c.asdiagrammatic~illustration c3f examples.of ; composite. fasteners.of.. the in~ention,,and .. ,~. .. .
.. , . . ~ .. .. .. . . . . . . .. . ... . . . .. . . .. . .

~' .

, n f~
:.: ;...

Fig. 13 is a diagrammatic illustration of stages in the : manufacture of a composite material using composite fasteners.
.
Referring to the drawings, and particula:rly to Fig. 1, in one embodimènt transversely spaced stacks 2 and 4 of intermediatè fabric material a~`e supplied on a release film 6. These stacks have been compacted or debulked under vacuum at room temperature. This compaction or debulking gives to each stack a degree of structural rigidity which aids assembly of the proposed composite material. Each stack'consists of a plurality of layers of the material placed together face to face. Each layer of intermediate fabric material is formed by embedding high strength f.ibres having a hiyh modulus of elasticity in a homogeneous matrix which may be an epoxy, bismalemide or a polyimide resin. The fibres may be uni-directional, woven or in the form~of a fibrous mat,: and thé fibres may be made of màterials such as carbon,~
aramid or boron. Each intermediate fabric-material layer is supplied with the resin matrix slightly cured to ensure that the fabrici-layer:is`'tacky'and flexible, and àt~this'3stage';~he fl'bres'are~not in a'fixed~position'in the matrix. The stacks 2 and 4'are rectangular`in shape.

The!'reièase film~63is-`rëmovéd from~the~stacks 2 and i, and a film of adhesive is applied to the lowër surface of the side portion 8 of the stack 2, and the upper surface of the-isidè portion!'1O of thè;stack 4.~ These side' '~ ' .
portions-'8Jànd''~o~'are'~;t~en~placied'''in~overlapping !'r-"':
relationship as~shown-~ln';Fig.-'1b~ Each"iside~'portion~is ' , , in the form of a strip running parallel to one edge of: . -the appropriate stack?2i~or 4.~ Thesë sideiportions 8`~and 10 are then crimp fastened together^by-a plurality-of WOgl/08892 PCT/GB90/01903 (~ ,'!
" ,~ 20,,~ 3 Q

fasteners 12 which are spaced along the side portions 8 and 10. As shown in Fig. lc, further layers 14 and 16 of intermediate fabric material are placed over the sidP
portions 8 and 10 to cover the fasteners 12.

Referring to Fig. 3, the crimp fiastened stacks 2 and 4 of intermediate fabric material are placed in a mould tool comprising a base plate-18 and a top mould plate 20. A
vacuum bag 22 is placed over the top mould plate 20, and an.airtight seal is made between the vacuum bag 22 and the base plate 18 by means of a peripheral sealer tape 24. . . .

Fig. 4 provides a more detailed illustration of part of the mould..tool of Fig. 3, and for clarity corresponding components in Figs. 3 and 4 have been given the same reference numerals. A release film 26 is located between the crimp fastened stacks 2 and 4 and the top mould plate 20 to.prevent the.tacky upper.:sur~ace of-the stacks-;;
adhering to.the plate-.20.~,: Simi'larly, a,release agent 28 is;located below.the stacks 2.and 4 ,to,,prevent these:
stacks,-from adhering.to::the,mould base plate 18.-:An~edge breather 30 extends round the base plate 18,adjacent to the edge of the vacuum bag 22, and a surface breather 32 of,rplat-e~form is..located~near.~the~upper portion~of~the vacuum.bag,~22.~ This surface-breather,J'32 has~an area'i slightly less than the area of the top of the:vacuum.'~bag 22. RPferring to Fig. 3, the space inside the vacuum bag 22 is evacuated by withdrawing air,~through a passage~34 _at'one~edge:_o~,the,,:vacuum.bag-~22.~ The~edge~breather-~30 andl~hecsurf.ace:breather..~32 assist in ens'uring_that.~air is withdrawn from substantially the entire region covered by the.-,vacuum bag 22,~ and.,that the vacuum--bàg`-22 does not wrinkle:or distort unduly.durinq evacuation.

.

WO 91/08892 PCI'/GB90/01903 o~ ~3~

In operation, the space under the vacuum bag 22 is evacuated, the crimp fastened stacks 2 and 4 are compressed by ~ringing together the mould pla~es 18 and 20, and the mould tool and vacuum bag assembly is then heated in an autoclave~t'o cure the crimp fastened stacks 2.and 4 while they rem'ain under pressure to form the required composite material. After the curing operation has been completed, the mould tool and vacuum bag assembly is removed from the autoclave, the vacuum bag 22 is removed,.the mould plates 18 and 20 are separated, and , the cured composite material is removed from between the separated mould plates 18 and 20.

,The invention also includes within its scope the above-mentioned method of manufacturing a composite material in which the top mould plate 20 is not used. In this alternative method the required degree of compression is obtained between the vacuum bag 22 and the base plate 18.
:The top mould plate is used (l) to produce a composite material ha~ing a:.tool:finish on both major surfaces,.~2) to dissipate-the autoclave pressure through the fasteners 12,and the,debulked stacks 2:and 4, and t3) to form the integral stiffening or structural element where~ m-applicable;

,Any~suitable..~orm of crimp:fastener may..be:.used,,and.
Figs. 6 to.:9 illustrate.!suitable examples of crimp..:, ..Jfasteners.,~ ~O ~ r,~ e .'ie''..' , ,',.'~ ?
rJ U -; ,~ ' t ~! C~ . .., 1~ .,.t.~
These-,crimp.-fasteners~:can be separably~-attached to one another~.in^a.:stacX to.facilitate..loading.into a:crimpiny machine~similar to a-conventional.ind~str.iai.~.stapler;i ', Fig. 5;illustrates the various~stages.-of.:fastening .~
together two:stacks of intermediate fabric material. iIn WO91/08892 PCT/GB9b/01903 ~.
~''`''.`' ,,,,,~

: the example of Fig. 5 however one stack 36 is in the form of a planar sheet, and the other stack 38 is in the form of a C section stiffener or girder. The debulked C .
sec~ion stack 38 is crimp fastened to the debulked planar stack 36 in order to assist in correctly locating the structure onto the base plate 18..
.
, , , . ~ ......... ... .. . . .. ... . . .
The method of the described.and illustrated embodiment provides a composite structure which is self sealing, and does not require expensive post jigging or drilling of the cured structure.

In a typical cure cycle of a composite material prepared by the method of the invention.the maximum cure pressure is in the range ~rom 5.86x105 to 6.89xlOsN/m2 with a.
maximum cure temperature of 179 + 5C maintained over a periodjof 120 ~ 5 minutes, a heat up rate of 0.5 to 2.5C
per.minute and a.maximum cool...down-rate of.2.5C per .... . .. . . .
minute. By "cure pressure".~is meant.the pressure inside the autoclave, and hence the external pressure exerted on the vacuum bag.~22. ..~

.. _ A full-vacuum.is'applied to the~interior of the mould ~ tool..and.vacuum.bag assembly.~. This..eguates to an ..... i .. . . .. . . . . . .. .. .. .. .. .... . . . . .. . . .. . .
external pressure of 1.013x105N/m2 (14.7 psig) which is produced..by.the column.of.air. acting.vertically above the vacuum bag 22.. The~.;minimum pressure.allowable on a vacuum bagged part placed in the autoclave before commencing~jthe.cure~cycle.~is}20".Hgj(0.65?xlO5N/m2). This ~ vacuum.~serves.to.. maintain the position~of.the bag, .: breather,3etc.. ,overj~vthe crimp fastened,stacks 2 and 4.
~ ;- J .~Jft3 .' f~ffILrl r.lT ~ ~ .C?~J.^:.f~,~it'f,~ n~
The ~acuum line connecting3the bagged part.and the vacuum pump which pr~duces the 0.667xlO5N/m~ minimum pressure is vented~to the.atmosphere.outside;the autoclave once the ;

. '- , .:

WO91/088~2 PCr/GB90/01903 internal autoclave pressure reaches 1.38x10sN/m2 (20psig).
The reason for this action is because once the autoclave pressure exceeds 1.013xlOsN/m2 (14.7psig~ there is no longer any advantage in applying a vacuum.

The statement "maintain pressure under vacuum bag of 0 to .345xl05N/m2" refers to:back pressure. Pressure may be 'generatéd under the vacuum bag by volatiles emitted by the curing prepreg and by-small leaks in the vacuum bag allowing autoclave pressure through to the vent line.
This tolerance of 0 to .345xl05N/m2 must not be exceeded since greater back pressure produces inferior components.

The described and illustrated embodiment of the invention possesses the following advantageous feàtures:-(a) (i) Imprc,ved'impact resistance, tensile, peel, shear strength and improved resistance to -- crack'propagation.'':' ~ii) The structural elements of these `
fasteners (staple flanges) can be placed to '- ~ '' align more-closely with-the applied loads than ''`' "' the~elements of''standard mech'anical`fastènérs.

(b)~ 'r'Overcomes't~e main p,roblemsi' àssoc'iate~-with standard:mèchanical''joints, i.é. ''-'' '' ' '(ij ? Any'`lncrease-in laminàte thickness~
normally';requiréd for-'mechani'cal''fàstening~is ~'5 ' 2~réduced'~to~'an ab'solute:mini'mum'~(~ecause-any damage to the laminate is minimal and to a ,,,,,~ -,!,, ~---degree--ls self-repairing). ''l~- ~ '--' '-' ' '' '~;'': :'':"(ii):-Typical problems associated with -WO91/08892 PCT/GB90~01903 .
f.'~ J^, ~ ' . ` 7 g mechanical fastening are avoided, i.e.
problems associated with drilling, jigging, counter sinking, riveting, etc.
r (iii) The joints are self sea:Ling and are therefore ideal for use against the environment and for containing fuel ~in a wet wing).

- (iv) The joints are more weight efficient than other mechanical fastened joints.
.. . . .
(v) The joints are aerodynamically smooth on the air wet surfaces and therefore any filling/~eathering/smoothing countersinking operations are not required.

(c) The joints can be used for local reinforcement, for example, at the "end" of stiffening - elements`to~

- -- (i)~~--Act~as anti-peel~fasteners-(used in a similar role for aluminium'-bonded stiffeners).

(ii) Accurately secure khe''structural elements ';'-`'`'- ~ ' in position prior'to and during the cure operation. "~

(d~ ''t-r!`.''jThe~fastening of thè !` mechanical'3'e'1ements is more labour efficient'than other'mechanical '''`'-~ -3~fasten'ing'te'chniquesi~bécaus'e~it'1jis completed in .~0.L~ C''~ n ~ one'efficient~rautomated-~`~opéra't'i~o'n;
. . .
.
(e) Any complications:usually-:invo'lved with ''I
i` r '~ ( fasteners''in:'a ~fuei'~cell''enviro'nment',-'e.g.'`the ;`risk'of arc plasm~:blow'by qs avoided bec:ause .. ' ' '' ' " ' . ' , ' ' ', : ' . ~' '' ' ' ~ :
, . . ,. , ~ : . . .: . , . ,, ~ . . .

WO 91/08$92 P~/GB90/01903 9~

the fasteners can be encapsulated into the , structure.

(f) Can be located in areas where extra securement is required and where fasteners would not normally be,employed, e.g. blade, stiffener , webs. , I

- (g) Crimp fastening may ~e employed to improve the through thickness structural strength of advanced composites (i.e. prevents delamination ' of the plies).

Recommended cure cycles for the method of the invention are as follows~

(a) Simple components:
Apply 700 kN/m2,pressure.
Heat to 175C at 1 to 20C per minute.
Cure ~or 1 hour at 175C.
~ , Cool;to below 60C before pressure removal and " ,,~ ,,,components,,ejection. ,,-, ~. ,,, ~--,(b) :i - Optimum,cycle:~ ~ ,,,, ",,, "~
, Heat,under,vacuum only,to 120C at 1 to 20C
per minute. ~ -- ,, When component reaches 120C apply 700 kN/m2 '~ '! pressure,and vent component,,to atmosphere.;, ~ -Continue,,heating,to,175~,C .rl.~
,~- ,,c,-,-,,~ -- ,-ure for,~ hour~at_.175,C and~cool;to 60C
before-,pressure-remo~al~,and,component ejection.
. . .
(c) ~ hi,c,k,c,omponent5 ~i",,,~ ;
To,avoid,exotherm on ~hick,components (>lOmm) it is - advi~able to incorporate a,;dwell of-2 to,3 hours at 130C
~ .
.
- : : . :.
: ~
.
:
: ~ :

WO91/08~92 PCT/GB90/01903 f; - ~.

2 ~7 0 ~3 ~
to 135C in the cure cycle mentioned in ~b) above.

The crimp fasteners of the-embodiment illustrated in Figs. 1 to 11 are made of any suitable m~etal or metal alloy.

Referring to Figs. 12-and 13, in a second embodimentj the layers of composite material may be fastened together by means of-composite--fasteners. In the specification, by "composite fastener" is meant a fastener made of a plurality of layers of woven and uni-directional material. Each layer may be made of a thermosetting or thermoplastics material, including a reinforcement made of Kevlar, carbon or boron. These layers are placed together face to face to form a stack which is placed in a mould tool, and cured to a desired configuration. Fig.
12 illustrates several different configurations of fastener, and Fig. 13(a) illustrates the preparation and curing of a layer stack having a Z configuration.

Referring to ~ig. 13(b) and tc) the cured stack is then cut to form a plurality of Z configuration fasteners.
The spacing of the cuts in the layer stack will of course define the width of each fastener.

As shown in Fig. 13(d), first and second L-shaped stacks of layered intermediate fabric material ar~ placed back to back on a third generally planar stack of layered intermediate fabric material. The stack combination is placed on a steel base plate. This base plate constitutes the base of a mould tool as illustrated in Fig. 4 and described in ~he corresponding part of the ,. . .
description. A series of holes are formed in the base parts of the two L-shaped stacks and the coaxial parts of the third stack by means of a punch.
' ':

' ~Q~ 3~ ~ ~

~ 12 -The Z-shaped fasteners illustrated in Fig. 13(c) are inserted through their respective holes and rotated into theirifastening position as illustrated in Fig.,13(e).
In-order to assist the insertion of the fasteners,into the stacks, all or part of the stacks may be lifted from the steel base plate. The fasteners are inserted manually using a suitab],y shaped tweezer type tool.

The three-stacks and the inserted composite fasteners are then compressed and heated as previously described in the specification.

.. . ..

..... . ..... . .. . . .
,. .. . . . . . .
, . ,.. - .. . .. ,, ;
... .... . . . . . . . ... .
,. . ,~ . . . . . ..
~ -; ? ' . s r, ,.. . .. ~ .. .. .. .j,., . . . .. ~ ,. ..... ........ .. .

.t 3 .~ t , ;, ~ J
. . . ,' '~. ' . r - ,-1 . , '. , " '' .

Claims (19)

CLAIMS:
1. A method of manufacturing a composite material comprising placing together face to face a plurality of layers of intermediate fabric material, each layer comprising high strength fibres having a high modulus of elasticity in a tacky homogeneous resin matrix, fastening together said layers at spaced locations thereon, and then compressing and heating the layer assembly to cure the resin.
2. A method according to claim 1, characterised in that the layers are fastened together by means of a plurality of fasteners (12) located at said spaced locations, each fastener having at least one leg.
3. A method as claimed in claim 2, characterised in that each leg of a fastener is forced through at least two overlapping layers by direct pressure exerted on the fastener.
4. A method according to claim 3, characterised in that the fastener is subjected to mechanical rotation during the leg forcing operation.
5. A method according to claim 3 or 4, characterised in that each fastener leg is deformed in a controlled manner when it protrudes through the overlapping layers to a required distance so a to provide said fastening action.
6. A method according to claim 5, characterised in that each fastener leg is deformed by crimping.
7. A method according to claim 5, characterised in that each fastener leg is deformed by punching.
8. A method according to any one of claims 2 to 4, characterised in that the fasteners are covered by at least one additional layer (14, 16) of intermediate fabric material before the layer assembly is compressed and heated.
9. A method according to any one of claims 1 to 4 further including applying a first film of adhesive to the lower surface of the side portion of a first stack (2) of layers of intermediate fabric material, and a second film of adhesive to the upper surface of the side portion of a second stack (4) of layers of intermediate fabric material, placing said side portions in overlapping relationship, and fastening together said overlapping side portions at spaced locations thereon.
10. A method according to claim 9, characterised in that said stacks (2,4) are located in transversely spaced relationship on a release film (6) which is removed before the adhesive is applied.
11. A method according to any one of claims 1 to 4, characterised in that the layer assembly is compressed and heated under a vacuum.
12. A method according to claim 1, characterised in that holes are made through the assembled layers at said spaced locations, a Z shaped fastener is inserted in each hole, and the fastener is then rotated into its fastening position.
13. A composite material manufactured by the method of claim 2, characterised in that at least one fastener (12) is made of metal and includes at least one leg adapted to pass through at least two overlapping layers.
14. A composite material manufactured by the method of claim 12, characterised in that each fastener is made of a plurality of layers of woven and uni-directional material.
15. A composite material according to claim 14, characterised in that each layer is made of a reinforced thermosetting material.
16 A composite material according to claim 14, characterised in that each layer is made of a reinforced thermoplastics material.
17. A method of manufacturing a composite material substantially as herein described with reference to the accompanying drawings.
18. Apparatus for manufacturing a composite material substantially as herein described and shown in the accompanying drawings.
19. A composite material substantially as herein described and shown in the accompanying drawings.
CA002070830A 1989-12-07 1990-12-06 Composite material Abandoned CA2070830A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB898927734A GB8927734D0 (en) 1989-12-07 1989-12-07 A composite material
GB8927734.7 1989-12-07

Publications (1)

Publication Number Publication Date
CA2070830A1 true CA2070830A1 (en) 1991-06-08

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ID=10667605

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Country Link
EP (1) EP0504247A1 (en)
JP (1) JPH05501994A (en)
AU (1) AU6907991A (en)
BR (1) BR9007901A (en)
CA (1) CA2070830A1 (en)
FI (1) FI922471A7 (en)
GB (2) GB8927734D0 (en)
IL (1) IL96596A0 (en)
WO (1) WO1991008892A1 (en)

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105269878A (en) * 2014-07-18 2016-01-27 波音公司 Apparatus and methods for bonding laminate structures
CN105269878B (en) * 2014-07-18 2018-07-17 波音公司 Device and method for making laminate structures combine
US10538037B2 (en) 2014-07-18 2020-01-21 The Boeing Company Apparatus for bonding laminate structures
CN114055806A (en) * 2021-10-26 2022-02-18 成都飞机工业（集团）有限责任公司 Composite material hybrid skin forming method
CN114055806B (en) * 2021-10-26 2022-08-12 成都飞机工业（集团）有限责任公司 Composite material hybrid skin forming method

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FI922471A0 (en) 1992-05-29
AU6907991A (en) 1991-07-18
EP0504247A1 (en) 1992-09-23
GB9026576D0 (en) 1991-01-23
IL96596A0 (en) 1991-09-16
FI922471A7 (en) 1992-05-29
BR9007901A (en) 1992-09-22
WO1991008892A1 (en) 1991-06-27
GB8927734D0 (en) 1990-02-07
JPH05501994A (en) 1993-04-15
GB2238977B (en) 1994-01-05
GB2238977A (en) 1991-06-19

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