GB2122939A - Jointed composite articles - Google Patents

Jointed composite articles Download PDF

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Publication number
GB2122939A
GB2122939A GB08317291A GB8317291A GB2122939A GB 2122939 A GB2122939 A GB 2122939A GB 08317291 A GB08317291 A GB 08317291A GB 8317291 A GB8317291 A GB 8317291A GB 2122939 A GB2122939 A GB 2122939A
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GB
United Kingdom
Prior art keywords
constituent parts
article
edge
sheet member
bonding
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.)
Granted
Application number
GB08317291A
Other versions
GB2122939B (en
GB8317291D0 (en
Inventor
Peter James Aird
Dr James Francis Clemmet
Jeffrey Alan Dickinson
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.)
BAE Systems PLC
Original Assignee
British Aerospace PLC
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 British Aerospace PLC filed Critical British Aerospace PLC
Priority to GB08317291A priority Critical patent/GB2122939B/en
Publication of GB8317291D0 publication Critical patent/GB8317291D0/en
Publication of GB2122939A publication Critical patent/GB2122939A/en
Application granted granted Critical
Publication of GB2122939B publication Critical patent/GB2122939B/en
Expired legal-status Critical Current

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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
    • 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
    • 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
    • B29C65/5042—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 covering both elements 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
    • 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
    • B29C66/11—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
    • B29C66/114—Single butt joints
    • B29C66/1142—Single butt to butt 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
    • B29C66/40—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
    • B29C66/50—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
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B29C66/543—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles joining more than two hollow-preforms to form said hollow 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
    • B29C66/70—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
    • B29C66/70—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
    • B29C66/725—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 being hollow-walled or honeycombs
    • B29C66/7252—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 being hollow-walled or honeycombs hollow-walled
    • B29C66/72525—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 being hollow-walled or honeycombs hollow-walled comprising honeycomb cores
    • 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
    • B29C66/73—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 intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/737—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 intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
    • B29C66/7375—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 intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured
    • B29C66/73755—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 intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured the to-be-joined area of at least one of the parts to be joined being fully cured, i.e. fully cross-linked, fully vulcanized
    • B29C66/73756—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 intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured the to-be-joined area of at least one of the parts to be joined being fully cured, i.e. fully cross-linked, fully vulcanized the to-be-joined areas of both parts to be joined being fully cured
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B1/00—Layered products having a non-planar shape
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B32B15/092—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising epoxy resins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/38—Layered products comprising a layer of synthetic resin comprising epoxy resins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/06—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01Q—ANTENNAS, i.e. RADIO AERIALS
    • H01Q15/00—Devices for reflection, refraction, diffraction or polarisation of waves radiated from an antenna, e.g. quasi-optical devices
    • H01Q15/14—Reflecting surfaces; Equivalent structures
    • H01Q15/141—Apparatus or processes specially adapted for manufacturing reflecting surfaces
    • H01Q15/142—Apparatus or processes specially adapted for manufacturing reflecting surfaces using insulating material for supporting the reflecting surface
    • H01Q15/144—Apparatus or processes specially adapted for manufacturing reflecting surfaces using insulating material for supporting the reflecting surface with a honeycomb, cellular or foamed sandwich 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without 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
    • B29C66/70—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
    • B29C66/71—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 composition of the plastics material of 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
    • 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
    • B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/34—Electrical apparatus, e.g. sparking plugs or parts thereof
    • B29L2031/3456—Antennas, e.g. radomes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B32B2305/024—Honeycomb

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Moulding By Coating Moulds (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

A reflector 1 for an antenna is made by forming constituent parts 2, 3, 4 thereof separately on a single mould tool so that the adjoining edge regions have a common surface profile, precisely aligning said formed constituent parts in edge-to-edge relationship and then bonding them together to form a composite article having a substantially smooth and continuous surface. <IMAGE>

Description

SPECIFICATION Jointed composite articles This invention relates to composite articles and in particular to the manufacture of composite articles having a relatively large active surface area which requires a substantially smooth and continuous surface profile, for example an antenna reflector.
For applications such as communications satellites it is required to provide a lightweight antenna reflector which has an active surface which is substantially smooth and continuous to give maximum performance for the range of operating frequencies, typically 1 GHz and higher.
In the past, these types of antenna reflector have been made of a composite sandwich comprising a relatively thick substrate of aluminium honeycomb material having a pair of relatively thin layers of fibre reinforced curable plastics material attached one to either side. The reflector is currently formed in one piece over a tool which corresponds to the full size of the dish and then curing the formed reflector. This has been acceptable for relatively small sizes of reflectors, but for the relatively large sizes of reflector currently envisaged - three or more metres in diameter - the capital cost of providing equipment such as the forming tool and an autoclave sufficiently large to accommodate the reflector for curing is very high, the cost of an autoclave typically increasing as the square of the diameter.
It is therefore an aim of this invention to provide a composite article which has a relatively large and substantially continuous active surface which is formed of two or more constituent parts.
In one aspect of this invention, there is provided a composite article having a substantially smooth and continuous active surface of generally curved profile, formed by bonding together in edge-toedge relationship two or more separately produced constituent parts, the shape and size of the parts being selected having regard to the profile of the composite article so that at least the adjoining regions of the constituent parts have a common active surface profile, said adjoining regions of the constituent parts being precisely aligned prior to bonding to form said composite article.
Naturally, the constituent parts will be of smaller size than the composite article and since the parts are separately produced, the size of autoclave required for any curing may be relatively small.
In addition, where the curvatures of the active surface of the composite article allow, a single tool may be used for the separate production of the constituent parts, with a corresponding reduction in the initial capital outlay.
The composite article may be a reflector for an antenna dish in which case the active surface is that surface which reflects radiation to or from the radiation receiving/transmitting means of the antenna, and may be of paraboloid form.
Alternatively, the composite article may be in shroud for a space craft on a launch vehicle; in this case the active surface is the external surface of the shroud.
In another aspect of this invention, there is provided a method of forming an article having a substantially smooth and continuous active surface, which method includes the steps of (i) providing a mould tool having a mould surface, (ii) forming constituent parts of said article upon said mould surface, and (iii) bonding together said formed constituent parts in edge-to-edge relationship to form said article, said mould surface being shaped to match spaced active surface regions of said article.
Preferably, the adjoining constituent parts are aligned in edge-to-edge relationship using a tool having an alignment surface shaped to match the surface profile of the adjoining regions in the formed article.
In a preferred embodiment, the formation of each constituent part includes the steps of (i) laying a sheet member of uncured fibrereinforced plastics material on the mould surface, (ii) curing said sheet member, (iii) removing said formed sheet member, (iv) laying a further sheet member of uncured fibre reinforced plastics material on the mould surface, (v) curing said further sheet member, (vi) bonding said formed sheet member and said formed further sheet member to either side ol a relatively thick core member to form said constituent part.
Conveniently, the formation of said constituent parts includes the step of introducing each constituent part together with the mould tool into an autoclave, thereby to subject the constituent part to an elevated temperature and an elevated pressure.
Advantageously, the bonding together of said formed constituent parts includes the step of introducing the formed constituent parts into an oven, thereby to subject the formed constituent parts to elevated temperatures to assist said bonding. This feature allows the bonding of the constituent parts to be carried out in an oven, which, compared to an autoclave, is a relatively inexpensive piece of equipment.
Conveniently, bonding of constituent parts in edge-to-edge relationship is achieved using a joining strip element of similar construction to said constituent parts.
By way of example only, one specific embodiment of a composite article will now be described with reference to the accompanying drawing, in which: Figure 1 is a plan view of a composite offset paraboloid reflector, and Figure 2 is a cross-section on line XX' of Figure 1.
Referring to Figure 1, the paraboloidal shape of the reflector 1 permits the easy reduction of the whole into three similar constituent parts 2, 3 and 4 delineated by lines AA' and BB', each constituent part having an active surface 5 defining curvatures which, at least in part, match the curvatures of the active surfaces of the other parts. Each part 2, 3 and 4 is of composite sandwich construction including a thin upper active surface layer 6 and a thin lower surface layer 7, each of multi-ply layers of carbon fibre with epoxy resin, which are bonded one to each side of a relatively thick substrate or core 8 of aluminium honeycomb material.
Each constituent part is manufactured independently and because the active surface profiles are at least in part common, they may be built up separately and then bonded using the same tool or a forming tool having the same shape as the mould tool, which is approximately onethird of the size of the finished dish.
The upper and lower surface layers 6, 7 are manufactured as multi-ply layers of carbon fibre reinforced with epoxy resin which is then cured on the tool. The formed and cured upper and lower layers 6, 7 are then bonded to the substrate 8 using a film adhesive 9.
Refering now to Figure 2, the edge regions of the constituent parts 2, 3 and 4 which in the finished reflector will be adjacent are formed as shown, so that the upper surface layer 6 extends outwardly of the substrate 8 and lower layer to provide a margin region 10.
After forming, curing and bonding each of the constituent parts, they are trimmed as necessary and aligned in edge-to-edge relationship with their respective margin regions 10 abutting over a tool having complementary curvatures to those of the parts to be joined, thereby ensuring precise alignment of the parts; alignment of a pair of constituent parts may be effected by using the same tool as used for forming or by using a different tool.
Referring to Figure 2, when two parts have been precisely aligned on a tool, a rebate is defined between the two substrates 8. Into this rebate are individually inserted a strip 6' of material similar to that of surface layer 6, a substrate strip 8' of material similar to that of substrate 8, and a further strip 7' of material similar to that of surface layer 7. Strips 6' and 7' and substrate strip 8' are individually of relatively low stiffness and this feature allows matching within the joint resulting in high integrity and overall combined stiffness once bonded.
The upper strip 6' underlies the join between the two margins 10 and is adhered thereto by film adhesive 9; the substrate strip 8' is bonded to the adjacent substrates 8 by means of a film or foaming adhesive 12, and the lower strip 7' overlaps end regions of the lower surfaces 7 and is adhered thereto by film adhesive 9.
The bonding together of constituent parts may be performed in an oven which is a relatively inexpensive item of capital equipment compared to an autoclave.
The joint formed by the joining element provides as near a homogenous structure as possible, together with sufficient stiffness and an ability to withstand thermal cycling without distortion. Moreover, the active surface defined by the constituent parts 2, 3 and 4 is substantially smooth and continuous.
With reference to Figure 1, the formed article may be trimmed to the desired shape (e.g.
circular plan form) and the peripheral offcuts may subsequently be used for quality control checks.

Claims (10)

1. A composite article having a substantially smooth and continuous active surface of generally curved profile formed by bonding together in edge-to-edge relationship two or more separately produced constituent parts, the shape and size of the constituent parts being selected having regard to the profile of the composite article, so that at least the adjoining edge regions of the constituent parts have a common active surface profile, said adjoining regions being precisely aligned prior to bonding to form said composite article.
2. A method of forming an article having a substantially smooth and continuous active surface, which method includes the steps of (i) providing a mould tool having a mould surface, (ii) forming constituent parts of said article upon said mould surface, and (iii) bonding together said formed constituent parts in edge-to-edge relationship to form said article, said mould surface being shaped to match spaced active surface regions of said article.
3. A method according to Claim 2, in which adjoining formed constituent parts are aligned in edge-to-edge relationship using a tool having an alignment surface shaped to match the surface profile of the adjoining regions in the formed article.
4. A method according to Claim 2 or Claim 3, in which the formation of each constituent part includes the steps of (i) laying a sheet member of uncured fibrereinforced plastics material on the mould surface, (ii) curing said sheet member, (iii) removing said formed sheet member, (iv) laying a further sheet member of uncured fibre reinforced plastics material on the mould surface, (v) curing said further sheet member, (vi) bonding said formed sheet member and said formed further sheet member to either side of a relatively thick core member to form said constituent part.
5. A method according to any of Claims 2 to 4, in which the formation of said constituent parts includes the step of introducing each constituent part together with the mould tool into an autoclave, thereby to subject the constituent part to an elevated temperature and an elevated pressure.
6. A method according to any of Claims 2 to 5, in which the bonding together of said formed constituent parts includes the step of introducing the formed constituent parts into an oven, thereby to subject the formed constituent parts to elevated temperatures to assist said bonding.
7. A method according to any of Claims 2 to 6, in which bonding of constituent parts in edge-toedge relationship is achieved using a joining strip element of similar construction to said constituent parts.
8. An article produced in accordance with the method as claimed in any of Claims 2 to 7.
9. A compositie article substantially as hereinbefore described with reference to and as illustrated in, any of the accompanying drawings.
10. A method of producing an article having a substantially smooth and continuous active surface profile, substantially as hereinbefore described, with reference to and as illustrated in, any of the accompanying drawings.
GB08317291A 1982-06-25 1983-06-24 Jointed composite articles Expired GB2122939B (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB08317291A GB2122939B (en) 1982-06-25 1983-06-24 Jointed composite articles

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB8218475 1982-06-25
GB08317291A GB2122939B (en) 1982-06-25 1983-06-24 Jointed composite articles

Publications (3)

Publication Number Publication Date
GB8317291D0 GB8317291D0 (en) 1983-07-27
GB2122939A true GB2122939A (en) 1984-01-25
GB2122939B GB2122939B (en) 1986-01-08

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ID=26283184

Family Applications (1)

Application Number Title Priority Date Filing Date
GB08317291A Expired GB2122939B (en) 1982-06-25 1983-06-24 Jointed composite articles

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GB (1) GB2122939B (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2022013513A1 (en) * 2020-07-17 2022-01-20 Arianegroup Sas Stiffened part formed from a thermoset composite material with a boxed structure and manufacturing method

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB517693A (en) * 1938-08-04 1940-02-06 Robert William Sampson Improvements in or relating to the manufacture of hollow rubber articles
GB657186A (en) * 1948-04-08 1951-09-12 Jules Donier Improvements in the manufacture of table-tennis balls
GB1538860A (en) * 1976-08-20 1979-01-24 Its Rubber Ltd Squash rackets balls
GB1587314A (en) * 1978-05-22 1981-04-01 Rolls Royce Method of forming an article from composite material

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB517693A (en) * 1938-08-04 1940-02-06 Robert William Sampson Improvements in or relating to the manufacture of hollow rubber articles
GB657186A (en) * 1948-04-08 1951-09-12 Jules Donier Improvements in the manufacture of table-tennis balls
GB1538860A (en) * 1976-08-20 1979-01-24 Its Rubber Ltd Squash rackets balls
GB1587314A (en) * 1978-05-22 1981-04-01 Rolls Royce Method of forming an article from composite material

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2022013513A1 (en) * 2020-07-17 2022-01-20 Arianegroup Sas Stiffened part formed from a thermoset composite material with a boxed structure and manufacturing method
FR3112506A1 (en) * 2020-07-17 2022-01-21 Arianegroup Sas STIFFENED PART IN THERMODSET COMPOSITE MATERIAL WITH BOXED STRUCTURE AND METHOD OF MANUFACTURING

Also Published As

Publication number Publication date
GB2122939B (en) 1986-01-08
GB8317291D0 (en) 1983-07-27

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