Patent Grant
8470404
1. Field of Invention
The present invention relates to connection of fiber reinforced structures, in particular the provision of exposed non-resin infused fiber at edges or surfaces of fiber reinforced components, which fiber may be beneficially used to reinforce subsequently formed joints between or to such fiber reinforced components.
2. Description of Related Art
Most adhesively bonded joints in fiber reinforced composites lack any continuity of reinforcement, with the notable exception of Z-pin technology such as is disclosed in U.S. Pat. No. 6,821,368 B2 to Benson et al. Continuity of fiber reinforcement across joints is desirable because the fiber reinforcement is far stronger than the polymer matrix and is stronger yet compared to adhesively bonded joints within a polymer matrix. Polymer joints lacking fiber reinforcement can be expected to lack the inherent fatigue resistance of fiber reinforced structures. Additionally, adhesively bonded joints between polymer structures are subject to environmental degradation. Cured resin systems of composite components leave relatively few sites for chemical bonding to occur when the article is later joined in a secondary bonding step. These limitations of conventional adhesively bonded joints in fiber reinforced composites have been well documented by
The benefits of z-axis fibers within individual composite articles are known. For example, individual plies of pre-preg material have been treated with flocked fibers in order to obtain improved inter-laminar strength. Three dimensional woven pre-forms have also been used. An example of such 3 dimensional woven pre-forms is disclosed in U.S. Pat. No. 6,712,099 B2 to Schmidt et al. Although such structures may provide superior Z axis delamination resistance within integrally cured components, such structures do not in themselves provide for increased adhesive joint strength. Several methods for providing reinforcement across joints have been proposed in the past. These include U.S. Pat. Nos. 5,879,492 and 6,645,610 B1 to Reis and Wong which disclose the use of peel ply sheets which, when peeled from the cured composite, are intended to leave embedded in the composite structure, fibers which are intended to reinforce a subsequent adhesive joint. The use of both co-woven and flocked fibers is disclosed. Such systems result in the conflicting requirements for good wetting properties of the fibers to be left behind in the cured resin, and for good release properties of the fiber to be peeled away. Obviously, this would not work well with a single type of fiber with a single type of surface treatment. Furthermore, release agents that might be applied to the fibers to be peeled may be prone to migrate during cure onto the fibers to be embedded, thus diminishing the strength and reliability of any adhesive joint which such embedded fibers are intended to reinforce.
Electro-statically flocked carbon fibers have also been used for the purpose of enhancing heat transfer from electrical components and for heat transfer in Stirling engines.
It is an object of one aspect of this invention to provide high strength connections between various fiber-reinforced structural components. For example, the interior of an aircraft fuselage structure might be provided with a generally circular zone of exposed fibers for the purpose of being adhesively bonded to a pressure bulkhead with its fuselage-fitting perimeter featuring similarly exposed fibers. Upon bonding, fibers continuous from within the fuselage structure are commingled and co-embedded in cured adhesive with fibers continuous from within the pressure bulkhead structure. The integrity of the combined structure is thus enhanced by continuity of fiber across the adhesive-to-cured-resin interfaces and thus does not rely on the strength of the adhesive-to-cured-resin bonds and also does not rely on the strength of un-reinforced adhesive. Loads may be reliably transferred from fiber to resin to fiber without the requirement for tensile load transfer across adhesive bond lines. Stresses within the adhesive itself are also reduced in accordance with the degree of fiber overlap achieved within the adhesive. Fiber overlap may be tailored to load requirements. For example, opposing electro-statically flocked bonding strips might be used in order to maximize the proportion of Z-axis fiber alignment within the joint. Connections with predominately shear loads might be adequately provided with partial exposure of woven reinforcing fabrics. Knitted fabrics would be expected to provide joint properties intermediate to those provided by flocked bonding strips and square woven fabric.
It is an object of an aspect of a further embodiment of this invention to provide a high strength connection between an underlying structure and a coating system. For example, a composite spacecraft structure might include surface zones of exposed fiber corresponding to zones of maximum reentry heating. Insulating refractory materials such as silica foam or alumina fiber may be readily attached to such a surface with adhesives such as RTV silicone elastomer. In this manner, the adhesive may be reliably attached to the underlying composite structure without reliance on a chemical bond to a cured resin surface which may be relatively chemically inert. Other example coating systems to which this invention is applicable include epoxy paint, elastomeric coatings, thermoplastic coatings, thermoset coatings such as phenolic coatings, radar absorbing coatings, electrochromic coatings, chemically resistant coatings, refractory coatings, electrically conductive coatings for EMI protection or lightening strike protection, ablative coatings, etc. Any material into which the fibers, exposed in accordance with this invention, may be embedded may be reliably attached to the underlying structure into which said fibers are continuous.
It is an object of a further aspect of this invention to provide a high strength, yet flexible, connection between several structural components. For example, the bonding of two relatively stiff structures which may move relative to each other may require a flexible joint in order to reduce joint loads to within safe limits. A landing gear or engine attachment to a fuselage might fall into this category. Provision, in accordance with this invention, of exposed fiber at the surfaces of the parts to be connected allows the creation of an elastomeric joint between otherwise relatively rigid structures. Integration of the exposed fibers of each structure into such an elastomeric joint provides not only joint attachment reliability but also the possibility of carrying substantial tensile loads through such a joint. Elastomeric connections of prior art have primarily used elastomeric elements in compression. In cases where loads reverse direction, redundant elastomeric elements have been required, with only one or the other elastomeric element carrying a load at any one time.
It is a further object of this invention to provide, within a zone of desired structural flexibility, a flexible matrix around fibers that may be generally continuous between two or more relatively articulated structural elements. For example, some of the structural fibers that comprise the reinforcement of a wing, wherein they are embedded in a rigid polymer matrix, might extend there from in exposed form through a zone of desired flexibility, into an aileron wherein they are embedded again in a rigid polymer matrix. The zone of exposed fiber would thus act as a hinge means and might be used with or without subsequent embedment in a flexible matrix such as elastomeric epoxy.
In accordance with a further aspect of the aforementioned embodiment of this invention, one or more sheets of reinforcing fabric may be selectively infused with resin and resin blocking substance in a pattern which provides for features desired in a cured component made there from. Such selective infusion may be accomplished by screen printing or ink jet printing, for example. Such sheets may then be assembled and cured after which zones with resin blocking substance may be washed clean of such substance and used to form hinges, with or without the addition of infused elastomer, as well as bonds.
It is a further object of this invention to provide improved discrete fasteners particularly advantageous for the connection of fiber reinforced structures, equivalent, for example, to nails, staples, or rivets. For example, a 5 cm length of carbon fiber yarn might be infused 1 cm on each end with rigid (non-plasticized) PVA, with the PVA further formed into sharp ends. This yarn might then be formed into the shape of a common paper staple with legs of 2 cm length. All of the non-PVA infused yarn would then be infused with resin and cured to a rigid form. Such a staple could be inserted through the thickness of a prepreg laminate, with the sharp PVA infused ends extending into a penetrable elastomeric pad similar to that used during the curing of structures incorporating Z-pins. After laminate curing, the PVA could be dissolved and the fibers at the ends of the “staple” spread out and glued to the surface of the laminate.
According to one aspect of an embodiment of the present invention, a zone of thermal gradient may be established normal to a desired boundary between resin impregnated fiber and non-resin impregnated fiber. A molten resin blocking substance such as paraffin may be supplied to the reinforcing fibers near the higher temperature end of the thermal gradient zone. The resin blocking substance, such as paraffin, will wet the heated fibers and follow the fibers by capillary action to a boundary where the temperature of the fiber causes solidification of the paraffin and cessation of capillary transport. Subsequent resin infusion of the portion of fiber not infused with paraffin results in a distinct resin boundary within the fiber matrix. Curing of the resin may be carried out at temperatures below the melting point of the resin blocking substance such as paraffin. After the resin is cured, the paraffin may be removed by vacuum sublimation followed by solution in citric acid solution, for example. This sequence leaves exposed non-resin infused fibers which may be readily incorporated into a secondary joint. For example, the marginal edges of two adjoining parts may be joined by overlapping or otherwise interlocking the exposed fibers of each part followed by resin infusion of the zone of interlocked fibers. The resulting structure benefits from continuity of reinforcement through the joint.
According to an aspect of another embodiment of the present invention a solution of plasticized polyvinyl alcohol (PVA) may be used to infuse a zone of fiber and to create a barrier for use in controlling the subsequent infusion of resin. After solidification, the plasticized PVA forms a flexible and heat resistant barrier which selectively blocks resin infusion during heated cure cycles, which may involve exothermically curing resin systems. Upon curing of the resin system, the PVA may be dissolved with warm water to leave exposed fibers which are useful for construction of subsequent joints.
According to a further aspect of one embodiment of this invention, a metal or alloy of metals may be infused under temperature gradient control into a fiber matrix. The remaining, non-metal infused, portion of the fiber matrix may subsequently be resin infused and the resin cured. Removal of the metal, if desired, may be accomplished by melting, chemical corrosion, or electrochemical removal. For certain applications the metal may be left in place to provide enhanced electrical properties, for example.
According to a further aspect of this invention a soluble flexible sheet may anchor short lengths of fiber oriented primarily normal to the plane of the elastomeric sheet. Such a sheet may be applied to the surface of an uncured composite structure and left in place during curing. Subsequent to curing, the flexible sheet may be dissolved, leaving exposed fibers protruding from the surface of the cured composite structure.
According to one aspect of a further embodiment of this invention, a fabric of soluble fiber such as PVA may be used in a manner similar to the supporting or ground fabric of carpet or velour. Reinforcing yarns, of carbon fiber for example, may subsequently be inserted and attached in accordance with conventional manufacturing techniques for carpets or incorporated as the looped fabric element of velour. The supporting or ground fabric surface may then be sealed with a flexible soluble filler, such as PVA. Such a fabric may then be applied to the surface of an uncured composite structure, with the exposed reinforcing fibers oriented towards the underlying structure. Resin to be cured may be pre-impregnated into such a fabric or may be infused into the fabric and the composite structure as a whole in accordance with vacuum assisted resin transfer molding practice, for example. After curing of the composite article, the soluble fabric and soluble filler would be dissolved, leaving exposed reinforcing fibers for subsequent use.
Alternatively, in accordance with a further aspect of an embodiment of this invention, a soluble polymer film, such as PVA compound in a softened and adhesive state, may have joint reinforcing fibers inserted therein endwise by means of electrostatic flocking. Electrostatic flocking has been used to insert in excess of 150,000 fibers per square inch. Upon hardening of the polymer film, the resulting flexible fiber bearing sheet may be applied to a surface of an uncured composite article, which surface is intended for subsequent bonding. In such a configuration, the non-fiber bearing face of the flexible polymer film would remain exposed while the fibers protruding there from would be pressed into and intermingled with the underlying fibers of the composite article. The aforementioned steps may occur either before or after introduction of the resin with which the article is ultimately infused. Upon curing of the resin infused article, the soluble polymer film may be dissolved and rinsed away, leaving a fuzzy surface well suited for subsequent adhesive bonding or for coating.
In accordance with a further aspect of the above mentioned embodiment of the present invention, joint reinforcing fibers may be applied in a purposely non-uniform orientation such as by means of pneumatic flocking.
In accordance with a further aspect of the above mentioned embodiments, a soluble adhesive may be used secure flocked joint reinforcing fibers to a sheet such as cloth woven from PVA fibers.
In accordance with a further aspect of the above mentioned embodiments, a soluble adhesive may be used to secure flocked joint reinforcing fibers to a non-soluble sheet to be mechanically removed at a later manufacturing stage by peeling, for example.
In accordance with a further aspect of this invention, flocking, with or without an electrostatic component, may be used to apply joint reinforcing fibers directly to the surface of a composite article after resin infusion of said article but prior to curing. Such a method eliminates the rinse step and may be useful in conjunction with articles fabricated by wet lay-up methods. In this case, the surface to feature exposed joint reinforcing fibers would not be conventionally vacuum bagged, but would instead be held at a gas pressure sufficient to balance the combined effects of surface tension and resin hydrostatic pressure: I case the gas pressure is allowed to be atmospheric pressure, control would be by means of resin hydrostatic pressure and design control of the wetting characteristics of the joint reinforcing fiber. The wetting characteristics of the joint reinforcing fabric would preferably be selected so as to completely wet the underlying structural fibers while only partially wetting the joint reinforcing fibers, based on surface energy, fiber diameter, and fiber spacing.
In accordance with a further aspect of this invention, a joint reinforcing fabric may be applied to the to-later-be-joined exterior surfaces of a composite article. Said joint reinforcing fabric would have controlled wetting characteristics, such that the underlying structural reinforcing fibers would be thoroughly wet out at a predetermined resin hydrostatic pressure, while the joint reinforcing fabric would become only partially wetted. Upon first stage curing of the composite article, the to-later-be-joined exterior surfaces would feature partially embedded joint reinforcement fibers.
In accordance with one aspect of a further embodiment of this invention, a joint may be provided in which one or more components are match molded to each other. For example, a laminate or sandwich structure may be built to include one or more surface zones wherein the outer fibers are protected by a resin blocking substance. Either before or after curing of such a structure, additional structures may be built thereon which incorporate corresponding zones of resin blocked fiber in a back-to-back configuration with resin blocked fiber elements of the first structure. Upon curing of such assembled structures in their respective assembled positions, the structures may be disassembled from each other and their respective bonding zones cleaned of resin blocking substance. Such disassembly may be useful or required for the removal of mandrels or the insertion of other components, for example. After removal of resin blocking substance, the structures may subsequently be reassembled and adhesively bonded to each other with an assured fit.
In accordance with a further aspect of one embodiment of this invention, inert wedges may be used to beneficially position, relative to each other, the marginal edges of a plurality of reinforcing plies. Such reinforcing plies are preferably through-thickness resin blocked within their length in contact with the wedges, except with the possible exception of the zones nearest the narrow ends of the wedges. In this manner, the fibers will fan out into a dovetail groove where they may be secured by a secondary resin infusion process.
In accordance with a further aspect of this invention, a thermal gradient may be used to directly control resin infusion in order to establish a desired resin infusion configuration or extent. In order to cure the resin without disturbing the resin configuration, a radiation source may be used in order to fix the resin in position while maintaining a sufficiently low temperature to prevent resin migration. Electron beam curing is preferred because of controllability and penetration. Ultra-violet, X-ray, and Gamma ray curing would also be suitable. In the case of curing with ultraviolet light, glass fibers may be configured to both direct light and to provide structural reinforcement.
In accordance with one aspect of a further embodiment of this invention, an assembly of reinforcing fabric may be infused in conjunction with the presence of curing radiation provided at locations of intended lack of infusion. In this manner, resin approaching the radiation source may be caused to cure, forming a dam that prevents further resin penetration. For example, an ultraviolet light source may be used to create a resin barrier just beneath the uppermost fibers on a selected surface of an article being infused. The resin dam thus created provides un-infused fibers that may be beneficially used to adhere other components or special coatings. Such a radiation cure of near surface resin may be immediately followed by a thermal cure of the remaining resin. Using prior art techniques, the drop in viscosity with the onset of exothermic cure would make controlled limiting of resin infusion unlikely.
In accordance with a further embodiment of one aspect of the present invention, a thermal gradient may be used to control the extent of infusion of a thermoplastic into a fiber matrix. Subsequent infusion of thermoset resin into the remainder of the fiber matrix can then be used to yield a part which may be thermally bonded to another such part with continuity of fiber reinforcement across the resin interfaces. This method combines the high glass transition temperature and favorable structural properties of thermoset resins with the weldability of thermoplastic parts.
The terms “joint reinforcing fibers” is meant to include fibers the function of which is to adhere a coating system to an article. The term “resin” is meant to include any polymerizable or cross-linkable compound which, when cured, provides a useful matrix connecting the fiber matrix from within. Examples include epoxy resins, polyester resins, acrylic resins, phenolic resins, vinyl resins, polyamides, silicones, and bis-maleimides.
a and 6b are scanning electron micrographs of carbon fibers exposed on the surface of a cured composite structure prepared in accordance with one aspect of this invention.
a through 11e illustrate the sequence of construction of a joint between a strut and a honeycomb sandwich structure in accordance with the present invention.
a and 12b illustrate the preparation of a stepped lap joint in accordance with one aspect of the present invention.
a through 13d illustrates the steps by which a dovetail joint may be produced in accordance with the present invention.
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Patents, publications, or other references mentioned in this application for patent are hereby incorporated by reference. In addition, as to each term used it should be understood that unless its utilization in this application is inconsistent with such interpretation, both traditional and common dictionary definitions should be understood as incorporated for each term and all definitions, alternative terms, and synonyms such as contained in the Random House Webster's Unabridged Dictionary, second edition are hereby incorporated by reference. Finally, all references listed in the list of References To Be Incorporated By Reference In Accordance With The Provisional Patent Application or other information statement filed with the application are hereby appended and hereby incorporated by reference, however, as to each of the above, to the extent that such information or statements incorporated by reference might be considered inconsistent with the patenting of this/these invention(s) such statements are expressly not to be considered as made by the applicant(s).
Thus, the applicant(s) should be understood to claim at least: i) each of the connection means as herein disclosed and described, ii) the related methods disclosed and described, iii) similar, equivalent, and even implicit variations of each of these devices and methods, iv) those alternative designs which accomplish each of the functions shown as are disclosed and described, v) those alternative designs and methods which accomplish each of the functions shown as are implicit to accomplish that which is disclosed and described, vi) each feature, component, and step shown as separate and independent inventions, vii) the applications enhanced by the various systems or components disclosed, viii) the resulting products produced by such systems or components, ix) methods and apparatuses substantially as described hereinbefore and with reference to any of the accompanying examples, x) the various combinations and permutations of each of the elements disclosed, xi) each potentially dependent claim or concept as a dependency on each and every one of the independent claims or concepts presented, and xxii) the various combinations and permutations of each of the above.
It should also be understood that for practical reasons and so as to avoid adding potentially hundreds of claims, the applicant may eventually present claims with initial dependencies only. Support should be understood to exist to the degree required under new matter laws—including but not limited to European Patent Convention Article 123(2) and United States Patent Law 35 USC 132 or other such laws—to permit the addition of any of the various dependencies or other elements presented under one independent claim or concept as dependencies or elements under any other independent claim or concept. Further, if or when used, the use of the transitional phrase “comprising” is and will be used to maintain the “open-end” claims herein, according to traditional claim interpretation. Thus, unless the context requires otherwise, it should be understood that the term “comprise” or variations such as “comprises” or “comprising”, are intended to imply the inclusion of a stated element or step or group of elements or steps but not the exclusion of any other element or step or group of elements or steps. Such terms should be interpreted in their most expansive form so as to afford the applicant the broadest coverage legally permissible.
This is a United States national phase patent application and claims priority to PCT Application No. PCT/US2005/031243, filed 31 Aug. 2005, published on 9 Mar. 2006 as WO 2006/026734, an application claiming priority to U.S. Provisional Application 60/606,231, filed 31 Aug. 2004, said PCT and provisional applications incorporated herein by reference.
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