US20080072527A1 - Fiber-reinforced composite member and method for producing structure using same - Google Patents
Fiber-reinforced composite member and method for producing structure using same Download PDFInfo
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- US20080072527A1 US20080072527A1 US11/882,329 US88232907A US2008072527A1 US 20080072527 A1 US20080072527 A1 US 20080072527A1 US 88232907 A US88232907 A US 88232907A US 2008072527 A1 US2008072527 A1 US 2008072527A1
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- fiber
- reinforced composite
- composite member
- projections
- members
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- 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
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
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- 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
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- 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
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- 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
- B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
- B29C66/128—Stepped joint cross-sections
- B29C66/1282—Stepped joint cross-sections comprising at least one overlap joint-segment
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- 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
- B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
- B29C66/128—Stepped joint cross-sections
- B29C66/1284—Stepped joint cross-sections comprising at least one butt joint-segment
- B29C66/12841—Stepped joint cross-sections comprising at least one butt joint-segment comprising at least two butt joint-segments
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- 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
- B29C66/5244—Joining profiled elements for forming fork-shaped connections, e.g. for making window frames or Y-shaped pieces
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- 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
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- 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
- B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
- B29C66/72141—Fibres of continuous length
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- 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
- B29C66/96—Measuring or controlling the joining process characterised by the method for implementing the controlling of the joining process
- B29C66/967—Measuring or controlling the joining process characterised by the method for implementing the controlling of the joining process involving special data inputs or special data outputs, e.g. for monitoring purposes
- B29C66/9672—Measuring or controlling the joining process characterised by the method for implementing the controlling of the joining process involving special data inputs or special data outputs, e.g. for monitoring purposes involving special data inputs, e.g. involving barcodes, RFID tags
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- 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
- B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
- B29C65/7802—Positioning the parts to be joined, e.g. aligning, indexing or centring
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- 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
- B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
- B29C65/7802—Positioning the parts to be joined, e.g. aligning, indexing or centring
- B29C65/7805—Positioning the parts to be joined, e.g. aligning, indexing or centring the parts to be joined comprising positioning features
- B29C65/7814—Positioning the parts to be joined, e.g. aligning, indexing or centring the parts to be joined comprising positioning features in the form of inter-cooperating positioning features, e.g. tenons and mortises
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- 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
- B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
- B29C66/124—Tongue and groove joints
- B29C66/1244—Tongue and groove joints characterised by the male part, i.e. the part comprising the tongue
- B29C66/12443—Tongue and groove joints characterised by the male part, i.e. the part comprising the tongue having the tongue substantially in the middle
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- 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
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- 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
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
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- 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
- B29L2031/001—Profiled members, e.g. beams, sections
- B29L2031/003—Profiled members, e.g. beams, sections having a profiled transverse cross-section
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- 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
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3076—Aircrafts
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49826—Assembling or joining
Definitions
- the present invention relates to a fiber-reinforced composite member with which a fiber-reinforced composite structure can be produced quickly and inexpensively, and a method for assembling a fiber-reinforced composite structure using such member.
- U.S. Pat. No. 5,560,102 proposes a method for producing an aircraft fuselage using self-locating detail parts whose positions are determined based on positioning holes. Specifically, the method comprises determining the positions of rivet-connecting holes in the structure by CAD in advance, memorizing the position of each rivet-connecting hole as a position of a hole to be formed in each member in a CAD/CAM main frame, providing each member with through-holes (positioning holes) by controlling an NC drill according to a connecting position information down-loaded from the CAD/CAM main frame, which may differ form member to member, and arranging the members based on the positioning holes.
- This method can produce high-accuracy structures by a small number of steps.
- an object of the present invention is to provide a fiber-reinforced composite member capable of being assembled to a fiber-reinforced composite structure quickly and inexpensively.
- Another object of the present invention is to provide a method for assembling a structure comprising such a fiber-reinforced composite member.
- the fiber-reinforced composite member of the present invention comprises projections having information concerning the identification and connecting positions of said additional members, to which said fiber-reinforced composite member is to be connected.
- the method of the present invention for assembling a fiber-reinforced composite structure by connecting fiber-reinforced composite members to additional members comprises the steps of providing at least one of said fiber-reinforced composite members with projections having information concerning the identification and connecting positions of said additional members, to which said fiber-reinforced composite member is to be connected, and positioning said additional members to said fiber-reinforced composite member using said projections.
- Said information is preferably given by at least one selected from the group consisting of the shapes, sizes, number and arrangement of said projections, and marks provided on said projections.
- the shapes, sizes, number and arrangement of said projections are preferably set such that said projections engage the connecting portions of said additional members.
- the connecting portions of said additional members are preferably provided with steps or recesses engageable with said projections of the fiber-reinforced composite member.
- Said projections and said additional members preferably have corresponding marks.
- said fiber-reinforced composite member comprises one or more pairs of I-shaped projections
- said additional members comprise rectangular connecting plate portions engageable with said I-shaped projections, said I-shaped projections being engaged with said rectangular connecting plate portions to arrange said additional members at predetermined connecting positions to said fiber-reinforced composite member.
- said fiber-reinforced composite member comprises one or more pairs of L-shaped projections
- said additional members comprise rectangular connecting plate portions engageable with said L-shaped projections, said L-shaped projections being engaged with said rectangular connecting plate portions to arrange said additional members at predetermined connecting positions to said fiber-reinforced composite member.
- FIG. 1 is a perspective view showing a fiber-reinforced composite member according to one embodiment of the present invention.
- FIG. 2 ( a ) is a partial, perspective view showing one example of the connection of an additional member to a fiber-reinforced composite member.
- FIG. 2 ( b ) is a partially-cross-sectioned, enlarged view showing a fiber-reinforced composite member and an additional member, which are to be connected.
- FIG. 2 ( c ) is a partially-cross-sectioned, enlarged view showing the fiber-reinforced composite member and additional member of FIG. 2 ( a ), which are connected to each other.
- FIG. 2 ( d ) is a partial plan view showing the connected fiber-reinforced composite member and additional member.
- FIG. 2 ( e ) is a partial, enlarged view showing a rectangular connecting plate portion of the additional member in FIG. 2 ( a ).
- FIG. 3 is a partial, perspective view showing another example of the connection of an additional member to the fiber-reinforced composite member of FIG. 1 .
- FIG. 4 is a partial, perspective view showing a further example of the connection of an additional member to the fiber-reinforced composite member of FIG. 1 .
- FIG. 5 ( a ) is a partial, perspective view showing an example of the connection of an additional member to a fiber-reinforced composite member according to another embodiment of the present invention.
- FIG. 5 ( b ) is a partial, enlarged view showing a connecting portion of the additional member shown in FIG. 5 ( a ).
- FIG. 6 is a perspective view showing a fiber-reinforced composite member according to a further embodiment of the present invention.
- FIG. 7 is a perspective view showing an example of the connection of an additional member to the fiber-reinforced composite member of FIG. 6 .
- FIG. 8 is a perspective view showing a fiber-reinforced composite member according to a still further embodiment of the present invention.
- FIG. 9 is a partial, perspective view showing an example of the connection of an additional member to the fiber-reinforced composite member of FIG. 8 .
- FIG. 10 is a partial, perspective view showing an example of the connection of an additional member to a fiber-reinforced composite member according to a still further embodiment of the present invention.
- FIG. 11 is a partial, perspective view showing the positioning of an additional member to the fiber-reinforced composite member of FIG. 1 on a table.
- FIG. 12 is a perspective view showing an example of aircraft fuselage structures using the fiber-reinforced composite member of the present invention.
- FIG. 13 ( a ) is a perspective view showing an example of dies for molding the fiber-reinforced composite member of FIG. 1 .
- FIG. 13 ( b ) is a view showing the upper die of FIG. 13 ( a ) from various angles.
- FIG. 13 ( c ) is a view showing the lower die of FIG. 13 ( a ) from various angles.
- FIG. 14 ( a ) is an enlarged, perspective view showing a portion A in FIG. 13 ( a ).
- FIG. 14 ( b ) is an enlarged, perspective view showing a portion B in FIG. 13 ( a ).
- FIG. 15 ( a ) is a side view showing a prepreg laminate placed on the upper die (lower die).
- FIG. 15 ( b ) is a side view showing the trimming of an excess margin of the prepreg laminate placed on the upper die (lower die).
- FIG. 15 ( c ) is a perspective view showing excess-margin-free prepreg laminates received in the cavities of the upper and lower dies.
- FIG. 15 ( d ) is a side view showing the closure of the upper and lower dies containing the excess-margin-free prepreg laminates.
- FIG. 15 ( e ) is a cross-sectional view showing the lamination of prepreg strips to the flanges of the combined prepreg laminates after the upper and lower dies are closed.
- FIG. 16 is a side view showing the attachment of side dies to the closed upper and lower dies.
- FIG. 17 is a cross-sectional view showing a prepreg assembly in the molding die covered by a bag film and evacuated.
- FIG. 18 is a cross-sectional view showing the prepreg assembly kept in vacuum.
- FIG. 19 is a cross-sectional view showing the insertion of a bolt into a through-hole of the upper die to separate the upper and lower dies.
- FIG. 20 is a partial, perspective view showing the insertion of a flat-tip tool into a groove of a flange of the lower die to pry the fiber-reinforced composite member out of the lower die.
- FIG. 21 is a cross-sectional view showing the dimensions of the lower die and the fiber-reinforced composite member at a curing temperature.
- FIG. 22 is a graph showing the dimensional changes of the fiber-reinforced composite member and the molding die caused by temperature variation.
- FIG. 1 shows a beam-shaped, fiber-reinforced composite member according to one embodiment of the present invention.
- This fiber-reinforced composite member 1 which is produced by curing prepregs of reinforcing fibers impregnated with a matrix resin, comprises a trapezoidal flat panel portion 10 , flanges 11 , 11 ′ extending from both side edges thereof toward both sides, and I-shaped, projections 12 , 12 , 13 , 13 provided on both surfaces of the flat panel portion 10 .
- One flange 11 vertically extends from the flat panel portion 10 , while the other flange 11 ′ extends in a slanting direction relative to the flange 11 .
- the projections 12 and 13 have information concerning the identification and predetermined connecting positions of said additional members to be connected to the fiber-reinforced composite member 1 .
- the distance L 1 between the outer ends of the projections 12 , 12 and distance L 2 between the outer ends of the projections 13 , 13 are the same as the longitudinal lengths L 3 and L 4 of rectangular connecting plate portions 23 and 33 of first and second additional members 2 , 3 shown in FIGS. 2 ( a )- 2 ( e ) and FIG. 3 .
- a first additional member 2 comprises a flat panel portion 20 , flange 21 , 21 ′ extending from both side edges thereof toward both sides, and a rectangular connecting plate portion 23 vertically extending from each end of the flat panel portion 20 .
- One flange 21 has a flat, straight surface, while the other flange 21 ′ has a curved surface.
- the rectangular connecting plate portion 23 has steps 23 a , 23 a at both ends, each having the same length as that of the projection 12 . As shown in FIGS.
- a second additional member 3 comprises a flat panel portion 30 , flanges 31 , 31 ′ extending from both side edges thereof toward both sides, and a rectangular connecting plate portion 33 vertically extending from each end of the flat panel portion 30 .
- One flange 31 has a flat, straight surface, while the other flange 31 ′ has a curved surface.
- the rectangular connecting plate portion 33 of the second additional member 3 also has at both ends steps 33 a , 33 a engageable with the projections 13 , 13 of the fiber-reinforced composite member 1 , so that the second additional member 3 can be disposed at a predetermined connecting position to the fiber-reinforced composite member 1 .
- the connecting portion 23 of the first additional member 2 may not have steps, as long as the distance L 1 between the outer ends of the projections 12 , 12 is the same as the length L 3 of the rectangular connecting plate portion 23 .
- the first additional member 2 can be disposed at a determined connecting position to the fiber-reinforced composite member 1 .
- vertical and horizontal positioning is preferably conducted by placing the fiber-reinforced composite member 1 and the additional member 2 on a table with their flat flanges 11 and 21 downward. With the fiber-reinforced composite member 1 and the additional member 2 disposed at the determined connecting position, the flanges 11 and 21 constitute a flat plane. The same is true of the second additional member 3 .
- the shapes, sizes, number and arrangement of the projections 12 and 13 may be arbitrarily set as long as the first and second additional members 2 and 3 can be disposed at the predetermined position.
- the shapes and sizes of the connecting portions 23 and 33 of the additional members 2 and 3 are not restricted to those shown in FIGS. 2-4 , either.
- U-shaped recesses 23 b , 23 b as long as the projections 12 , 12 may be provided on the edge of the connecting portion 23 of the first additional member 2 at positions engageable with the projections 12 , 12 .
- FIG. 6 shows a fiber-reinforced composite member according to another embodiment of the present invention.
- the same members and portions as in FIG. 1 are provided with the same reference numerals.
- This fiber-reinforced composite member 1 is the same as shown in FIG. 1 , except that I-shaped projections 12 and 13 are provided with letters “A” and “B”, respectively, as marks.
- the marks formed on the projections 12 and 13 are not restricted to letters, but may be numbers, symbols, combinations including them, etc. indicating the numbers, materials, etc. of the additional members.
- a first additional member 2 is provided with a mark 24 consisting of the letter “A,” and a second additional member 3 (see FIG. 3 ) is provided with a mark consisting of the letter “B.”
- the first and second additional members 2 and 3 are arranged to the fiber-reinforced composite member 1 shown in FIG. 6 in the same manner as described above.
- FIG. 8 shows a fiber-reinforced composite member according to a further embodiment of the present invention.
- This fiber-reinforced composite member is the same as shown in FIG. 1 , except that it has L-shaped projections 12 and 13 .
- the shapes, sizes, number and arrangement of the L-shaped projections 12 and 13 are adapted to the shape and size of the connecting portion 23 of the first additional member 2 , the gap L 5 between parallel portions of the projections 12 , 12 being the same as the length L 3 of the connecting portion 23 .
- both corners of the connecting portion 23 are fit to the inside corners of the L-shaped projections 12 , 12 , resulting in the arrangement of the members 1 and 2 at the predetermined connecting positions.
- the L-shaped projections 12 , 12 make steps 23 a or recesses 23 b unnecessary in the connecting portion 23 of the first additional member 2 , to easily arrange the first additional member 2 at the predetermined connecting position to the fiber-reinforced composite member 1 .
- the gap L 6 between the parallel portions of the projections 13 , 13 is the same as the length L 4 of the connecting portion 33 of the second additional member 3 (see FIG. 3 ), so that both corners of the connecting portion 33 is fit to the inside corners of the L-shaped projections 13 , 13 .
- FIG. 10 shows a fiber-reinforced composite member according to a still further embodiment of the present invention.
- This fiber-reinforced composite member 1 is the same as shown in FIG. 8 , except that it has four L-shaped projections 12 .
- the shapes, sizes, number and arrangement of the L-shaped projections 12 are adapted to the shape and size of the connecting portion 23 of the first additional member 2 , so that four corners of the connecting portion 23 are fit to the inside corners of the four L-shaped projections 12 , resulting in the accurate arrangement of the members 1 and 2 at the predetermined connecting positions.
- the fiber-reinforced composite structure is produced by positioning additional members to the fiber-reinforced composite member 1 , and fixing them by fastening with rivets, bolts, etc., or by adhesion. Though not restrictive, when positioning is conducted by placing the members 1 and 2 on a table 5 with their flat flanges 11 and 21 below as shown in FIG. 11 , the position of the members 1 and 2 in both X and Y directions can be easily set. The same is true of positioning an additional member 3 to the fiber-reinforced composite member 1 .
- FIG. 12 shows an example of aircraft fuselage structures using the fiber-reinforced composite member of the present invention.
- the flat panel portion 10 of the fiber-reinforced composite member 1 having L-shaped projections 12 , 13 is connected to the fiber-reinforced composite members 2 , 3 with fasteners 50
- a fiber-reinforced composite member 4 having connecting portions 43 is connected between the L-shaped projections 22 , 32 of the fiber-reinforced composite members 2 , 3 with fasteners 50 .
- the additional members connected to the fiber-reinforced composite member of the present invention are not restricted to fiber-reinforced composite members, but may be aluminum alloy members, etc.
- the fiber-reinforced composite structure is not restricted to comprise only fiber-reinforced composite members, but may have other members than fiber-reinforced composite members.
- the structure shown in FIG. 12 can be used for aircraft floors.
- FIGS. 13-14 show one example of molds for forming the fiber-reinforced composite panel 1 shown in FIG. 1 .
- This mold comprises upper and lower molds 6 , 7 having cavities 60 , 70 for forming the flat panel portion 10 and flanges 11 , 11 ′ of the fiber-reinforced composite 1 , and side molds 8 , 8 ′, clamped to the upper and lower molds 6 , 7 .
- the upper die 6 comprises a cavity 60 having a horizontal portion 60 a , a vertical portion 60 b and a slanting portion 60 c for forming the flat panel portion 10 , and flanges 11 , 11 ′, respectively, of the fiber-reinforced composite member 1 .
- the upper die 6 has pluralities of holes 66 for receiving the heads 90 a of pins 90 .
- the cavity 60 is surrounded by a groove 61 for receiving a resin-leak-preventing seal 91 , a flange 62 being formed between the cavity 60 and the groove 61 .
- the horizontal portion 60 a has recesses 63 , 63 , 64 , 64 for forming the projections 12 , 12 , 13 , 13 of the fiber-reinforced composite member 1 .
- the upper die 6 properly has a shallow groove 65 on an inner surface of the flange 62 (end surface 60 d of the cavity 60 ), into which a flat-tip tool such as a minus driver, etc. is inserted.
- the lower die 7 has a shape corresponding to the upper die 6 .
- the lower die 7 comprises a cavity 70 having a horizontal portion 70 a , a vertical portion 70 b and a slanting portion 70 c for forming the flat panel portion 10 , and flanges 11 , 11 ′, respectively, of the fiber-reinforced composite member 1 .
- the lower die 7 has pluralities of holes 76 for receiving pins 90 . With each pin head 90 a inserted into the hole 66 of the upper die 6 , and each body of the pin 90 inserted into the lower die 7 , the upper and lower dies 6 and 7 are accurately positioned.
- the cavity 70 is surrounded by a groove 71 for receiving a resin-leak-preventing seal 91 , a flange 72 being formed between the cavity 70 and the groove 71 .
- the horizontal portion 70 a has recesses 73 , 73 , 74 , 74 for forming the projections 12 , 12 , 13 , 13 of the fiber-reinforced composite member 1 .
- the lower die 7 is also provided with a shallow groove 75 on an inner surface of the flange 72 (end surface 70 d of the cavity 70 ), into which a flat-tip tool for prying the resultant fiber-reinforced composite member 1 out of the lower die 7 is inserted.
- the total thickness of the cavities 60 , 70 of the upper and lower dies 6 , 7 is preferably smaller than the target thickness of the fiber-reinforced composite member 1 by about 0.1 mm.
- Materials forming the upper and lower dies 6 , 7 may be cast iron, cast steel (for instance, JIS SS400, etc.), carbon steel (for instance, JIS S45C-H, etc.), etc. Cast iron having a low linear thermal expansion coefficient is commercially available under the trademark of “NOBINITE” from Enomoto Chukousho Co., Ltd.
- Materials forming the side dies 8 may be aluminum, etc.
- Materials forming the pin 90 may be alloyed steel (for instance, JIS SCM435H, etc.).
- Materials forming the seal 91 may be rubbers having enough heat resistance to withstand the curing temperature, such as fluororubbers such as polytetrafluoroethylene (PTFE), silicone rubbers, etc.
- fluororubbers such as polytetrafluoroethylene (PTFE), silicone rubbers, etc.
- PTFE seals include GORE-TEX No. 3300 available from Japan Gore-Tex Inc.
- the holes 63 , 64 of the upper die 6 and the holes 73 , 74 of the lower die 7 are first filled with a resin.
- This resin is preferably the same as the prepreg matrix resin.
- Pluralities of trapezoidal prepreg cloths are laminated on the upper die 6 and the lower die 7 .
- prepreg laminates 1 a , 1 b on the upper die 6 and the lower die 7 respectively have excess margins.
- the prepreg is composed of a reinforcing fiber cloth impregnated with a matrix resin.
- the reinforcing fibers are not particularly restrictive, but may be properly selected from carbon fibers, aramide fibers, glass fibers, boron fibers, etc. depending on applications.
- the matrix resin is preferably a heat-setting resin, which may be properly selected from epoxy resins, polyurethanes, unsaturated polyesters, bismaleimide resins, phenol resins, etc. depending on applications.
- the reinforcing fibers are preferably carbon fibers
- the matrix resin is preferably an epoxy resin.
- an excess margin of the flange 11 a of the prepreg laminate 1 a is cut off or trimmed along the end surface 60 c of the cavities 60 of the upper die 6
- an excess margin of the flange 11 b of the prepreg laminate 1 b is trimmed along the end surface 70 d of the cavities 70 of the and lower die 7 .
- Trimming is usually conducted at room temperature.
- the seal 91 is attached to the groove 61 of the upper die 6 and to the groove 71 of the lower die 7 .
- the groove 65 of the upper die 6 and the lower die 7 of the groove 75 are filled with a silicone piece. As shown in FIG.
- the pins 90 are inserted into the holes 76 of the lower die 7 , and their heads 90 a are inserted into the holes 66 of the upper die 6 .
- the upper die 6 is attached to the lower die 7 such that the prepreg laminates 1 a and 1 b are in contact with each other.
- the method of the present invention can easily produce fiber-reinforced composite members with better cut surfaces than conventional methods of trimming cured prepreg moldings.
- prepreg strips 1 c , 1 c are laminated on the flanges 11 a , 11 b , and the flanges 11 a ′, 11 b ′ of the prepreg laminates 1 a , 1 b via a filler 1 d made of reinforcing fibers and a matrix resin, to strengthen the flanges 11 , 11 ′.
- a prepreg assembly 1 ′ integrally comprising the prepreg laminates 1 a , 1 b , the prepreg strip 1 c , and the filler 1 d.
- side dies 8 , 8 are clamped to side surfaces of the combined upper and lower dies 6 , 7 , to support the flanges of the prepreg assembly 1 ′.
- the overall die is placed on a base plate 93 and covered with a bag film 94 as shown in FIG. 17 .
- the bag film 94 is evacuated through a pipe 95 connected to a vacuum pump.
- an adhesive seal 96 is placed between the bag film 94 and the base plate 93 .
- Heating is conducted while keeping the bag film 94 in a vacuum state (see FIG. 18 ), to cure the matrix resin. Heating may be conducted in an oven, etc., but it is preferably conducted while pressurizing in an autoclave, etc.
- the heating temperature is preferably 120-180° C., though slightly different depending on the type of the heat-setting resin.
- pressurization is preferably conducted at about 3-6 MPa.
- each hole 66 of the upper die 6 has a threaded portion.
- a bolt 97 is screwed into the threaded hole 66 to push the head 90 a of the pin 90 with its tip end, thereby easily separating the upper die 6 from the lower die 7 .
- a flat-tip tool 98 such as a minus driver is inserted into the groove 65 provided on the flange 62 of the upper die 6 to pry the fiber-reinforced composite member 1 out of the upper die 6 .
- a flat-tip tool 98 is also inserted into the groove 75 provided on the flange 72 of the lower die 7 to pry the fiber-reinforced composite member 1 out of the lower die 7 .
- the fiber-reinforced composite member 1 (prepreg assembly 1 ′) and the molding die preferably have as close linear thermal expansion coefficients as possible.
- CFRP used for the fiber-reinforced composite member 1 has a linear thermal expansion coefficient of about 2.6 ⁇ 10 ⁇ 6 /° C.
- the dimensions of the cavities of the dies 6 , 7 at room temperature are preferably set such that they have the same dimension as that of the fiber-reinforced composite member 1 at a curing temperature.
- ⁇ 1 is the linear thermal expansion coefficient of the fiber-reinforced composite member 1
- ⁇ 2 is the linear thermal expansion coefficient of the lower die 7
- ⁇ T is the difference (° C.) between room temperature and the curing temperature.
- angles between the horizontal portions 60 a , 70 a and the vertical portions 60 b , 70 b , and angles between the horizontal portions 60 a , 70 a and the slanting portions 60 c , 70 c in the cavities 60 , 70 are preferably set larger than those of the final product by the possible decrement (for instance, about 0.5-1.5°).
- additional members to be connected to the fiber-reinforced composite member can be quickly identified, and the positioning of additional members can be conducted accurately and quickly, thereby providing high-accuracy structures by a small number of steps. Accordingly, using the fiber-reinforced composite member of the present invention, fiber-reinforced composite structures used in fuselages, wings, etc. of aircrafts can be produced quickly and inexpensively.
Abstract
A method for assembling a fiber-reinforced composite structure by connecting fiber-reinforced composite members to additional members, comprising the steps of providing at least one of said fiber-reinforced composite members with projections having information concerning the identification and connecting positions of said additional members, to which said fiber-reinforced composite member is to be connected, and positioning said additional members to said fiber-reinforced composite member using said projections.
Description
- The present invention relates to a fiber-reinforced composite member with which a fiber-reinforced composite structure can be produced quickly and inexpensively, and a method for assembling a fiber-reinforced composite structure using such member.
- When pluralities of fiber-reinforced composite members of carbon-fiber-reinforced plastics (CFRP), etc. are combined to produce such structures as fuselages and wings of aircrafts, etc., the members are conventionally disposed at the predetermined positions and connected. However, the accurate positioning of members needs large assembling jigs, or optical positioning apparatuses, for instance, an apparatus of detecting the positions of other members relative to holes, etc. of one member, and moving the other members to desired positions based on the difference between the detected positions and the preset positions, resulting in high production cost.
- U.S. Pat. No. 5,560,102 proposes a method for producing an aircraft fuselage using self-locating detail parts whose positions are determined based on positioning holes. Specifically, the method comprises determining the positions of rivet-connecting holes in the structure by CAD in advance, memorizing the position of each rivet-connecting hole as a position of a hole to be formed in each member in a CAD/CAM main frame, providing each member with through-holes (positioning holes) by controlling an NC drill according to a connecting position information down-loaded from the CAD/CAM main frame, which may differ form member to member, and arranging the members based on the positioning holes. This method can produce high-accuracy structures by a small number of steps. When an aircraft structure is produced by combining large numbers of members, however, high efficiency cannot be achieved unless quickly determining the combination and positions of members to be connected. Because only positioning holes are provided in the method of U.S. Pat. No. 5,560,102, the combination and positions of members to be connected cannot be quickly determined.
- Accordingly, an object of the present invention is to provide a fiber-reinforced composite member capable of being assembled to a fiber-reinforced composite structure quickly and inexpensively.
- Another object of the present invention is to provide a method for assembling a structure comprising such a fiber-reinforced composite member.
- As a result of intense research in view of the above object, the inventors have found that when a fiber-reinforced composite member is provided with projections having information concerning the identification and connecting positions of said additional members, to which said fiber-reinforced composite member is to be connected, a fiber-reinforced composite structure can be quickly and inexpensively assembled by using such fiber-reinforced composite member. The present invention has been completed based on such finding.
- Thus, the fiber-reinforced composite member of the present invention comprises projections having information concerning the identification and connecting positions of said additional members, to which said fiber-reinforced composite member is to be connected.
- The method of the present invention for assembling a fiber-reinforced composite structure by connecting fiber-reinforced composite members to additional members comprises the steps of providing at least one of said fiber-reinforced composite members with projections having information concerning the identification and connecting positions of said additional members, to which said fiber-reinforced composite member is to be connected, and positioning said additional members to said fiber-reinforced composite member using said projections.
- Said information is preferably given by at least one selected from the group consisting of the shapes, sizes, number and arrangement of said projections, and marks provided on said projections. The shapes, sizes, number and arrangement of said projections are preferably set such that said projections engage the connecting portions of said additional members. To position said additional members to the fiber-reinforced composite member having such projections, said projections need only be engaged with the connecting portions of said additional members. The connecting portions of said additional members are preferably provided with steps or recesses engageable with said projections of the fiber-reinforced composite member. Said projections and said additional members preferably have corresponding marks.
- In a preferred embodiment of the present invention, said fiber-reinforced composite member comprises one or more pairs of I-shaped projections, and said additional members comprise rectangular connecting plate portions engageable with said I-shaped projections, said I-shaped projections being engaged with said rectangular connecting plate portions to arrange said additional members at predetermined connecting positions to said fiber-reinforced composite member.
- In another embodiment of the present invention, said fiber-reinforced composite member comprises one or more pairs of L-shaped projections, and said additional members comprise rectangular connecting plate portions engageable with said L-shaped projections, said L-shaped projections being engaged with said rectangular connecting plate portions to arrange said additional members at predetermined connecting positions to said fiber-reinforced composite member.
-
FIG. 1 is a perspective view showing a fiber-reinforced composite member according to one embodiment of the present invention. -
FIG. 2 (a) is a partial, perspective view showing one example of the connection of an additional member to a fiber-reinforced composite member. -
FIG. 2 (b) is a partially-cross-sectioned, enlarged view showing a fiber-reinforced composite member and an additional member, which are to be connected. -
FIG. 2 (c) is a partially-cross-sectioned, enlarged view showing the fiber-reinforced composite member and additional member ofFIG. 2 (a), which are connected to each other. -
FIG. 2 (d) is a partial plan view showing the connected fiber-reinforced composite member and additional member. -
FIG. 2 (e) is a partial, enlarged view showing a rectangular connecting plate portion of the additional member inFIG. 2 (a). -
FIG. 3 is a partial, perspective view showing another example of the connection of an additional member to the fiber-reinforced composite member ofFIG. 1 . -
FIG. 4 is a partial, perspective view showing a further example of the connection of an additional member to the fiber-reinforced composite member ofFIG. 1 . -
FIG. 5 (a) is a partial, perspective view showing an example of the connection of an additional member to a fiber-reinforced composite member according to another embodiment of the present invention. -
FIG. 5 (b) is a partial, enlarged view showing a connecting portion of the additional member shown inFIG. 5 (a). -
FIG. 6 is a perspective view showing a fiber-reinforced composite member according to a further embodiment of the present invention. -
FIG. 7 is a perspective view showing an example of the connection of an additional member to the fiber-reinforced composite member ofFIG. 6 . -
FIG. 8 is a perspective view showing a fiber-reinforced composite member according to a still further embodiment of the present invention. -
FIG. 9 is a partial, perspective view showing an example of the connection of an additional member to the fiber-reinforced composite member ofFIG. 8 . -
FIG. 10 is a partial, perspective view showing an example of the connection of an additional member to a fiber-reinforced composite member according to a still further embodiment of the present invention. -
FIG. 11 is a partial, perspective view showing the positioning of an additional member to the fiber-reinforced composite member ofFIG. 1 on a table. -
FIG. 12 is a perspective view showing an example of aircraft fuselage structures using the fiber-reinforced composite member of the present invention. -
FIG. 13 (a) is a perspective view showing an example of dies for molding the fiber-reinforced composite member ofFIG. 1 . -
FIG. 13 (b) is a view showing the upper die ofFIG. 13 (a) from various angles. -
FIG. 13 (c) is a view showing the lower die ofFIG. 13 (a) from various angles. -
FIG. 14 (a) is an enlarged, perspective view showing a portion A inFIG. 13 (a). -
FIG. 14 (b) is an enlarged, perspective view showing a portion B inFIG. 13 (a). -
FIG. 15 (a) is a side view showing a prepreg laminate placed on the upper die (lower die). -
FIG. 15 (b) is a side view showing the trimming of an excess margin of the prepreg laminate placed on the upper die (lower die). -
FIG. 15 (c) is a perspective view showing excess-margin-free prepreg laminates received in the cavities of the upper and lower dies. -
FIG. 15 (d) is a side view showing the closure of the upper and lower dies containing the excess-margin-free prepreg laminates. -
FIG. 15 (e) is a cross-sectional view showing the lamination of prepreg strips to the flanges of the combined prepreg laminates after the upper and lower dies are closed. -
FIG. 16 is a side view showing the attachment of side dies to the closed upper and lower dies. -
FIG. 17 is a cross-sectional view showing a prepreg assembly in the molding die covered by a bag film and evacuated. -
FIG. 18 is a cross-sectional view showing the prepreg assembly kept in vacuum. -
FIG. 19 is a cross-sectional view showing the insertion of a bolt into a through-hole of the upper die to separate the upper and lower dies. -
FIG. 20 is a partial, perspective view showing the insertion of a flat-tip tool into a groove of a flange of the lower die to pry the fiber-reinforced composite member out of the lower die. -
FIG. 21 is a cross-sectional view showing the dimensions of the lower die and the fiber-reinforced composite member at a curing temperature. -
FIG. 22 is a graph showing the dimensional changes of the fiber-reinforced composite member and the molding die caused by temperature variation. - [1] Fiber-Reinforced Composite Member
-
FIG. 1 shows a beam-shaped, fiber-reinforced composite member according to one embodiment of the present invention. This fiber-reinforcedcomposite member 1, which is produced by curing prepregs of reinforcing fibers impregnated with a matrix resin, comprises a trapezoidalflat panel portion 10,flanges projections flat panel portion 10. Oneflange 11 vertically extends from theflat panel portion 10, while theother flange 11′ extends in a slanting direction relative to theflange 11. Theprojections composite member 1. In this embodiment, to identify the additional members, the distance L1 between the outer ends of theprojections projections plate portions additional members FIG. 3 . - As shown in
FIG. 2 (e), a firstadditional member 2 comprises aflat panel portion 20,flange plate portion 23 vertically extending from each end of theflat panel portion 20. Oneflange 21 has a flat, straight surface, while theother flange 21′ has a curved surface. The rectangular connectingplate portion 23 hassteps projection 12. As shown in FIGS. 2(a)-2(d), when the connectingportion 23 of the firstadditional member 2 is abutted to theflat panel portion 10 of the fiber-reinforcedcomposite member 1 such that thesteps projections additional member 2 to the fiber-reinforcedcomposite member 1 in both X and Y directions is determined, so that the firstadditional member 2 can be disposed at a predetermined connecting position to the fiber-reinforcedcomposite member 1. - As shown in
FIG. 3 , a secondadditional member 3 comprises aflat panel portion 30,flanges plate portion 33 vertically extending from each end of theflat panel portion 30. Oneflange 31 has a flat, straight surface, while theother flange 31′ has a curved surface. Like the firstadditional member 2, the rectangular connectingplate portion 33 of the secondadditional member 3 also has at both endssteps projections composite member 1, so that the secondadditional member 3 can be disposed at a predetermined connecting position to the fiber-reinforcedcomposite member 1. - As shown in
FIG. 4 , the connectingportion 23 of the firstadditional member 2 may not have steps, as long as the distance L1 between the outer ends of theprojections plate portion 23. When the rectangular connectingplate portion 23 is abutted to theflat panel portion 10 such that both ends of the connectingportion 23 are positioned at the outer ends of theprojections additional member 2 can be disposed at a determined connecting position to the fiber-reinforcedcomposite member 1. As described later, vertical and horizontal positioning is preferably conducted by placing the fiber-reinforcedcomposite member 1 and theadditional member 2 on a table with theirflat flanges composite member 1 and theadditional member 2 disposed at the determined connecting position, theflanges additional member 3. - The shapes, sizes, number and arrangement of the
projections additional members portions additional members FIGS. 2-4 , either. As shown in FIGS. 5(a) and 5(b),U-shaped recesses projections portion 23 of the firstadditional member 2 at positions engageable with theprojections -
FIG. 6 shows a fiber-reinforced composite member according to another embodiment of the present invention. InFIG. 6 , the same members and portions as inFIG. 1 are provided with the same reference numerals. This fiber-reinforcedcomposite member 1 is the same as shown inFIG. 1 , except that I-shapedprojections projections - To identify additional members to be connected to the fiber-reinforced
composite member 1 shown inFIG. 6 , as shown inFIG. 7 , a firstadditional member 2 is provided with amark 24 consisting of the letter “A,” and a second additional member 3 (seeFIG. 3 ) is provided with a mark consisting of the letter “B.” The first and secondadditional members composite member 1 shown inFIG. 6 in the same manner as described above. -
FIG. 8 shows a fiber-reinforced composite member according to a further embodiment of the present invention. InFIG. 8 , the same members and portions as inFIG. 1 are provided with the same reference numerals. This fiber-reinforced composite member is the same as shown inFIG. 1 , except that it has L-shapedprojections FIGS. 8 and 9 , the shapes, sizes, number and arrangement of the L-shapedprojections portion 23 of the firstadditional member 2, the gap L5 between parallel portions of theprojections portion 23. Accordingly, both corners of the connectingportion 23 are fit to the inside corners of the L-shapedprojections members projections steps 23 a or recesses 23 b unnecessary in the connectingportion 23 of the firstadditional member 2, to easily arrange the firstadditional member 2 at the predetermined connecting position to the fiber-reinforcedcomposite member 1. The gap L6 between the parallel portions of theprojections portion 33 of the second additional member 3 (seeFIG. 3 ), so that both corners of the connectingportion 33 is fit to the inside corners of the L-shapedprojections -
FIG. 10 shows a fiber-reinforced composite member according to a still further embodiment of the present invention. InFIG. 10 , the same members and portions as inFIG. 1 are provided with the same reference numerals. This fiber-reinforcedcomposite member 1 is the same as shown inFIG. 8 , except that it has four L-shapedprojections 12. The shapes, sizes, number and arrangement of the L-shapedprojections 12 are adapted to the shape and size of the connectingportion 23 of the firstadditional member 2, so that four corners of the connectingportion 23 are fit to the inside corners of the four L-shapedprojections 12, resulting in the accurate arrangement of themembers - [2] Production Method of Fiber-Reinforced Composite Structure
- The fiber-reinforced composite structure is produced by positioning additional members to the fiber-reinforced
composite member 1, and fixing them by fastening with rivets, bolts, etc., or by adhesion. Though not restrictive, when positioning is conducted by placing themembers flat flanges FIG. 11 , the position of themembers additional member 3 to the fiber-reinforcedcomposite member 1. -
FIG. 12 shows an example of aircraft fuselage structures using the fiber-reinforced composite member of the present invention. Theflat panel portion 10 of the fiber-reinforcedcomposite member 1 having L-shapedprojections composite members fasteners 50, and a fiber-reinforced composite member 4 having connectingportions 43 is connected between the L-shapedprojections composite members fasteners 50. It should be noted, however, that the additional members connected to the fiber-reinforced composite member of the present invention are not restricted to fiber-reinforced composite members, but may be aluminum alloy members, etc. Accordingly, the fiber-reinforced composite structure is not restricted to comprise only fiber-reinforced composite members, but may have other members than fiber-reinforced composite members. The structure shown inFIG. 12 can be used for aircraft floors. - [3] Production Method of Fiber-Reinforced Composite Member
- Taking for example the beam-shaped, fiber-reinforced
composite member 1 shown inFIG. 1 , the production method of the fiber-reinforced composite member of the present invention will be explained below. - (1) Molding Die
- (a) Shape
-
FIGS. 13-14 show one example of molds for forming the fiber-reinforcedcomposite panel 1 shown inFIG. 1 . This mold comprises upper andlower molds cavities flat panel portion 10 andflanges composite 1, andside molds lower molds - As shown in FIGS. 13(a) and 13(b), The
upper die 6 comprises acavity 60 having ahorizontal portion 60 a, avertical portion 60 b and a slantingportion 60 c for forming theflat panel portion 10, andflanges composite member 1. Theupper die 6 has pluralities ofholes 66 for receiving theheads 90 a of pins 90. Thecavity 60 is surrounded by agroove 61 for receiving a resin-leak-preventingseal 91, aflange 62 being formed between thecavity 60 and thegroove 61. Thehorizontal portion 60 a has recesses 63, 63, 64, 64 for forming theprojections composite member 1. - As shown in
FIG. 14 (a), to pry the resultant fiber-reinforcedcomposite member 1 out of theupper die 6, theupper die 6 properly has ashallow groove 65 on an inner surface of the flange 62 (end surface 60 d of the cavity 60), into which a flat-tip tool such as a minus driver, etc. is inserted. - As shown in FIGS. 13(a) and 13(c), the
lower die 7 has a shape corresponding to theupper die 6. Thelower die 7 comprises acavity 70 having ahorizontal portion 70 a, avertical portion 70 b and a slantingportion 70 c for forming theflat panel portion 10, andflanges composite member 1. Thelower die 7 has pluralities ofholes 76 for receiving pins 90. With eachpin head 90 a inserted into thehole 66 of theupper die 6, and each body of thepin 90 inserted into thelower die 7, the upper and lower dies 6 and 7 are accurately positioned. Thecavity 70 is surrounded by agroove 71 for receiving a resin-leak-preventingseal 91, aflange 72 being formed between thecavity 70 and thegroove 71. Thehorizontal portion 70 a has recesses 73, 73, 74, 74 for forming theprojections composite member 1. - As shown in
FIG. 14 (b), thelower die 7. is also provided with ashallow groove 75 on an inner surface of the flange 72 (end surface 70 d of the cavity 70), into which a flat-tip tool for prying the resultant fiber-reinforcedcomposite member 1 out of thelower die 7 is inserted. - Because the cured fiber-reinforced
composite member 1 tends to become thicker by about 0.1 mm after opening the die, the total thickness of thecavities composite member 1 by about 0.1 mm. - (b) Materials
- Materials forming the upper and lower dies 6, 7 may be cast iron, cast steel (for instance, JIS SS400, etc.), carbon steel (for instance, JIS S45C-H, etc.), etc. Cast iron having a low linear thermal expansion coefficient is commercially available under the trademark of “NOBINITE” from Enomoto Chukousho Co., Ltd. Materials forming the side dies 8 may be aluminum, etc.
- Materials forming the
pin 90 may be alloyed steel (for instance, JIS SCM435H, etc.). Materials forming theseal 91 may be rubbers having enough heat resistance to withstand the curing temperature, such as fluororubbers such as polytetrafluoroethylene (PTFE), silicone rubbers, etc. Commercially available PTFE seals include GORE-TEX No. 3300 available from Japan Gore-Tex Inc. - (2) Production Steps
- (a) Lamination of Prepregs
- The
holes upper die 6 and theholes lower die 7 are first filled with a resin. This resin is preferably the same as the prepreg matrix resin. Pluralities of trapezoidal prepreg cloths are laminated on theupper die 6 and thelower die 7. As shown inFIG. 15 (a), prepreg laminates 1 a, 1 b on theupper die 6 and thelower die 7 respectively have excess margins. - The prepreg is composed of a reinforcing fiber cloth impregnated with a matrix resin. The reinforcing fibers are not particularly restrictive, but may be properly selected from carbon fibers, aramide fibers, glass fibers, boron fibers, etc. depending on applications. The matrix resin is preferably a heat-setting resin, which may be properly selected from epoxy resins, polyurethanes, unsaturated polyesters, bismaleimide resins, phenol resins, etc. depending on applications. When the panel-shaped, fiber-reinforced
composite member 1 is used for the aircraft fuselage, the reinforcing fibers are preferably carbon fibers, and the matrix resin is preferably an epoxy resin. - (b) Trimming of Excess Margin
- As shown in
FIG. 15 (b), using atrimming tool 92 such as a cutter, etc., an excess margin of theflange 11 a of the prepreg laminate 1 a is cut off or trimmed along theend surface 60 c of thecavities 60 of theupper die 6, and an excess margin of theflange 11 b of the prepreg laminate 1 b is trimmed along theend surface 70 d of thecavities 70 of the andlower die 7. Trimming is usually conducted at room temperature. Theseal 91 is attached to thegroove 61 of theupper die 6 and to thegroove 71 of thelower die 7. Thegroove 65 of theupper die 6 and thelower die 7 of thegroove 75 are filled with a silicone piece. As shown inFIG. 15 (c), thepins 90 are inserted into theholes 76 of thelower die 7, and theirheads 90 a are inserted into theholes 66 of theupper die 6. Theupper die 6 is attached to thelower die 7 such that the prepreg laminates 1 a and 1 b are in contact with each other. - Because excess margins are cut off from the easily trimmable uncured prepreg laminates 1 a, 1 b, the method of the present invention can easily produce fiber-reinforced composite members with better cut surfaces than conventional methods of trimming cured prepreg moldings.
- (c) Lamination of Prepregs for Flanges
- As shown in FIGS. 15(d) and 15(e), prepreg strips 1 c, 1 c are laminated on the
flanges flanges 11 a′, 11 b′ of the prepreg laminates 1 a, 1 b via afiller 1 d made of reinforcing fibers and a matrix resin, to strengthen theflanges prepreg assembly 1′ integrally comprising the prepreg laminates 1 a, 1 b, theprepreg strip 1 c, and thefiller 1 d. - (d) Curing
- As shown in
FIG. 16 , side dies 8, 8, are clamped to side surfaces of the combined upper and lower dies 6, 7, to support the flanges of theprepreg assembly 1′. The overall die is placed on abase plate 93 and covered with abag film 94 as shown inFIG. 17 . Thebag film 94 is evacuated through apipe 95 connected to a vacuum pump. To keep a vacuum state, anadhesive seal 96 is placed between thebag film 94 and thebase plate 93. - Heating is conducted while keeping the
bag film 94 in a vacuum state (seeFIG. 18 ), to cure the matrix resin. Heating may be conducted in an oven, etc., but it is preferably conducted while pressurizing in an autoclave, etc. The heating temperature is preferably 120-180° C., though slightly different depending on the type of the heat-setting resin. When an autoclave is used, pressurization is preferably conducted at about 3-6 MPa. - (e) Removal from Die
- The dies 6-8 are detached from the resultant fiber-reinforced
composite member 1. As shown inFIG. 19 , eachhole 66 of theupper die 6 has a threaded portion. Abolt 97 is screwed into the threadedhole 66 to push thehead 90 a of thepin 90 with its tip end, thereby easily separating theupper die 6 from thelower die 7. A flat-tip tool 98 such as a minus driver is inserted into thegroove 65 provided on theflange 62 of theupper die 6 to pry the fiber-reinforcedcomposite member 1 out of theupper die 6. As shown inFIG. 20 , a flat-tip tool 98 is also inserted into thegroove 75 provided on theflange 72 of thelower die 7 to pry the fiber-reinforcedcomposite member 1 out of thelower die 7. - (3) Setting of Dimension of Molding Die
- To prevent decrease in dimensional accuracy due to thermal expansion during the heat curing, the fiber-reinforced composite member 1 (
prepreg assembly 1′) and the molding die preferably have as close linear thermal expansion coefficients as possible. Specifically, because CFRP used for the fiber-reinforcedcomposite member 1 has a linear thermal expansion coefficient of about 2.6×10−6/° C., it is preferable to use NOBINITE CS-5 having a linear thermal expansion coefficient of 2.5×10−6/° C. (200° C.), or CN-5 having a linear thermal expansion coefficient of 2.7×10−6/° C. (200° C.). However, when there is a relatively large difference between their linear thermal expansion coefficients, the dimensions of the cavities of the dies 6, 7 at room temperature are preferably set such that they have the same dimension as that of the fiber-reinforcedcomposite member 1 at a curing temperature. - Because dimensional accuracy is important in the
flat panel portion 10 in the fiber-reinforcedcomposite member 1, its length is designed as W1, and the length of the cavity for providing such designed length is set as W2. When heated from room temperature to the curing temperature, as shown inFIGS. 21 and 22 , the length W1 of theflat panel portion 10 becomes W1+ΔW1 (=α1·W1·ΔT), and the length W2 of the cavity becomes W2+ΔW2 (=α2·W2·ΔT). Here, α1 is the linear thermal expansion coefficient of the fiber-reinforcedcomposite member 1, α2 is the linear thermal expansion coefficient of thelower die 7, and ΔT is the difference (° C.) between room temperature and the curing temperature. Because the length of theflat panel portion 10 is equal to that of the cavity at the curing temperature, W1+α1·W1·ΔT=W2+α2·W2·ΔT. Accordingly, W2 is expressed by the following formula (1):
W 2 =W 1×(1+α1 ·ΔT)/(1+α2 ·ΔT) (1). - When the fiber-reinforced
composite member 1 is taken out of the dies 6, 7, an angle between theflat panel portion 10 and theflange 11 in the fiber-reinforcedcomposite member 1 tends to become slightly smaller. Accordingly, angles between thehorizontal portions vertical portions horizontal portions portions cavities - According to the present invention, additional members to be connected to the fiber-reinforced composite member can be quickly identified, and the positioning of additional members can be conducted accurately and quickly, thereby providing high-accuracy structures by a small number of steps. Accordingly, using the fiber-reinforced composite member of the present invention, fiber-reinforced composite structures used in fuselages, wings, etc. of aircrafts can be produced quickly and inexpensively.
Claims (12)
1. A fiber-reinforced composite member comprising projections having information concerning the identification and connecting positions of said additional members, to which said fiber-reinforced composite member is to be connected.
2. The fiber-reinforced composite member according to claim 1 , wherein said information is given by at least one selected from the group consisting of the shapes, sizes, number and arrangement of said projections, and marks provided on said projections.
3. The fiber-reinforced composite member according to claim 2 , wherein said additional members are provided with connecting portions having steps or recesses, which engage the projections of said fiber-reinforced composite member.
4. The fiber-reinforced composite member according to claim 2 , wherein said projections and said additional members have corresponding marks.
5. The fiber-reinforced composite member according to claim 1 , wherein said fiber-reinforced composite member comprises one or more pairs of I-shaped projections, and said additional members comprise rectangular connecting plate portions engageable with said I-shaped projections, whereby said additional members are arranged at predetermined connecting positions to said fiber-reinforced composite member when said rectangular connecting plate portions are engaged with said I-shaped projections.
6. The fiber-reinforced composite member according to claim 1 , wherein said fiber-reinforced composite member comprise one or more pairs of L-shaped projections, and said additional members comprise rectangular connecting plate portions engageable with said L-shaped projections, whereby said additional members are arranged at predetermined connecting positions to said fiber-reinforced composite member when said rectangular connecting plate portions are engaged with said L-shaped projections.
7. A method for assembling a fiber-reinforced composite structure by connecting fiber-reinforced composite members to additional members, comprising the steps of providing at least one of said fiber-reinforced composite members with projections having information concerning the identification and connecting positions of said additional members, to which said fiber-reinforced composite member is to be connected, and positioning said additional members to said fiber-reinforced composite member using said projections.
8. The method for assembling a fiber-reinforced composite structure according to claim 7 , wherein said information is given by at least one selected from the group consisting of the shapes, sizes, number and arrangement of said projections, and marks provided on said projections.
9. The method for assembling a fiber-reinforced composite structure according to claim 8 , wherein said additional members are provided with connecting portions having steps or recesses engageable with said projections, and wherein said projections are engaged with said steps or recesses to arrange said additional members at predetermined connecting positions to said fiber-reinforced composite member.
10. The method for assembling a fiber-reinforced composite structure according to claim 7 , wherein said projections and said additional members are provided with corresponding marks.
11. The method for assembling a fiber-reinforced composite structure according to claim 7 , wherein at least one of said fiber-reinforced composite members is provided with one or more pairs of I-shaped projections, and said additional members are provided with rectangular connecting plate portions engageable with said I-shaped projections, said I-shaped projections being engaged with said rectangular connecting plate portions to arrange said additional members at predetermined connecting positions to said fiber-reinforced composite member.
12. The method for assembling a fiber-reinforced composite structure according to claim 7 , wherein at least one of said fiber-reinforced composite members is provided with one or more pairs of L-shaped projections, and said additional members are provided with rectangular connecting plate portions engageable with said L-shaped projections, said L-shaped projections being engaged with said rectangular connecting plate portions to arrange said additional members at predetermined connecting positions to said fiber-reinforced composite member.
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JP2006-209776 | 2006-08-01 | ||
JP2006209776 | 2006-08-01 |
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US11/882,329 Abandoned US20080072527A1 (en) | 2006-08-01 | 2007-07-31 | Fiber-reinforced composite member and method for producing structure using same |
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US20130209746A1 (en) * | 2012-02-14 | 2013-08-15 | Gulfstream Aerospace Corporation | Reinforced composite structures for aircrafts and methods for making the same |
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US20150375843A1 (en) * | 2014-06-26 | 2015-12-31 | The Boeing Company | Elongated Structures and Related Assemblies |
US20170320275A1 (en) * | 2014-10-30 | 2017-11-09 | Lm Wp Patent Holding A/S | Manufacture of i-shaped shear web |
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US9023455B2 (en) | 2013-01-30 | 2015-05-05 | Ford Global Technologies, Llc | Method of making reinforced composite articles with reduced fiber content in local areas and articles made by the method |
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US9186867B2 (en) * | 2013-02-15 | 2015-11-17 | Ford Global Technologies, Llc | Assembly including a reinforced composite part with a pre-formed rivet receiving button |
US8826510B1 (en) * | 2013-02-15 | 2014-09-09 | Ford Global Technologies, Llc | Method of making assemblies including reinforced composite parts with pre-formed rivet receiving buttons and articles made by the method |
US9200442B2 (en) * | 2013-10-09 | 2015-12-01 | Brigham Young University | Structural members and related methods and systems |
US20150096244A1 (en) * | 2013-10-09 | 2015-04-09 | Brigham Young University | Structural members and related methods and systems |
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WO2017211528A1 (en) * | 2016-06-08 | 2017-12-14 | Bayerische Motoren Werke Aktiengesellschaft | Fiber-reinforced plastic component and method for producing same |
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