METHOD FOR UNITING COMPONENTS

专利摘要:
method for joining components a method of forming a structural assembly which may include providing a first component and a second component to be joined together is described. the method may additionally include sweeping a contour of a first conjugated surface of the first component and sweeping a contour of a second conjugated surface of the second component. the method may additionally include producing a thermoplastic element with opposing first and second element surfaces to substantially match an outline of the first conjugated surface and the second conjugated surface.
公开号:BR102014029087B1
申请号:R102014029087-7
申请日:2014-11-21
公开日:2020-07-14
发明作者:Charles R. Prebil；James R. Fox
申请人:The Boeing Company；
IPC主号:

专利说明:

“METHOD FOR UNITING COMPONENTS” BACKGROUND OF THE INVENTION
[0001] Composite materials and components are used in increasing quantities in a wide variety of applications. For example, commercial aircraft are incorporating increasing amounts of composite materials into the primary and secondary structures because of the favorable mechanical properties of composite materials. Such favorable mechanical properties can allow for a reduction in weight and an increase in the payload capacity and fuel efficiency of an aircraft. In addition, the use of composite materials can extend the life of the aircraft.
[0002] Laminated composite components can be joined together using different techniques. For example, composite components can be joined using mechanical fasteners that may require drilling fastener holes in components using specialized drill bits. After drilling the holes in the fasteners, it may be necessary to disassemble the composite components to allow digging up and / or inspecting each hole in the fastener, followed by reassembling the composite components. Mechanical fasteners can be installed in the fastener holes and the fasteners can be tightened to a predetermined torque value. As can be seen, the use of mechanical fasteners to join composite components can require multiple steps, resulting in a time-consuming and labor-intensive process.
[0003] Composite components can also be joined together without mechanical fasteners, joining the components together using an adhesive. The adhesive can be applied between the combined surfaces of the composite components to form a joint. The joint has a thickness of the joint line which is ideally relatively thin to minimize stress concentrations along the edges of the joint and increase the shear strength and tensile strength of the joint. Occasionally, the mating surfaces of one or both of the composite components may have uneven contours, resulting in gaps in the joint.
[0004] Prior art methods of filling gaps between the composite surfaces of the composite components may include applying extra adhesive material between the conjugated surfaces and allowing the adhesive to drain into the gaps during the bonding process. However, the extra adhesive material can increase the thickness of the joint line which can undesirably affect the strength properties of the joint. In another approach to fill gaps, specialized tooling can be developed to apply high compressive forces to the joint to eliminate gaps between mating surfaces. However, specialized tooling can increase overall manufacturing costs. In addition, the high compressive forces applied by specialized tooling can induce undesirable stresses in composite components.
[0005] As can be seen, there is a need in the technique for a system and method for joining composite components that accommodates variations in the contours of the combined surfaces of the composite components, while minimizing the thickness of the joining line.
[0006] This order relates to U.S. order serial number 13 / 693,958 entitled JOINING COMPOSITE COMPONENTS USING LOW TEMPERATURE THERMOPLASTIC FILM FUSION, filed on December 4, 2012. BRIEF SUMMARY OF THE INVENTION
[0007] The above-mentioned needs associated with joining composite components are specifically addressed by the present disclosure that provides methods of forming a structural assembly. In one embodiment, the method may include providing a first component and a second component to be joined together. The method may additionally include sweeping a contour of a first matched surface of the first component and sweeping the contour of a second matched surface of the second component. The method may additionally include producing a thermoplastic element with opposing first and second element surfaces that substantially match the contour of the respective first and second conjugated surfaces.
[0008] In an additional embodiment, a method of joining components is disclosed including providing a first component with a first thermoplastic film applied to a first conjugated surface. The method may also include providing a second component with a second thermoplastic film applied to a second conjugated surface. The method may include scanning the first thermoplastic film and the second thermoplastic film to determine a contour thereof. The method may additionally include producing a thermoplastic sheet from material that is substantially similar to the first thermoplastic film and / or the second thermoplastic film. The thermoplastic sheet may have a first sheet surface and a second sheet surface, respectively, matching the contour of the first conjugated surface and the second conjugated surface. The method may additionally include mounting the first component and the second component with the thermoplastic sheet pressed between them, and applying heat and compaction pressure to the thermoplastic sheet, the first thermoplastic film and / or the second thermoplastic film. The method may also include fusing the thermoplastic sheet, the first thermoplastic film and the second thermoplastic film together to join the first component to the second component to form a structural assembly.
[0009] A method of joining components is also disclosed including providing a first component with a first thermoplastic film. The first mating surface can include a first rounded surface. The method may also include providing a second component with a second thermoplastic film. The first mating surface can include a first rounded surface. The method may additionally include producing a thermoplastic round reinforcement filler with a side surface of the rounded reinforcer and a base surface of the rounded reinforcer substantially matching a respective contour of the first rounded surface and the second conjugated surface. The method may additionally include mounting the first component, the second component and the thermoplastic round reinforcement filler and applying heat and compaction pressure to the thermoplastic round reinforcement filler, the first thermoplastic film and / or the second thermoplastic film. The application of heat and / or compaction pressure can result in the fusion of the first thermoplastic film, the second thermoplastic film and / or the rounded thermoplastic reinforcement charge with each other to join the first component in the second component to form a structural assembly.
[00010] The features, functions and advantages that have been discussed can be achieved independently in various modalities of the present disclosure or can be combined in still other modalities, whose additional details can be seen with reference to the following description and drawings below. BRIEF DESCRIPTION OF THE FIGURES
[00011] These and other features of the present disclosure will become more apparent by reference to the drawings in which equal numbers refer to equal parts in the description and in which: it is an illustration of a block diagram of a structural assembly including a first joined component in a second component by a thermoplastic element with element surfaces that can be contoured to substantially match the contour of the respective conjugated surface of the first component and the second component; is a perspective illustration of an example of a structural assembly configured as a reinforced panel with a back and a plurality of L-shaped reinforcers that can each be joined on the back using one or more thermoplastic elements in a thermoplastic joining process. low melting temperature revealed here; it is a sectional view of a reinforcer attached to a back using a thermoplastic element; A-4H are non-limiting examples of different types of mismatches that can occur between the contour of a first component (for example, a reinforcer) and the contour of a second component (for example, a back); it is a flow chart illustrating one or more operations that can be included in a method of joining components; it is an exploded side view of a stack of mixed layers and a thermoplastic film before being co-consolidated to form an example of a second component; it is a side view of the stack of layers and the thermoplastic film assembled during the application of pressure and heat of consolidation to form the second component as a laminated composite back; it is a perspective illustration of a scanning device scanning the thermoplastic film of the second component; it is an exploded side view of a stack of layers of thermoplastic prepreg (or a stack of layers of thermosetting prepreg) and a thermoplastic film before co-consolidation to form an example of a first component; it is a side view of the assembled stack of layers of thermoplastic prepreg and thermoplastic film during the application of pressure and heat of consolidation to form the first component as a laminated composite L-shaped reinforcer; it is a perspective illustration of a scanning device scanning the thermoplastic film of the first component; is a perspective illustration of a thermoplastic element configured as a thermoplastic sheet formed with opposing sheet surfaces that can be contoured to substantially match the contour of the first thermoplastic film and the second thermoplastic film in the respective first component and second component; it is an exploded side view of the first component and the second component with the thermoplastic sheet positioned between them; it is a perspective illustration of the thermoplastic sheet directly manufactured in the thermoplastic film of the second component in an additive manufacturing process; it is an exploded side view of the first component and the second component with the thermoplastic sheet positioned between them; it is a side view of the application of heat and pressure to fuse the thermoplastic sheet, the first thermoplastic film and the second thermoplastic film together and form a thermoplastic gasket to join the first component to the second component; it is a side view of the integrated structural assembly showing the thermoplastic joint joining the first component and the second component; it is a perspective illustration of a scanner scanning a first rounded surface of the first component; it is a perspective illustration of a scanning device sweeping a thermoplastic film covering the first rounded surface; is a computer model perspective illustration of a rounded reinforcer based on contour data generated by scanning the first rounded surface; is a perspective illustration of a thermoplastic element configured as a round thermoplastic reinforcement charge, and in which the round thermoplastic reinforcement charge is additively manufactured on the second thermoplastic film of the second component; it is an exploded side view of the first component assembled with the second component with the rounded thermoplastic reinforcement load positioned between them; it is a side view of an integrated structural assembly showing the rounded thermoplastic reinforcement filler fused with the thermoplastic film joining the first component and the second component; it is a perspective illustration of a rounded thermoplastic reinforcement filler and a thermoplastic sheet formed integrally as a unitary structure; it is a side view of an exploded side view of the rounded thermoplastic reinforcement load and integrated thermoplastic sheet positioned between the first component and the second component; it is a side view of an integrated structural assembly including a thermoplastic joint with a rounded thermoplastic reinforcement load and joining reinforcements back to back in an L-shaped back; it is a side view of an integrated structural assembly including a thermoplastic joint with a rounded reinforcer and joining a Z-shaped reinforcer on one back; and is a side view of an integrated structural assembly including a thermoplastic joint with a pair of rounded reinforcement charges and attaching a hat-shaped reinforcer to one back. DESCRIPTION OF THE PREFERRED EMBODIMENTS
[00012] Referring now to the drawings in which what is shown is intended to illustrate preferred embodiments and various disclosure modalities, a block diagram of a structural assembly 100 including a first component 300 joined to a second is shown in figure 1 component 400 using a thermoplastic element 500. In one embodiment, the thermoplastic element 500 can be configured as a thermoplastic sheet 506 (Figure 12). In other embodiments, the thermoplastic element 500 can be configured as a rounded thermoplastic reinforcement charge 512 (Figure 20), described below, or as a combined thermoplastic sheet 506 / rounded thermoplastic reinforcement charge 512 formed as a unitary structure 518 (Figure 24).
[00013] In some examples, a thermoplastic sheet 506 (Figure 12) can include opposite sheet surfaces 508, 510. At least one of the surfaces of sheet 508, 510 can be contoured to substantially match the contour of the first component 300 and / or the second component 400. For example, the thermoplastic sheet 506 can include a first surface of the sheet 508 (Figure 12) that can be contoured to substantially match the contour of a first thermoplastic film 306 (Figures 9-11) that can be provided with the first component 300. The first thermoplastic film 306 can be a relatively thin film that can be applied to the first conjugated surface 302 (Figure 9) of the first component 300 before joining the first component 300 to the second component 400. For example, the first thermoplastic film 306 can be directly applied to the first conjugated surface 302 of the first component 300 and can be co-consolidated or co-cured with one or more c mixed belts 202 (Figure 9) to form a first laminated composite component 300.
[00014] In the present application, a composite component (e.g., a first component 300, a second component 400, etc.) can be described as a component formed of fiber-reinforced polymer matrix material. In some examples, the composite component may include substantially continuous fibers embedded in a matrix material. The fibers can be provided in any of a variety of arrangements such as unidirectional fibers, bidirectional fibers, or other fiber arrangements. In another example, the fibers may be non-continuous fibers such as short fibers or chopped fibers arranged in any orientation such as random orientations. In other embodiments, the first and / or second components 300, 400 can be provided as a hybrid composite laminate (not shown) with mixed and mixed non-layered layers (e.g. metallic layers, ceramic layers) to form a fiber-metal laminate . For example, the first and / or second components 300, 400 can be provided as a fiber-metal laminate with fiberglass layers and alternating metal layers. In some examples, the first and / or second components 300, 400 can be formed from non-composite material such as metallic material, ceramic material and / or other non-composite materials or combinations thereof. A thermoplastic film 306, 406 can be applied to the conjugated surface of a first non-composite component 300 and / or to the conjugated surface of a second non-composite component 400 before joining the first and second components 300, 400 using a thermoplastic element 500 such as a thermoplastic sheet 506.
[00015] The first thermoplastic film 306 can be relatively thin in such a way that when the first thermoplastic film 306 is applied to the first conjugated surface 302 of the first component 300, the contour of the first conjugated surface 302 can be transferred to the outer surface of the first thermoplastic film 306, or duplicated therein. The second thermoplastic film 406 (Figures 6-8) can also be a relatively thin film applied to the second conjugated surface 402 of the second component 400 in such a way that the contour of the second conjugated surface 402 can be transferred to the outer surface of the second thermoplastic film. 406, or duplicated in it. The thermoplastic sheet 506 can include a second sheet surface which can be contoured to match the contour of the second thermoplastic film 406 which can be provided with the second component 400.
[00016] The thermoplastic element 500 can facilitate the joining of the first component 300 to the second component 400 in a process of joining the low melting thermoplastic film by applying heat to melt and melt the thermoplastic element 500, the first thermoplastic film 306 and the second thermoplastic film 406 on each other. In some examples where the first and / or second components 300, 400 are formed from composite material 204 such as thermoplastic material, heat can be applied in a way to limit the temperature of the first and / or second components 300, 400 below the temperature of melting of the composite material 204. Keeping the temperature of the first and / or second components 300, 400 below the melting temperature can prevent unwanted softening and / or remelting of the pre-consolidated composite components. In this way, the shape and integrity of the pre-consolidated composite components can be maintained. Although the present disclosure is described in the context of using a thermoplastic element 500 to join two (2) components (for example, joining a first component 300 to a second component 400), the method disclosed here may include using one or more thermoplastic elements 500 to join any number of components.
[00017] Compaction pressure 524 (see Figure 16) can be applied to the thermoplastic element 500 and / or the first and / or second thermoplastic films 306, 406 during the process of joining the first component 300 to the second component 400. The pressure of compaction 524 can be applied during the application of heat to the thermoplastic sheet 506, thermoplastic films 306, 406 and / or components 300, 400 during the process of joining the first component 300 to the second component 400. Compaction pressure 524 can also be applied during cooling of the thermoplastic element 500, thermoplastic film 306, 406 and / or components 300, 400. In embodiments where the thermoplastic element 500 is configured as a thermoplastic sheet 506, the fusion of the thermoplastic sheet 506 with the first and second thermoplastic films 306, 406 each other may result in a fused thermoplastic joint 112 (Figure 17) joining the first component 300 to the second component 400.
[00018] As previously indicated, prior to joining components 300, 400, the thermoplastic element 500 may be formed or provided with element surfaces 502, 504 (Figure 12) contoured to match the contour of the first component 300 and the second component 400. For example, where the thermoplastic element 500 is configured as a thermoplastic sheet 506 (Figure 12), the thermoplastic sheet 506 can include surfaces of the sheet that can be contoured in a way to accommodate variations and / or mismatches between the surface contour conjugate 302 of the first component 300 and the conjugate surface 402 of the second component 400. In this respect, the thermoplastic sheet 506 can accommodate variations in the thickness of the joining line 114 (Figure 3) at different locations in the thermoplastic joint 112 between the first and second components 300, 400, and can thereby reduce or prevent the occurrence of voids or gaps (not shown) in the thermoplastic joint 112 between the first eg components 300, 400. In this regard, the use of one or more thermoplastic elements 500 in a low melting thermoplastic film joining process can result in an improvement in the strength of the thermoplastic gasket 112. For example, the use of one or more thermoplastic sheets 506 to join the first component 300 to the second component 400 can result in an improvement in shear strength and / or tensile strength of the thermoplastic joint 112. The use of one or more thermoplastic elements 500 in a joining process Low temperature melting thermoplastic film can also improve the durability and energy absorption capacity of thermoplastic gasket 112 because of a reduction or elimination of gaps in thermoplastic gasket 112.
[00019] Shown in figure 2 is an example of a structural assembly 100 configured as a panel 102. Panel 102 may include a back 104 which may have a substructure to increase strength or reinforce the back 104. The substructure may include a plurality of reinforcers 106 (e.g., a plurality of first components 300) that can be joined on the back 104 (e.g., the second component 400) using one or more thermoplastic sheets 506 in a low melting thermoplastic joining process. Each of the reinforcers 106 is shown with an L-shaped cross section including a web 110 and a flange 108 extending out of the web 110. However, the reinforcer 106 can be provided in any of a variety of different sectional shapes. transversal and is not limited to an L-shaped cross section. The back 104 and the reinforcers 106 can each be formed of composite material 204 such as a fiber-reinforced thermoplastic material and / or fiber-reinforced thermoset material. However, as indicated herein, the joining process disclosed herein can be implemented to join components formed of any type of material, without limitation, and is not limited to joining components formed of composite materials. Furthermore, the joining process can be implemented to join components of any size, shape and configuration, without limitation, and is not limited to joining a back 104 and reinforcer 106 shown in figure 2.
[00020] Shown in figure 3 is a cross-sectional view of one of the reinforcers 106 joined to a portion of a back 104. The flange 108 of the reinforcer 106 (for example, the first component 300) can include a first mating surface 302. The back 104 (for example, the second component 400) can include a second conjugate surface 402 which can be joined to the first conjugated surface 302 in a thermoplastic joint 112 using a thermoplastic sheet 506 in the joining process disclosed here. The thermoplastic sheet 506 can accommodate real variations in the thickness of the joining line 114 at different locations in the thermoplastic joint 112 between the first component 300 and the second component 400. Furthermore, the use of low melting thermoplastic material from the thermoplastic sheet 506 between the first component 300 and the second component 400 can fill gaps in the joining line, and can result in a relatively small overall thickness of the joining line 114. For example, the use of a thermoplastic sheet 506 in the joining process disclosed here it can result in a thickness of the joining line 114 of approximately 0.001 to 0.010 inch (0.0254 to 0.254 mm) or more. The relatively low thickness of the joint line 114 can reduce stress concentrations in the corners of the thermoplastic joint 112 which can improve the strength of the thermoplastic joint 112.
[00021] Figures 4A-4H illustrate some examples of different types of mismatches that can occur between the contour of a first component 300 and the contour of a second component 400, and which can be accommodated by the thermoplastic sheet 506 and the thermoplastic bonding process revealed here. However, as can be seen, the joining process can accommodate mismatches of any size, shape and configuration, and is not limited to the examples shown. Figure 4A illustrates the edge of the flange 108 being slightly raised, resulting in a gap between the edge of the flange and the back 104 in relation to other locations of the flange 108. Figure 4B illustrates the middle of the flange 108 arched upward, resulting in greater clearance with the back 104 at that location. Figure 4C illustrates a depression formed in panel 102 directly below flange 108, resulting in an increase in the gap clearance in the depression. Figure 4D illustrates a swelling formed in panel 102 directly below flange 108, resulting in a gap between back 104 and the flange on opposite sides of the swell. Figure 4E illustrates the combined surface of the back 104 with waves or folds, creating variations in the thickness of the joint line 114 between the flange 108 and the back 104. Figure 4F illustrates the combined surface of the back 104 with waves or folds creating variations in joining line thickness 114. Figure 4G illustrates the curvature of flange 108 offset from the curvature of panel 102, resulting in a variation in the thickness of the joining line. Figure 4H illustrates a mismatch in the taper angle between flange 108 and back 104.
[00022] Referring to figure 5 with additional reference to figures 6-25, a flow chart with one or more operations that can be included in a method 600 of joining components to form a structural assembly 100 is shown in figure 5. 602 of method 600 may include providing a first component 300 (Figure 13) and a second component 400 (Figure 13) to be joined together to form a structural assembly 100 (Figure 17). The first component 300 can include a first conjugate surface 302 (Figure 13) and the second component 400 can include a second conjugate surface 402 (Figure 13) configured to be joined to the first conjugate surface 302. The first conjugate surface 302 can have a first contour 306. The second boundary surface 402 may have a second contour 404. In some instances, the first contour 306 may have a mismatch with the second contour 404. In embodiments where the first component 300 and second component 400 are formed of thermoplastic material and / or thermosetting material, the method may include forming the first component 300 and / or the second component 400 according to a process similar to the process disclosed in US application Serial No. 13 / 693,958 entitled JOINING COMPOSITE COMPONENTS USING LOW TEMPERATURE THERMOPLASTIC FILM FUSION deposited on December 4, 2012, the entire contents of which are incorporated by reference.
[00023] For example, to form the structural assembly 100 shown in figure 2, method 600 may include forming the second component 400 of a stack 200 of layers 202 of thermoplastic prepreg 206, as shown in figure 6. The first component 300 may also be formed of a stack 200 of layers 202 of thermoplastic prepreg 206, as shown in figure 9. One or more of layers 202 of thermoplastic prepreg 206 may include reinforcement fibers in a resin matrix. The resin matrix can be formed from organic material or inorganic material. In some examples, the resin matrix can be a thermoplastic polymer such as a polyarylethylketone resin, a polyetherethylketone resin, a polyethylketon acetone resin, or a polyphenyl sulfone resin. The resin matrix can have a glass transition temperature and a melting temperature that can be higher than the glass transition temperature. The glass transition temperature can be the temperature at which the resin matrix softens. The melting temperature can be the temperature at which the resin matrix molecules are disordered. In some examples, the resin matrix may be a thermoplastic polymer with a melting temperature above approximately 500 degrees F (260 ° C).
[00024] In some examples, the first component 300 (Figure 9) and / or the second component 400 (Figure 6) can be formed by arranging a stack 200 of layers 202 of uncured thermosetting prepreg 202 similar to that shown in the figures 6 and 9, and as disclosed in the aforementioned order serial number 13 / 693,958. The uncured thermoset prepreg 208 may include reinforcement fibers in a thermoset resin matrix such as epoxy resin. The thermosetting resin matrix can have a curing temperature that can be less than the glass transition temperature of the thermoplastic resin matrix. For example, the thermosetting resin matrix may have a curing temperature of less than approximately 400 degrees F (204 ° C), such as approximately 350 degrees F (177 ° C) or less. Layers 202 of thermoplastic prepreg 206 and / or layers 202 of thermoset prepreg 208 may include reinforcement fibers such as unidirectional fibers, bidirectional fibers, or other fiber configurations or combinations of fiber configurations. The fibers can be formed from any material, without limitation, including glass, carbon, ceramic material, metallic material, and / or any type of organic material, inorganic material, or combinations thereof. Layers 202 in a stack 200 (Figures 6 and 9) can be arranged in predetermined fiber orientations according to a predetermined layer stacking sequence.
[00025] Step 604 of method 600 may include applying a first thermoplastic film 306 to a first matched surface 302 of the first component 300 (see figure 9), and applying a second thermoplastic film 406 to a second matched surface 402 of the second component 400 (see figure 6). In some examples, the thermoplastic film 306, 406 may be formed of thermoplastic material that has properties that allow the thermoplastic film to be co-consolidated with the conjugated surface of the first component 300 and / or second component 400. In this regard, the thermoplastic film 306 406 can have a composition that is compatible with the thermoplastic resin matrix of thermoplastic prepreg 206. In one embodiment, the thermoplastic film 306, 406 can be formed of thermoplastic material that is substantially similar to the resin matrix of thermoplastic prepreg 206.
[00026] For embodiments where the first component 300 and / or second component 400 are formed from a stack 200 of layers 202 of thermoplastic prepreg 206, the method may include co-consolidating a thermoplastic film with layers 202 of thermoplastic prepreg 206. For example, a first thermoplastic film 306 (Figure 10) and / or a second thermoplastic film 406 (Figure 7) can be arranged or applied to a respective first and / or second conjugated surfaces 402 of a respective first and / or second components 300, 400. The the first component 300 and / or the second component 400 can be supported in the consolidation tool 526 which can approximate the final target shape of the consolidated composite component 300, 400. Co-consolidation may include heating the thermoplastic prepreg 206 and the thermoplastic film 306, 406 to a temperature that is greater than or equal to the highest melting temperature of the thermoplastic film 306, 406 and the melting temperature of the resin matrix of the thermoplastic prepreg ico 206.
[00027] Heat can be applied by placing the thermoplastic prepreg 206 and the thermoplastic film 306, 406 in an autoclave or an oven. In some instances, heat can be applied using heated tooling, infrared heating, radiation heating, hot air heating, or other heating methods. Coconsolidation may also include applying consolidation pressure 522 to thermoplastic film 306, 406 and stack 200 of layers 202 of thermoplastic prepreg 206 during application of heat. Consolidation pressure 522 can be applied to thermoplastic film 306, 406 and stack 200 of layers 202 using consolidation tool 526, vacuum bagging, autoclave pressure and / or other techniques. Application of heat and pressure of consolidation 522 can cause the thermoplastic film 306, 406 and layers 202 of thermoplastic prepreg 206 to be consolidated into one another in an integrated composite laminate component, shown in figures 8 and 11.
[00028] For embodiments where the first component 300 and / or the second component 400 are formed from thermosetting prepreg 208, the method may include curing a thermoplastic film with a stack 200 of layers 202 of thermosetting prepreg 208. In some embodiments, the thermoplastic film can be comprised of the thermoplastic resin described above. A thermoplastic film 306, 406 can be arranged or applied to the respective first and / or second conjugated surfaces 302, 402 of the respective first and / or second components 300, 400, as shown in figures 7 and 10 in a manner previously described. In some instances, the thermoplastic film 306, 406 can be comprised of an epoxy layer applied to the conjugated surface of the outermost pre-heat layer 208 in stack 200. The method may include heating the set of the thermoplastic film and stack 200 of layers 202 of uncured thermoset prepreg 208 to a cure temperature of the thermoset resin. In some instances, the assembly may be heated to a temperature that is greater than or equal to a glass transition temperature of the thermoplastic film that may be greater than the curing temperature of the thermosetting resin. Consolidation pressure 522 can be applied to the thermoplastic film and the uncured thermosetting prepreg 208, while still maintaining heating at the cure temperature of the thermosetting resin to cure the set.
[00029] Step 606 of method 600 may include sweeping (see figure 8) the second conjugate surface 402 of the second component 400 (Figure 8) and sweeping the first conjugate surface 302 of the first component 300 (Figure 11) to map the contours of the first and second mating surfaces 302, 402 as shown in figures 8 and 11. In this regard, method 600 may include sweeping the thermoplastic film on the mating surface of a coconsolidated thermoplastic component and / or sweeping the thermoplastic film on the mating surface of a component thermosetting as previously described. Scanning the first and / or second thermoplastic films 306, 406 covering the respective first and / or second conjugate surfaces 302, 402 can provide a means to map, measure and / or record the contour of the conjugated surfaces 302, 402 so that a thermoplastic element 500 such as a thermoplastic sheet 506 can be produced with opposing sheet surfaces 508, 510 which respectively match the contour 306 404 of the mating surfaces 302, 402 of the first and second components 300, 400 to be joined. In some embodiments, the method may include digitally inspecting the matched surfaces and / or the thermoplastic films covering the matched surfaces. Digital inspection or digital scanning of the mating surfaces can be performed using any of a variety of different techniques and devices.
[00030] For example, referring to figures 8 and 11, examples are shown of a scanning device 520 sweeping the first thermoplastic film 306 (Figure 11) and the second thermoplastic film 406 (Figure 8) covering the respective first and second mating surfaces 302, 402 of the respective first and second components 300, 400. The scanning device 520 may comprise an optical sensor, a digital scanning device, a laser scanning device, or other scanning system. In some examples, one or more optical sensors or scanning devices (not shown) can be mounted in a fixed position relative to the surface to be scanned. Optical sensors or scanning devices can scan optically on the length and / or width of the thermoplastic film to map, measure and / or register its contour. Optical sensors or scanning devices can be provided in any of a variety of different configurations including, without limitation, any non-contact scanning device or optical measuring system or device that can use optics to measure the topography and / or contour of one or more of the mating surfaces and / or the thermoplastic films covering the mating surfaces of one or more components.
[00031] In some examples, scanning or measuring contours can be done by a scanning device configured as a triangulation scanning device and / or as a flight-time scanning device. In some examples, laser scanning devices may collect three-dimensional positional data from a plurality of points (for example, up to 100,000 or more points) to form one or more point clouds representative of the contour of one or more conjugated surfaces or thermoplastic films that cover the mating surfaces. Point cloud data can be recorded and stored just like in a computer memory. In one embodiment, a point cloud can be used to form a three-dimensional digital model or computer model 530 (for example, Figures 12, 20, and 24) of the thermoplastic element 500 to be produced or manufactured for use in joining the first component 300 in the second component 400. In some modalities, the method may include the use of one or more cameras to record images of the conjugated surfaces and / or thermoplastic films, and to generate a three-dimensional model of the contour of each of the conjugated surfaces to be joined. The contour of the conjugated surfaces and / or thermoplastic films covering the conjugated surfaces can also be measured using one or more contact metrology devices such as a coordinate measuring machine (CMM) or other contact inspection device or technique.
[00032] Scanning the contour of the conjugated surface (s) and / or thermoplastic film (s) can be carried out relative to one or more data (not shown) or reference resources (not shown) ) that can be established. For example, although not shown, a reference feature such as a coordinate system, for example, a Cartesian coordinate system, can be established on the outer surface of the dorsum 104 (for example, the second component 400) in figure 8. The coordinate system (not shown) can be located on a corner of the second thermoplastic film 406 covering the second conjugated surface 402 of the second component 400. The coordinate system can be oriented in such a way that the xy axes of the coordinate system are coincident with a local plane of the outer surface of the dorsum 104, or, if the outer surface is not planar, the coordinate system can be oriented in such a way that the xy axes are both tangent to the outer surface of the dorsum 104 at the corner of the second thermoplastic film 406. The z axis of the coordinate system can extend outside the outer surface of the second component 400. After establishing the location and orientation of the coordinates, a digital scanning device, a laser scanning device, a camera, contour measuring device, coordinate measuring machine (CMM), or other device can measure and record the contour of the second 406 thermoplastic film relative to the coordinates. A three-dimensional computer model 530 of the contour of the second thermoplastic film 406 can be generated and stored in a computer system memory (not shown).
[00033] In figure 11, the desired location and orientation of reinforcer 106 (for example, a first component 300) can be defined in relation to the second component (not shown). For example, a computer aided design (CAD) model (not shown) of the first and second assembled components 300, 400 may be establishing the target location and orientation of the second component 400 in relation to the first component 300. The CAD model may therefore thereby defining the target thickness of the joint line 114 between the first component 300 and the second component 400 at one or more locations along a thermoplastic joint 112 to be formed between the first component 300 and the second component 400. In some examples , a determination can be made regarding the minimum and / or maximum thickness of the joining line 114 (for example, the thickness tolerance) at any location along the thermoplastic joint 112.
[00034] A scanning device 520, optical sensor, or other contour measuring device can measure and record the contour of the first thermoplastic film 306 of the first component 300 in relation to the aforementioned coordinate system established in the second component 400. A model of computer (not shown) of the contour of the first thermoplastic film 306 can be generated based on contour measurements of the scanning device 520. The position and orientation of the three-dimensional computer model of the contour of the first thermoplastic film 306 can be defined in relation to the system coordinate set in the second component 400, and can be stored in a computer system memory (not shown). The method may include using the computer models of the contour of the first and second thermoplastic film 306, 406 to generate a three-dimensional computer model 530 of a thermoplastic element 500 such as a thermoplastic sheet 506 illustrated in figure 12. Computer model 530 of thermoplastic sheet 506 can have opposing first and second sheet surfaces 508, 510 which can substantially match the contour of the respective mating surfaces 302, 402 of the first and / or second components 300, 400 and / or the thermoplastic films 306, 406 covering the mating surfaces 302, 402. Furthermore, the computer model 530 of the thermoplastic sheet 506 can define the thickness of the thermoplastic sheet 506 which can vary at different locations along the thermoplastic joint 112. In this way, the thermoplastic sheet 506 can accommodate thickness variations in the joining line between the first and second components 300, 400. Information can optionally be provided with rel action to a minimum thickness and maximum thickness (for example, thickness tolerance) of the thermoplastic sheet 506 and which can later be used for inspection and / or structural analysis of the thermoplastic joint 112.
[00035] Step 608 of method 600 of figure 5 may include producing or manufacturing a thermoplastic element 500 with element surfaces 502, 504 that match the contour of the first mating surface and the second mating surface respectively. For example, the thermoplastic element 500 can be formed as a thermoplastic sheet 506 (Figure 12) with opposing first and second sheet surfaces 508, 510 substantially matching the respective contours of the first and second mating surfaces 302, 402, or substantially matching the respective contours of the thermoplastic films 306, 406 covering the first and second mating surfaces 302, 402. In one embodiment, method 600 may include producing thermoplastic sheet 506 with a minimum thickness of approximately 0.002 inch (0.051 millimeter) or less. As previously indicated, minimizing the thickness of the joining line 114 by minimizing the thickness of the thermoplastic sheet 506 can improve the strength properties of the thermoplastic joint 112 between the first component 300 and the second component 400. In some examples, the thermoplastic sheet 506 can be produced with a minimum thickness of approximately 0.005 inch (0.127 mm) or more which can improve the productivity and / or handling of the 506 thermoplastic sheet. In other examples, the 506 thermoplastic sheet can be produced with the thickness range of approximately 0.002 to approximately 0.010 inch (0.051 and 0.254 mm). However, the 506 thermoplastic sheet can be provided in thicknesses greater than 0.010 inch (0.254 mm).
[00036] Although the thermoplastic sheet 506 in figure 12 is shown with a generally flat rectangular element, the thermoplastic sheet 506 can be provided in any size, shape and configuration, without limitation, including curved shapes (for example, non-flat) ), folded shapes (for example, not flat), and other shapes and / or configurations, or combinations thereof. Furthermore, the thermoplastic sheet 506 can have a perimeter shape other than the rectangular shape shown in figure 12. In addition, multiple thermoplastic sheets 506 can be produced for a given thermoplastic joint. Multiple thermoplastic sheets 506 can be stacked on top of one another in a thermoplastic joint, and / or multiple thermoplastic sheets 506 can be arranged side by side with each other to cover the area of a thermoplastic joint between two or more components a be united.
[00037] Method 600 of joining components may include making a thermoplastic element 500 such as a thermoplastic sheet 506 (Figure 12) using direct fabrication, rapid prototyping, or other techniques including, but not limited to, additive fabrication such as three-dimensional printing, stereolithography , and direct digital fabrication. In addition, the thermoplastic element 500 can be manufactured using subtractive fabrication such as laser cutting, machining via computer numerical control (e.g. CNC machining), or other subtractive fabrication techniques. The manufacture of the thermoplastic element 500 such as a thermoplastic sheet 506 can use a computer model 530 of the thermoplastic sheet 506 which can be generated with the aid of digital inspection or scanning the contour of the first and second conjugated surfaces 302, 402 (or thermoplastic films) ) using one or more scanning devices, cameras, CMMs, or other contour measurement device previously discussed. In some examples, the thermoplastic element 500 can be manufactured using molding techniques such as injection molding, compression molding and other techniques.
[00038] In some examples, the thermoplastic element 500 (Figure 12) can be formed of substantially the same or similar material to the first thermoplastic film 306 (Figure 13) and / or the second thermoplastic film 406 (Figure 13). As previously indicated, the thermoplastic element 500 can preferably be made of the same thermoplastic resin as the low melting thermoplastic film that covers the conjugated surface of the first component 300 and / or the second component 400. In some examples, the thermoplastic element 500 may be formed of thermoplastic material with a glass transition temperature that can be less than the melting temperature of the first component 300 and / or the second component 400 to prevent softening of the first and / or second components 300, 400 which may otherwise compromise the shape and / or integrity of the first and / or second components 300, 400.
[00039] Step 608 of method 600 may optionally include additively manufacturing thermoplastic element 500. For example, in figure 14, thermoplastic sheet 506 can be additively manufactured directly on the first thermoplastic film 306 and / or directly on the second thermoplastic film 406 of respective first component 300 and second component 400. Additive manufacturing techniques may allow customized adjustment of the thermoplastic element 500 directly on the first component 300 and / or the second component, or directly on the thermoplastic films 306, 406 of the respective first and / or second components 300 , 400. Additive manufacturing directly on the first and / or second components 300, 400 can reduce the tooling complexity required to align the first and second components 300, 400 during the assembly process of the first component 300 and the second component 400. In any of the modalities revealed here, in which the thermoplastic film in the first and / or following nd components 300, 400 is an epoxy adhesive layer, the method may include additively fabricating the thermoplastic element 500 directly into the epoxy adhesive layer. Any of the above-described techniques for additive manufacturing can be implemented to additively manufacture the thermoplastic element 500 directly in the first component 300 and / or the second component, or in the first and / or second thermoplastic films 306, 406.
[00040] Step 610 of method 600 of figure 5 may include mounting the first component 300 and the second component 400 with the thermoplastic element 500. For example, method 600 may include mounting the first component 300 and the second component 400 with the thermoplastic sheet 506 pressed between them. In this regard, the first thermoplastic film 306 and the second thermoplastic film 406 can be positioned in face-to-face contact with the respective first surface of sheet 508 and second surface of sheet 510 of thermoplastic sheet 506, as shown in figure 13. Figure 13 illustrates an example of a separately formed thermoplastic sheet 506 positioned between the first component 300 and the second component 400 before assembling the components in face-to-face contact with the surfaces of the sheet 508, 510 of the thermoplastic sheet 506. Figure 15 illustrates a example of an additively manufactured thermoplastic sheet 506 manufactured directly on the second thermoplastic film 406 of the second component 400. In one embodiment, the method may include additively manufacturing a portion of the thermoplastic sheet 506 on one of the components 300, 400, and additively manufacturing a remaining portion of the thermoplastic sheet 506 on the remaining component 300, 400, and then assemble the components 300, 400 ju in such a way that the two portions of thermoplastic sheet 506 are brought into contact face to face (not shown) with each other. The method can optionally include fabricating mounting tooling 528 (Figure 16) to maintain components 300, 400 in fixed relationship with each other in the assembled state.
[00041] Step 612 of method 600 of figure 5 may include heating the thermoplastic element 500, the first thermoplastic film 306 and / or the second thermoplastic film 406 at the glass transition temperature of the thermoplastic element 500, of the first thermoplastic film 306 and / or the second thermoplastic film 406. In one embodiment, the thermoplastic element 500 and the first and second thermoplastic films 306, 406 can be formed from the same material, in which case the thermoplastic element 500 and the first and second thermoplastic films 306, 406 can have the same glass transition temperature. If the thermoplastic element 500 is formed from a material other than the first thermoplastic film 306 and / or the second thermoplastic film 406, then the temperature that may be required to fuse components 300, 400 together may be the highest of the glass transition temperatures of the thermoplastic element 500 and the first and second thermoplastic film 306, 406. In some instances, the thermoplastic element 500, the first thermoplastic film 306 and / or the second thermoplastic film 406 can be heated to a temperature below approximately 500 degrees F ( 260 ° C).
[00042] For embodiments where the first component 300 and / or the second component 400 are formed of thermoplastic material, the temperature at which the thermoplastic element 500 and first and second thermoplastic films 306, 406 are heated can be kept below the lowest temperature of melting the first component 300 and the second component 400. In some embodiments, the thermoplastic element 500, the first thermoplastic film 306 and / or the second thermoplastic film 406 can be heated by placing the assembly of the first and second components 300, 400 and the thermoplastic element 500 in an autoclave or an oven. In other examples, the first thermoplastic film 306 and / or the second thermoplastic film 406 can be heated by the mounting tool 528 (Figure 16) which holds components 300, 400 in a fixed position relative to each other. Heat can also be applied using infrared heating, radiation heating, hot air heating, or other heating methods.
[00043] Step 614 of method 600 of figure 5 may include applying compaction pressure 524 to the thermoplastic element 500, the first thermoplastic film 306 and the second thermoplastic film 406 during heating. Figure 16 illustrates an example of the localized application of compaction pressure 524 on a thermoplastic sheet 506 using tooling positioned on opposite sides of the first and second components 300, 400. The compaction pressure 524 can be applied by a mechanical device such as with the press (not shown), for example, to apply compaction pressure 524 to the area of the thermoplastic sheet 506 and to the first and second thermoplastic films 306, 406. However, compaction pressure 524 can be applied by a vacuum bag or other means. The compaction pressure 524 can be applied in a way that compresses the thermoplastic sheet 506 pressed between the first component 300 and the second component 400. In one embodiment, the compaction pressure 524 can be applied to a level that causes or facilitates fusion of the thermoplastic sheet 506 with the first and second thermoplastic films 306, 406. The compaction pressure 524 applied to the thermoplastic sheet 506 and the first and second thermoplastic films 306, 406 may be less than the consolidation pressure 522 to co-consolidate the thermoplastic prepreg 206 with the thermoplastic film. For example, compaction pressure 524 can be less than 100 psi.
[00044] Step 616 of method 600 of figure 5 may include fusing together the thermoplastic element 500, the first thermoplastic film 306 and the second thermoplastic film 406 in response to the application of heat and compaction pressure 524. In some instances, heat can be applied to soften initially the thermoplastic element 500 and / or the first and second thermoplastic films 306, 406. Compaction pressure 524 can be applied before and / or during the application of heat, or when the thermoplastic element 500 and the first and second thermoplastic films 306, 406 reach their glass transition temperatures. Optionally, compaction pressure 524 can be applied continuously after heat is removed and the thermoplastic element 500 and the first and second thermoplastic films 306, 406 are actively and / or passively cooled below the glass transition temperature. The fusion of the thermoplastic element 500 and the first and second thermoplastic films 306, 406 can result in the formation of the thermoplastic joint 112 joining the first component 300 to the second component 400. After the melting and cooling of the thermoplastic element 500 and the first and second thermoplastic films 306, 406, mounting tooling 528 can be removed, resulting in an integrated structural assembly 100 shown in figure 17.
[00045] Referring to figure 18, in some embodiments, one or more of the components may include a rounded surface. For example, in figure 18, the first matched surface 302 of the first component 300 can include a first rounded surface 304 in the transition between the flange 108 and the core 110. When the first component 300 is assembled with the second component in the general planar 400, a wedge gap (not shown) can occur at the location of the first rounded surface 304. It may be desirable to fill the wedge gap with a rounded thermoplastic reinforcement load 512 (Figure 21) to improve the strength of the thermoplastic joint 112 joining the first component 300 in the second component 400. Although the first rounded surface 304 is shown with a generally constant convex radius, the first rounded surface 304 can be formed as a non-constant radius. In addition, the first component 300 may include an angled surface or a faceted surface that can result in a wedge gap with the second overall planar surface, and requiring a rounded thermoplastic reinforcement load 512 to fill the gap to increase joint strength. thermoplastic 112 joining the first component 300 to the second component 400.
[00046] The method currently disclosed provides a means to form a thermoplastic element 500 as a thermoplastic round reinforcement filler 512 to fill the wedge gap between the first component 300 and the second component 400. For example, the thermoplastic round reinforcement filler 512 can be formed to match the contour of the first rounded surface 304 of the first component 300 and the second generally planar surface 402 of the second component 400. An example of a rounded thermoplastic reinforcement load 512 can be seen in figures 21-22 which is shown with a pair of side surfaces of the rounded reinforcement load 514 and a base surface of the rounded reinforcement load 516. At least one of the side surfaces of the rounded reinforcer 514 which can each have a concave shape that can substantially match a convex shape of the first rounded surface 304 of the first component 300. The base surface of the rounded reinforcement load 516 can be generally flat and / or contoured to match the second contour 404 of the second conjugate surface 402.
[00047] In figure 18, the method of producing a thermoplastic element 500 as a rounded thermoplastic reinforcement charge 512 may include sweeping the first rounded surface 304 of a first component 300 using a scanning device 520. In some embodiments, the first surface conjugate 302 may include a first thermoplastic film 308 and the first rounded surface 304 may be devoid of a thermoplastic film 308. In other embodiments, the first conjugated surface 302 may be devoid of a first thermoplastic film 308 and the first rounded surface 304 may include a thermoplastic film 308. Regardless of the presence or absence of thermoplastic film 308 on the first matched surface 302 or the first rounded surface 304, the scanner can generate contour data representing the first of the first rounded surface 304. The method may additionally include sweeping the contour of the second surface co njugada 402 to generate contour data. Although the contour of the second conjugate surface 402 is shown in the general planar, the second contour 404 can have any shape, without limitation, and is not limited to a planar shape. A scanning device 520 can scan the second contour 404 and can generate contour data representing the second contour 404. The contour data of the first rounded surface 304 and the contour data of the second conjugated surface 402 can be used to generate a model of computer 530 of the rounded thermoplastic reinforcement charge 512 similar to the example shown in figure 20.
[00048] Referring to figure 19, in some embodiments of the first component 300, the first thermoplastic film 308 can be applied to the first conjugated surface in the general planar 302 and can extend continuously in a portion of the first rounded surface 304, or substantially throughout the first rounded surface 304. In such embodiments, the method may include using a scanner 520 in any manner, as previously described, to scan the thermoplastic film 308 and generate contour data from the first rounded surface 304 and of the first matched surface 302. Scanner 520 can again be used to scan the second contour 404 of the second component 400 and generate contour data in a manner as described. The contour data of the first conjugated surface 302 and the first rounded surface 304 can be combined with the contour data of the second conjugated surface 402 to generate a computer model 530 of the thermoplastic element 500 that integrally combines a thermoplastic sheet 506 with the load of rounded thermoplastic reinforcement 512 similar in configuration to the rounded thermoplastic reinforcement load 512 shown in figure 24. As described in more detail below, the unit thermoplastic element 500 of figure 24 can be assembled with the first component 300 and the second component 400 and cast to form a thermoplastic joint 112 with an integral rounded reinforcement load.
[00049] Referring to figure 20, the computer model 530 generated by the scanning device data can be used to manufacture a rounded thermoplastic reinforcement load 512 using additive or subtractive fabrication in any of the methods described above to produce a thermoplastic sheet. 506. For example, computer model 530 can be used to manufacture a rounded thermoplastic reinforcement load 512 using subtractive fabrication such as machining techniques. In one example, the rounded thermoplastic reinforcement load 512 can be machined from bulky material. Alternatively, the rounded thermoplastic reinforcement filler 512 can be shaped or cast using a mold with a contour that substantially duplicates the contours of the computer model 530.
[00050] Referring to figure 21, in some embodiments, the rounded thermoplastic reinforcement filler 512 can be additively manufactured directly on the second component 400. For example, the rounded thermoplastic reinforcement filler 512 can be made additively on the second thermoplastic film 406 of the second component 400. Alternatively, the rounded thermoplastic reinforcement filler 512 can be additively manufactured in a portion of the second component 400 that is devoid of the second thermoplastic film 406. Any suitable additive manufacturing technique (e.g., three-dimensional printing, stereolithography, etc. .) can be implemented to directly manufacture the thermoplastic round reinforcement filler 512 in the second component 400. Although not shown, the thermoplastic round reinforcement filler 512 can optionally be additively manufactured directly in the first round reinforcer of the first component 300. As previously indicated, manufacture additive n the rounded thermoplastic reinforcement load 512 directly on the first and / or second components 300, 400 can advantageously reduce or eliminate the need for separate tooling to align the first and second components 300, 400 during the assembly process.
[00051] Referring to figure 22, an illustration of the assembly process of the first component 300 on the second component 400 is shown. The structural assembly 100 includes the rounded thermoplastic reinforcement load manufactured additively 512. However, as previously indicated, the load rounded thermoplastic reinforcement 512 can be manufactured or produced subtractively as a separate component, and then assembled with the first component 300 and the second component 400 similar to the process illustrated in figure 13 and previously described.
[00052] Referring to figure 23, a modality of a structural assembly 100 is shown including the first component 300 joined to the second component 400. In an assembly process similar to the process described above and illustrated in figure 16-17, compaction pressure 524 and / or heat can be applied to the first component 300 and the second component 400 in figure 23. Compaction pressure 524 can be applied by mechanical device such as with a press (not shown), vacuum bag, or any of a variety of other means for applying pressure to the thermoplastic sheet 506. A rounded block (not shown) or a vacuum bag (not shown) can optionally be applied laterally against the exposed side surface of the rounded reinforcer 514 of the rounded thermoplastic reinforcement charge 512 during the application of compaction pressure 524. Heat can be applied before, during or after the application of compaction pressure 524. Heat can be applied from a way and at a temperature that result in the melting of the thermoplastic films of the first and second components 300, 400 and, optionally, to melt portions of the first and / or second thermoplastic films 308, 406 with portions of the rounded thermoplastic reinforcement filler 512 that are in contact with the 308,406 thermoplastic film.
[00053] Referring to figure 24, there is shown an embodiment of a thermoplastic element 500 comprised of a rounded thermoplastic reinforcement charge 512 and a thermoplastic sheet 506 integrally formed as a unitary structure 518. As previously indicated, the integral thermoplastic sheet 506 / rounded thermoplastic reinforcement load 512 can be formed using the contour data generated when scanning the first component 300 and the second component 400. Figure 25 illustrates the assembly of the integral thermoplastic sheet 506 / rounded thermoplastic reinforcement load 512 with the first component 300 and the second component 400. The assembly process can be similar to that previously described with respect to the thermoplastic sheet 506 illustrated in figure 13. Alternatively, the integral thermoplastic sheet 506 / rounded thermoplastic reinforcement filler 512 can be additively manufactured directly in the second 406 thermoplastic film of the second component 400 s similar to the additive manufacture of the aforementioned thermoplastic 512 round reinforcement filler. Compaction heat and pressure 524 can be applied to fuse the first and second components 300, 400 with the thermoplastic sheet 506 / round thermoplastic reinforcement filler 512 integral.
[00054] Figure 26 illustrates the implementation of the thermoplastic joining process to join L-shaped reinforcements coast-to-coast (for example, first components 300) on a back (for example, second component 400). As shown, the side surfaces of the rounded reinforcement load 514 of the thermoplastic rounded reinforcement load 512 are in contact with the first opposite rounded surfaces 304 of the L-shaped reinforcements coast to coast. Figure 27 illustrates an embodiment of an integrated structural assembly 100 including a thermoplastic joint 112 with rounded thermoplastic reinforcement load 512 joining a Z-shaped reinforcer (for example, a first component 300) to a back (for example, a second component 400). Figure 28 illustrates an integrated structural assembly 100 including a thermoplastic joint 112 with a pair of rounded thermoplastic reinforcement loads 512 and joining a hat-shaped reinforcer on one back. As can be seen, the above described thermoplastic joining process is not limited to joining the examples of first and second components 300, 400 shown in the figures. In this regard, the thermoplastic joining process can be implemented to join two or more components of any size, shape and configuration, without limitation.
[00055] Further modifications and improvements to the present disclosure may be apparent to those skilled in the art. Thus, the particular combination of parts described and illustrated here is intended to represent only certain modalities of the present disclosure and is not intended to serve as limitations on alternative modalities or devices within the spirit and scope of the disclosure. Additionally, the disclosure comprises modalities according to the following clauses:
[00056] Clause 1. A method of joining components, comprising the steps of: providing a first component with a first conjugated surface, the first conjugated surface having a first contour; providing a second component with a second conjugated surface to be joined to the first conjugated surface, the second conjugated surface having a second contour; and producing a thermoplastic element with a first surface of the element and a second surface of the element respectively substantially matching the first contour and the second contour.
[00057] Clause 2. The method of clause 0, in which: the first contour of the first conjugated surface has a mismatch with the second contour of the second conjugated surface.
[00058] Clause 3. The method of clause 0, in which the step of producing the thermoplastic element comprises: producing a thermoplastic sheet with a first surface of the sheet and a second surface of the sheet substantially matching the first contour and the second contour.
[00059] Clause 4. The method of clause 0, wherein the step of producing the thermoplastic element comprises: producing the thermoplastic element with opposing first and second element surfaces substantially matching a respective contour of a first thermoplastic film and a second film thermoplastic respectively applied to the first conjugated surface and the second conjugated surface.
[00060] Clause 5. The method of clause 0, wherein the first matched surface includes a first rounded surface, the step of producing the thermoplastic element comprises: producing a rounded thermoplastic reinforcement load with a side surface of the rounded reinforcement load and a base surface of the rounded reinforcement load substantially matching the respective contour of the first rounded surface and the second conjugated surface.
[00061] Clause 6. The method of clause 0, in which the step of producing the thermoplastic element comprises: integrally forming a thermoplastic sheet with the rounded thermoplastic reinforcement load; and the thermoplastic sheet having a first sheet surface and a second sheet surface substantially matching the first contour and the second contour.
[00062] Clause 7. The method of clause 0, additionally comprising the step of: sweeping the first conjugated surface and / or the second conjugated surface to determine the first contour and the second contour.
[00063] Clause 8. The method of clause 0, in which the scanning step includes: scanning using a digital scanning device, a camera, a coordinate measuring machine, or any combination thereof.
[00064] Clause 9. The method of clause 0, wherein the step of producing the thermoplastic element comprises: producing the thermoplastic element using additive fabrication, subtractive fabrication, or a combination thereof.
[00065] Clause 10. The method of clause 0, in which the step of producing the thermoplastic element comprises: additively manufacturing the thermoplastic element directly in a first thermoplastic film of the first component or a second thermoplastic film of the second component.
[00066] Clause 11. The clause 0 method, additionally comprising the step of: assembling the first component and the second component with the thermoplastic element pressed between them; and fusing the thermoplastic element, a first thermoplastic film and a second thermoplastic film to each other to form a thermoplastic gasket joining the first component to the second component.
[00067] Clause 12. The method of clause 0, in which the melting step comprises: at least one of the thermoplastic element, the first thermoplastic film and / or the second thermoplastic film up to at least one glass transition temperature thereof.
[00068] Clause 13. The method of clause 0, in which the thermoplastic element includes a thermoplastic sheet, the melting step includes: compressing a thermoplastic sheet pressed between the first component and the second component.
[00069] Clause 14. The method of clause 0, wherein the step of producing the thermoplastic element includes: producing the thermoplastic element from material with a glass transition temperature that is less than a melting temperature of the first component and / or the second component.
[00070] Clause 15. The method of clause 0, wherein the step of producing the thermoplastic element includes: producing the thermoplastic element from material that is substantially similar to the material of the first thermoplastic film and / or the second thermoplastic film.
[00071] Clause 16. The method of clause 0, in which: the first component and / or the second component are formed from a thermosetting material or a thermoplastic material.
[00072] Clause 17. The method of clause 0, wherein the step of providing the first component and the second component comprises: forming the first component and / or the second component by co-consolidating a thermoplastic film with a stack of prepreg layers thermoplastic.
[00073] Clause 18. The method of clause 0, in which the step of providing the first component and the second component comprises: forming the first component and / or the second component by curing a thermoplastic film with a stack of prepreg layers of thermosetting.
[00074] Clause 19. A method of joining components, comprising the steps of: providing a first component with a first thermoplastic film applied to a first conjugated surface; providing a second component with a second thermoplastic film applied to a second conjugated surface; sweeping the first thermoplastic film and the second thermoplastic film to determine its contour; produce a thermoplastic sheet from material that is substantially similar to the first thermoplastic film and / or the second thermoplastic film, the thermoplastic sheet having a first sheet surface and a second sheet surface matching the contour of the first conjugated surface and the second conjugated surface; assembling the first component and the second component with the thermoplastic sheet pressed between them; apply heat and compaction pressure to the thermoplastic sheet, the first thermoplastic film and / or the second thermoplastic film; and fusing the thermoplastic sheet, the first thermoplastic film and the second thermoplastic film together to join the first component to the second component to form a structural assembly.
[00075] Clause 20. A method of joining components, comprising the steps of: providing a first component with a first thermoplastic film applied to a first conjugated surface, the first conjugated surface including a first rounded surface; providing a second component with a second thermoplastic film applied to a second conjugated surface; producing a thermoplastic rounded reinforcement load with a side surface of the rounded reinforcement load and a base surface of the rounded reinforcement load substantially matching the respective contour of the first rounded surface and the second conjugated surface; assemble the first component, the second component and the rounded thermoplastic reinforcement load; apply heat and compaction pressure to the rounded thermoplastic reinforcement load, the first thermoplastic film and / or the second thermoplastic film; and fusing the first thermoplastic film, the second thermoplastic film and / or the rounded thermoplastic reinforcement filler together to join the first component to the second component to form a structural assembly.

权利要求:
Claims (19)
[0001]
1. Method for joining components, characterized by the fact that it comprises the steps of: providing a first component (300) with a first conjugated surface (302), the first conjugated surface (302) having a first contour; providing a second component (400) with a second conjugated surface (402) to be joined on the first conjugated surface (302), the second conjugated surface (402) having a second contour; and sweeping (606) at least one of the first conjugated surface (302) and the second conjugated surface (402) to determine, respectively, the first contour and the second contour; additively manufacture (608), based on the scan, a solid unit thermoplastic element (500) directly in at least one of the first component (300) and the second component (400) before assembly with a remainder of the first component (300) and the second component (400), the thermoplastic element (500) with at least one of the first surface of the element and a second surface of the element, respectively, matching the first contour and the second contour.
[0002]
2. Method according to claim 1, characterized by the fact that the first contour of the first conjugated surface (302) has a mismatch with the second contour of the second conjugated surface (402).
[0003]
Method according to claim 1, characterized in that the step of additively manufacturing the thermoplastic element (500) comprises: additively manufacturing a thermoplastic sheet (506) with at least one of a first sheet surface (508) and a second sheet surface (510) matching the first contour and the second contour.
[0004]
4. Method according to claim 1, characterized in that the step of additively manufacturing the thermoplastic element (500) comprises: producing the thermoplastic element (500) with at least one of the first and second opposing element surfaces to match with a respective contour of a first thermoplastic film (306) and a second thermoplastic film (406) respectively applied to the first conjugated surface (302) and the second conjugated surface (402).
[0005]
5. Method according to claim 1, characterized in that the first conjugated surface (302) includes a first rounded surface, the step of additively manufacturing the thermoplastic element (500) comprises: additively manufacturing a rounded thermoplastic reinforcement load with a side surface of the rounded reinforcer and a base surface of the rounded reinforcer matching a respective contour of the first rounded surface and the second conjugated surface (402).
[0006]
6. Method according to claim 5, characterized by the fact that the step of additively manufacturing the thermoplastic element (500) comprises: integrally forming a thermoplastic sheet (506) with the rounded thermoplastic reinforcement load; and the thermoplastic sheet (506) having at least one of a first sheet surface (508) and a second sheet surface (510) matching the first contour and the second contour.
[0007]
7. Method according to claim 1, characterized by the fact that the scanning step additionally comprises the step of: scanning using a digital scanning device, a camera, a coordinate measuring machine, or any combination thereof.
[0008]
8. Method according to claim 1, characterized in that the step of additively manufacturing the thermoplastic element (500) directly in at least one of the first component (300) and the second component (400) comprises: manufacturing additively the thermoplastic element (500) directly in at least one of a first thermoplastic film (306) of the first component (300) or a second thermoplastic film (406) of the second component (400).
[0009]
9. Method according to claim 1, characterized in that it additionally comprises the step of: assembling (610) the first component (300) and the second component (400) with the thermoplastic element (500) pressed between them; and fusing the thermoplastic element (500), a first thermoplastic film (306) and a second thermoplastic film (406) together to form a thermoplastic gasket (112) joining the first component (300) to the second component (400).
[0010]
Method according to claim 9, characterized in that the melting step comprises: heating (612) at least one of the thermoplastic element (500), the first thermoplastic film (306) and / or the second thermoplastic film (406) up to at least one glass transition temperature thereof.
[0011]
11. Method according to claim 9, characterized in that the thermoplastic element (500) includes a thermoplastic sheet (506), the melting step includes: compressing a thermoplastic sheet (506) pressed between the first component (300 ) and the second component (400).
[0012]
12. Method according to claim 9, characterized in that the step of additively manufacturing the thermoplastic element (500) includes: additively manufacturing the thermoplastic element (500) from material with a glass transition temperature that is lower than a melting temperature of the first component (300) and / or the second component (400).
[0013]
13. Method according to claim 9, characterized in that the step of additively manufacturing the thermoplastic element (500) includes: additively manufacturing the thermoplastic element (500) from material that is similar to the material of the first thermoplastic film (306) and / or the second thermoplastic film (406).
[0014]
14. Method according to claim 1, characterized by the fact that: the first component (300) and / or the second component (400) is formed from a thermosetting material or a thermoplastic material.
[0015]
15. Method according to claim 1, characterized by the fact that the step of providing the first component (300) and the second component (400) comprises: forming the first component (300) and / or the second component (400 ) by co-consolidating a thermoplastic film with a stack (200) of layers (202) of thermoplastic prepreg (206).
[0016]
16. Method, according to claim 1, characterized by the fact that the step of providing the first component (300) and the second component (400) comprises: forming the first component (300) and / or the second component (400 ) by curing a thermoplastic film with a stack (200) of layers (202) of thermosetting prepreg.
[0017]
17. Method, according to claim 1, characterized by the fact that the additive manufacturing stage comprises three-dimensional printing, stereolithography, and direct digital manufacturing.
[0018]
18. Method for joining components, characterized by the fact that it comprises the steps of: providing a first component (300) with a first thermoplastic film (306) applied to a first conjugated surface (302); providing a second component (400) with a second thermoplastic film (406) applied to a second conjugated surface (402); sweeping the first thermoplastic film (306) and the second thermoplastic film (406) to determine an outline thereof; additively manufacturing, based on the scan, a solid unitary thermoplastic element (500) directly in at least one of the first thermoplastic film (306) and the second thermoplastic film (406) before assembly with a remainder of the first component (300) and of the second component (400), the thermoplastic sheet (506) being formed from a material that is similar to the first thermoplastic film (306) and / or the second thermoplastic film (406), the thermoplastic sheet (506) having at least one of a first leaf surface (508) and a second leaf surface (510) matching, respectively, the outline of the first conjugated surface (302) and the second conjugated surface (402); mounting the first component (300) and the second component (400) with the thermoplastic sheet (506) pressed between them; apply (614) heat and compaction pressure (524) to the thermoplastic sheet (506), the first thermoplastic film (306) and / or the second thermoplastic film (406); and fusing (616) the thermoplastic sheet (506), the first thermoplastic film (306) and the second thermoplastic film (406) together to join the first component (300) to the second component (400) to form a structural assembly (100) .
[0019]
19. Method, according to claim 18, characterized by the fact that the additive manufacturing step comprises one of: three-dimensional printing, stereolithography, and direct digital manufacturing.

类似技术:

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法律状态:
2016-03-01| B03A| Publication of a patent application or of a certificate of addition of invention [chapter 3.1 patent gazette]|

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2018-02-27| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2020-02-11| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2020-06-02| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2020-07-14| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 21/11/2014, OBSERVADAS AS CONDICOES LEGAIS. |

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2020-07-28| B16C| Correction of notification of the grant [chapter 16.3 patent gazette]|Free format text: REF. RPI 2584 DE 14/07/2020 QUANTO AO ENDERECO. |

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