Composite structures having composite-to-metal joints and method for making the same
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B32B-003/14
B32B-003/18
출원번호
US-0857835
(2010-08-17)
등록번호
US-8652606
(2014-02-18)
발명자
/ 주소
Griess, Kenneth Harlan
Georgeson, Gary E.
출원인 / 주소
The Boeing Company
대리인 / 주소
Yee & Associates, P.C.
인용정보
피인용 횟수 :
8인용 특허 :
81
초록
A composite structure comprises stacked sets of laminated fiber reinforced resin plies and metal sheets. Edges of the resin plies and metal sheets are interleaved to form a composite-to-metal joint connecting the resin plies with the metal sheets.
대표청구항▼
1. A composite structure, comprising: a first laminated stack of fiber reinforced resin plies; anda second stack of metal sheets, configured to form a composite-to-metal finger joint connecting the first laminated stack of fiber reinforced resin plies with the second stack of metal sheets, such that
1. A composite structure, comprising: a first laminated stack of fiber reinforced resin plies; anda second stack of metal sheets, configured to form a composite-to-metal finger joint connecting the first laminated stack of fiber reinforced resin plies with the second stack of metal sheets, such that the second stack of metal sheets consists of metal sheets and an adhesive layer between each metal sheet, such that the metal sheets comprise at least one of: a titanium sheet, and a titanium alloy sheet, and such that an end of each metal sheet in the second stack of metal sheets abuts an end of multiple fiber reinforced resin plies from the first laminated stack, and the second stack of metal sheets configured to comprise, with an interface between the first laminated stack of fiber reinforced resin plies and the second stack of metal sheets, a waveguide for ultrasonic waves. 2. The composite structure of claim 1, wherein: the first stack of fiber reinforced resin plies and the second stack of metal sheets are arranged in layers, wherein each of the layers includes a first metal sheet and at least one of the fiber reinforced resin plies. 3. The composite structure of claim 2, wherein a first thickness of the fiber reinforced resin plies in each of the layers is generally equal to a second thickness of the first metal sheet in the layer. 4. The composite structure of claim 2, wherein: the at least one of the fiber reinforced resin plies and the first metal sheet in each of the layers having substantially abutting edges forming a resin-to-metal transition point in each of the layers. 5. The composite structure of claim 4, wherein the transition point in each of the layers is staggered relative to each other. 6. The composite structure of claim 2, wherein the layers form a fiber reinforced resin-to-metal finger joint between the first laminated stack of fiber reinforced resin plies and the second stack of metal sheets. 7. The composite structure of claim 1, wherein: the metal sheets consist of the titanium alloy, andthe fiber reinforced resin plies comprise carbon. 8. The composite structure of claim 1, further comprising at least one of: a microelectromechanical sensor, a piezo-electric sensor, and a transducer. 9. A hybrid composite resin-metal structure, comprising: a composite resin portion comprising laminated plies of fiber reinforced resin;a metal portion consisting of metal sheets and an adhesive layer between each of the metal sheets, such that the metal sheets comprise at least one of: titanium, and a titanium alloy; anda transition section between the composite resin portion and the metal portion, the transition section including staggered overlaps between the laminated plies and the metal sheets, configured such that an end of each of the metal sheets abuts an end of multiple laminated plies, and the staggered overlaps comprise a waveguide configured to support nondestructive evaluations of a bond quality in the composite resin metal structure. 10. The hybrid composite resin-metal structure of claim 9, wherein: the laminated plies and the metal sheets are arranged in layers, andeach of the layers includes one of the metal sheets and a plurality of the laminated plies in substantially edge-to-edge abutment. 11. The hybrid composite resin-metal structure of claim 10, wherein a first thickness of the laminated plies in each of the layers is substantially equal to a second thickness of the metal sheet in the layer. 12. The hybrid composite resin-metal structure of claim 9, wherein the staggered overlaps form a composite-to-metal finger joint between the composite resin portion and the metal portion. 13. The hybrid composite resin-metal structure of claim 9, further comprising a layer of adhesive between each of the metal sheets for bonding the sheets together and unitizing the metal portion. 14. The hybrid composite resin-metal structure of claim 9, wherein each of the metal sheets consists of the titanium alloy. 15. A hybrid composite metal part having a full thickness, comprising: a layup of multiple plies of a fiber reinforced composite material having a first thickness, the layup terminating at an interface location; anda metal sheet of the first thickness, in a stack that consists of: metal sheets, and an adhesive layer between each metal sheet, such that an end of each metal sheet in the stack abuts an end of multiple fiber reinforced composite plies, such that the metal sheet comprises at least one of: titanium, and a titanium alloy, and continues to a metal edge of the hybrid composite metal part, and the layup is repeated with a composite to metal interface that is staggered toward the metal edge of the part from the interface location and includes a ply of structural adhesive between each sheet in the stack, with the next metal to composite interface staggered away from the metal edge of the hybrid composite metal part to produce a nested splice, and the staggered interface stacking produces nested tabs continuing to the full thickness of the hybrid composite metal part with no metal sheet in the stack extending fully to an edge opposite the metal edge of the hybrid composite metal part, the stack configured to comprise a waveguide comprising the interface location and the stack. 16. The hybrid composite metal part of claim 15, further comprising a sensor configured to receive an ultrasonic wave. 17. A hybrid composite resin-metal aircraft structure, comprising: a plurality of laminated layers forming a fiber reinforced, all composite portion;a unitized metal portion consisting of a plurality of metal sheets and an adhesive layer, the adhesive layer, being between at least a first metal sheet and a second metal sheet within the plurality of metal sheets, configured to unitize the first and the second metal sheets, such that each metal sheet abuts multiple plies of composite resin; anda hybrid composite-metal finger joint connecting the composite portion with the unitized metal portion, each layer within the plurality of laminated layers including a plurality of plies of composite resin; such that the metal sheets consist of at least one of: titanium, and a titanium alloy, and wherein the plurality of plies and the plurality of metal sheets are arranged in edge-to-edge abutment with each other forming a composite-to-metal transition point, the plurality of metal sheets configured to comprise a waveguide with the composite-to-metal transition point, and wherein the plurality of laminated layers comprises a plurality of transition points in the plurality of laminated layers such that the plurality of transition points are configured staggered relative to each other to form the hybrid composite-metal finger joint. 18. The hybrid composite resin-metal aircraft structure of claim 17, further comprising a transducer configured to receive an ultrasonic wave. 19. The transducer of claim 18, wherein the transducer comprises at least one of: a microelectromechanical sensor and a piezo-electric sensor. 20. A composite structure, comprising: a first stack of laminated fiber reinforced resin plies;a second stack consisting of: metal sheets, and an adhesive layer between each adjacent metal sheet, configured to form a composite-to-metal joint connecting the first laminated stack of fiber reinforced resin plies with the second stack, such that each metal sheet consists of at least one of: titanium, and a titanium alloy, and such that an end of each metal sheet in the second stack abuts ends of multiple laminated fiber reinforced plies in the first stack, and the second stack comprised by a waveguide configured to facilitate nondestructive evaluations of a bond quality of the composite structure; anda sensor configured to receive an ultrasonic wave.
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