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WO2004018183A1 - Procede et outil permettant de former un support en materiau composite et ledit support - Google Patents

Procede et outil permettant de former un support en materiau composite et ledit support Download PDF

Info

Publication number
WO2004018183A1
WO2004018183A1 PCT/GB2003/003552 GB0303552W WO2004018183A1 WO 2004018183 A1 WO2004018183 A1 WO 2004018183A1 GB 0303552 W GB0303552 W GB 0303552W WO 2004018183 A1 WO2004018183 A1 WO 2004018183A1
Authority
WO
WIPO (PCT)
Prior art keywords
bracket
blank
forming
fold line
composite material
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/GB2003/003552
Other languages
English (en)
Inventor
Allan Kaye
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
BAE Systems PLC
Original Assignee
BAE Systems PLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by BAE Systems PLC filed Critical BAE Systems PLC
Priority to EP03748237A priority Critical patent/EP1536938A1/fr
Priority to AU2003267546A priority patent/AU2003267546A1/en
Priority to US10/525,063 priority patent/US20050241358A1/en
Publication of WO2004018183A1 publication Critical patent/WO2004018183A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64C—AEROPLANES; HELICOPTERS
    • B64C3/00—Wings
    • B64C3/18—Spars; Ribs; Stringers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64F—GROUND OR AIRCRAFT-CARRIER-DECK INSTALLATIONS SPECIALLY ADAPTED FOR USE IN CONNECTION WITH AIRCRAFT; DESIGNING, MANUFACTURING, ASSEMBLING, CLEANING, MAINTAINING OR REPAIRING AIRCRAFT, NOT OTHERWISE PROVIDED FOR; HANDLING, TRANSPORTING, TESTING OR INSPECTING AIRCRAFT COMPONENTS, NOT OTHERWISE PROVIDED FOR
    • B64F5/00—Designing, manufacturing, assembling, cleaning, maintaining or repairing aircraft, not otherwise provided for; Handling, transporting, testing or inspecting aircraft components, not otherwise provided for
    • B64F5/10—Manufacturing or assembling aircraft, e.g. jigs therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2307/00—Use of elements other than metals as reinforcement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2309/00—Use of inorganic materials not provided for in groups B29K2303/00 - B29K2307/00, as reinforcement
    • B29K2309/08—Glass
    • 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
    • B29L2031/3085—Wings

Definitions

  • the present invention relates to components joined together using structural joints and more particularly to brackets used for securing components together in such joints.
  • Brackets are commonly made from metal or metal alloys, such as steels and aluminium alloys, being formed in a shape that matches the profile of the joint of the components they are intended to secure. Fasteners such as rivets or bolts attach the bracket to the components it is joining together. The shape of the bracket allows it to support and stiffen the joint and provide a load path to transfer loads from one component to another.
  • brackets are regularly used for joining aircraft structural components and are known as 'cleats'. They are particularly used to join wing ribs to wingskins and to their associated stringers; equivalent rib, skin and stringer components in tail-fins, horizontal tail-planes and similar structures, and fuselage frames to fuselage skins and their associated stringers.
  • the brackets are designed to have the necessary strength characteristics to support, stiffen and act as a load path for the attached components and thus not fail at loads expected at the joint in question. For highly loaded structures this means the brackets have to be made of relatively thick material, as indeed are the components. If the joint is complex, (e.g. four separate components being joined together at varying angles to a given normal) then the shape of the bracket will also be complex. If either of both these requirements are necessary, normal manufacture is by forging followed by machining to finish the bracket.
  • brackets used for aircraft manufacture are high loaded and complex in shape, thus each individual bracket can be a relatively expensive item, due to the complex forging tooling requirements, (different for each bracket design) and further process step of 'finishing', machining the bracket to the finished shape, (considering that there may well be hundreds of individual brackets of many different shapes in a single aircraft) these brackets can add significantly to the cost of manufacture of the aircraft. Indeed, large aircraft such as the Airbus A380 have over a thousand such brackets.
  • each bracket is of a significant enough weight that the total weight of all of the hundreds of brackets utilised in the aircraft structure becomes substantial.
  • Weight in aircraft design is very significant, as the heavier an aircraft is, the more fuel it requires to fly from A to B and as the aircraft is designed with a maximum all up weight the potential payload of the aircraft is reduced as the weight of the fuel and the structure increases. Any savings in aircraft weight or manufacturing costs offer significant advantages to the aircraft manufacturer and operators.
  • a method of forming a bracket including the steps of:
  • bracket may be cured at the same time as the bending operation is undertaken or for part of this time or once the bending operation is completed.
  • the forming tool may be configured so that it can be set to create different values of said predetermined angle allowing different three- dimensional shaped brackets to be formed from the same original blank.
  • This invention provides a simpler and quicker and thus more cost effective method of producing a bracket than forging and than machining to finish a metal bracket.
  • Forging requires a different mould/tool for each bracket that has a different three-dimensional shape.
  • Any bracket that can be formed, using the method of the present invention from the same blank can be formed to its finished three-dimensional shape using the same tool and resetting the angle to which the blank is bent.
  • the tool can be manufactured so that different patterns of blank can be bent to the required three-dimensional shape, by including in the tool designing movable locating points for holding the blank during forming.
  • the tool can be placed into, or even incorporated in, an autoclave or other pressure and/or temperature device, so that curing of the bracket can take place during or directly after the forming process.
  • a blank cut from a sheet of composite material for forming a bracket having at least one fold line defining first and second regions of the blank so that when the blank is bent about the at least one fold line creating a predetermined angle between first and second regions a three-dimensional bracket is formed.
  • the blank may be substantially Z-shaped in profile.
  • the composite material the blanks are cut from may comprise fibres such as carbon fibre or glass fibre and the matrix surrounding the material could be, for example, thermoplastic or thermosetting resin material.
  • An initial stage of manufacture may be to build up material sheets by laying up several thin layers, or plies, on top of one another and the sheets so produced may be tailored to suit different structural requirements by using different numbers of plies and by orienting the fibres in different plies in different directions. If more strength is required additional fibres can also be introduced at key areas of the blank, for example, additional 90° fibres at and around the fold line.
  • the matrix may be introduced into the fibre plies before laying up, in which case the material is known as 'pre-peg'.
  • the matrix may be introduced into the fibre plies after laying up; in this case the fibre plies may initially be stitched together or a binding agent may be used to bind them together temporarily.
  • One method by which a bracket having additional fibres at and around the fold line could be made is to lay up a sheet from layers having the majority of the fibres in each layer orientated in substantially the same direction and a majority of the layers are aligned in a main direction.
  • a blank cut from such a made sheet is placed on a tool to form the bend about the fold line and the blank is constrained against movement in a direction substantially perpendicular to the plane of the said main direction layers, wherein force is applied to the blank in the plane thereof in a direction substantially perpendicular to the said main direction of said fibres, thereby to urge the blank to bend as required whilst substantially maintaining the continuity of the said fibre.
  • the profile of the blanks may be cut from the sheet material by hand or by using an automatically controlled cutting technique, such as water-jet or laser cutters. Whichever method is used, it is relatively simple after the profiles to suit different designs of blank. The blanks thus cut out may be stored until required for the next stage of manufacture.
  • thermoplastic materials an individual blank can be formed into a finished bracket in under 10 minutes, a much shorter time than forging and then finishing a bracket, allowing large production runs to be undertaken in relatively short period of time.
  • the blanks can then be formed by a bending operation into the required three-dimensional shape.
  • the bending operation may be a manual or automated process.
  • the blanks may have to be heated prior to, and during, forming and pressure may be applied to the material during the forming process; on subsequent cooling they will retain the new form they have been given. If the blanks are made from pre- peg, then the blanks will have to be cured in their new shape by the application of heat and pressure, which may be done whilst on the forming tool in an autoclave or by other suitable means. If the blanks are not pre-impregnated with a matrix material, then the tool used for forming may also be used to introduce the matrix material to the blanks before curing takes place.
  • a bracket may be formed from a blank produced as described above and then undertaking a bending operation to bend the blank about the at least one fold line to create a predetermined angle between said first and second regions to form the required three-dimensional shape.
  • a bracket formed from a single cut-out shape from a sheet of composite material cut into a predetermined shape.
  • the cut-out shape may have at least one fold line defining first and second regions of the bracket about which the material has been bent to form a three-dimensional bracket shape.
  • Brackets made in accordance with the present invention have been found to be 15% lighter than the equivalent bracket in aluminium alloy. A significant weight saving.
  • the brackets may then have fastener holes drilled as required. They may then be assembled into structures in a similar way to the metallic brackets of the prior art. They may be used together with surrounding structural components made from any of the usual materials such as metal alloys or from composite material.
  • a tool for forming a bracket as described above comprising two surfaces on which the blank is placed connected by a hinge, the fold line of the blank being aligned with the hinge and the hinge being set to allow the blank to be bent about the fold line to the predetermined angle to form the three-dimensional bracket required.
  • Brackets can be made much more simply than forging moulds, as there is no requirement for the tool to match all the surfaces of the finished bracket. All that is required is that the bracket is securely positioned so that the fold line is correctly positioned on the hinge and the amount of bending is carefully controlled.
  • a component made from composite material having an integral bracket said bracket formed from a shaped sheet of composite material having at least one fold line defining first and second regions of the bracket about which the material has been bent to form a three-dimensional bracket shape. If the bracket is formed from part of one of the components to be joined, less attachment points and fasteners are required, making the joint stronger and lighter.
  • an aircraft wing rib and stringer arrangement including a series of brackets wherein each bracket in the series is formed from composite sheet material cut to the same general profile.
  • Each of the brackets may havine at least one fold line, defining first and second regions of the bracket, about which the bracket is bent to a predetermined angle defined by the position of the rib and stringer.
  • Brackets are especially suitable for joining aircraft rib and stringers, as the basic design of each joint in a particular wing is similar, but the angle between the components changes and thus the angle of the bracket as you move down the wing from the root to the tip.
  • brackets as described in any aspect of the invention above may be used in construction of aircraft and are especially suitable for use in aircraft wing construction.
  • Figure 1a shows an example of an angle bracket
  • Figure 1 b shows the angle bracket of Figure 1a inverted and viewed from the rear;
  • Figure 2a shows an example of a box bracket
  • Figure 2b shows the box bracket of Figure 2a viewed from the rear
  • Figure 3a shows an example of a butterfly bracket
  • Figure 3b shows the butterfly bracket of Figure 3a viewed from the rear
  • Figure 4 shows a part of an aircraft wing construction having wing rib to wing stringer joints
  • Figure 5 shows a blank in accordance with the present invention cut from composite material
  • Figure 6 shows the blank of Figure 5 having been formed to the required three-dimensional shaped bracket
  • Figure 7 shows the bracket of Figure 6 on a forming tool used to bend the blank of Figure 6 to the required three-dimensional shape;
  • Figure 8 shows a finished bracket according to the present invention
  • Figure 9 shows a finished bracket according to the present invention having two fold lines about which the bracket has been bent
  • Figure 10 shows a blank from which the bracket of Figure 9 could be formed.
  • Figures 1 to 3 examples of brackets used in aircraft manufacture as well as other constructions are shown.
  • Figures 1a and 1b show an angle bracket 10 used to joint two components (not shown), the components being attached to surfaces 12 and 14 with fasteners such as bolts and nuts 16, through holes 18a, 18b drilled in the bracket 10.
  • Figures 2a and 2b show a box bracket 20 used to join at least two components, the components being attached at surfaces 22, 24, 26, 28.
  • Figures 3a and 3b show a butterfly bracket 30 used to join at least two components, the components being attached at surfaces 32 and 34.
  • Figure 4 shows how complex structures can be joined using brackets as described above.
  • Part of a wing box 40 is constructed using butterfly brackets, 42a, 42b, 42c, to join stringers 44a, 44b, 44c to rib 46.
  • Figure 5 shows a blank 50 in accordance with the present invention cut from a sheet of composite material with a resin matrix.
  • a fold line 52 defining regions 54 and 56 is marked on the upper surface of the blank to act as a guide during the subsequent bending operation.
  • the blank 50 is substantially 'Z- shaped. This shape allows a bracket suitable for use where a butterfly bracket 30 according to the prior art would previously have been used to be formed in a one-stage forming process.
  • Figure 6 shows the blank 50 having been bent about the fold line 52. Region 54 is no longer in the same plane as region 56. The angle between the two regions 54, 56 can be controlled to create the required three-dimensional shaped bracket. As the blank is bent about fold line 52 curve 58 is formed.
  • FIG. 7 shows the blank 50 of Figure 6 on the tooling 70 used to bend the blank 50 to the required bracket shape.
  • the tooling 70 comprises two forming plates 74, 76 attached via a hinge or other hinge-like mechanism that will allow the plates 74, 76 to rotate with respect to each other.
  • plate 76 is held fixed and plate 76 is allowed to rotate about the hinge that has previously been aligned with fold line 52 and the blank 50 secured in position.
  • Figure 8 shows a finished bracket 80 that has been formed as described above and with fastener holes 82a, 82b, 82c, 82d drilled ready for use.
  • Figure 9 shows a bracket 90 manufactured according to the invention having two curves 92, 94 and fastener holes 96a, 96b, 96c, 96b.
  • Figure 10 shows the blank 100 bracket 90 was formed from having two fold lines 102, 104, defining regions, 106, 108, 110 that can be bent to form the required three-dimensionally shaped bracket.

Landscapes

  • Engineering & Computer Science (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Transportation (AREA)
  • Moulding By Coating Moulds (AREA)

Abstract

L'invention concerne des composants raccordés les uns aux autres au moyen de raccords structuraux et plus particulièrement des supports utilisés pour fixer des composants les uns aux autres dans lesdits raccords. Ces supports sont constitués d'une forme découpée unique obtenue à partir d'une feuille de matériau composite, et comprennent au moins une ligne de pliage définissant une première et une deuxième zone du support autour de laquelle le matériau a été plié afin d'obtenir une forme tridimensionnelle. L'invention concerne également un procédé de fabrication dudit support.
PCT/GB2003/003552 2002-08-21 2003-08-14 Procede et outil permettant de former un support en materiau composite et ledit support Ceased WO2004018183A1 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
EP03748237A EP1536938A1 (fr) 2002-08-21 2003-08-14 Procede et outil permettant de former un support en materiau composite et ledit support
AU2003267546A AU2003267546A1 (en) 2002-08-21 2003-08-14 Method and tool for forming a bracket in composite material and bracket
US10/525,063 US20050241358A1 (en) 2002-08-21 2003-08-14 Method and tool for forming a bracket in composite material and bracket

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0219451.2 2002-08-21
GBGB0219451.2A GB0219451D0 (en) 2002-08-21 2002-08-21 A bracket

Publications (1)

Publication Number Publication Date
WO2004018183A1 true WO2004018183A1 (fr) 2004-03-04

Family

ID=9942700

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB2003/003552 Ceased WO2004018183A1 (fr) 2002-08-21 2003-08-14 Procede et outil permettant de former un support en materiau composite et ledit support

Country Status (5)

Country Link
US (1) US20050241358A1 (fr)
EP (1) EP1536938A1 (fr)
AU (1) AU2003267546A1 (fr)
GB (1) GB0219451D0 (fr)
WO (1) WO2004018183A1 (fr)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007110586A1 (fr) * 2006-03-27 2007-10-04 Airbus Uk Limited élément d'aéronef
WO2008067460A3 (fr) * 2006-11-30 2008-07-10 Boeing Co Barre de cisaillement composite
WO2008094528A3 (fr) * 2007-01-29 2008-12-31 Polystrand Inc Liaison structurelle composite
WO2009062712A1 (fr) * 2007-11-13 2009-05-22 Airbus Deutschland Gmbh Élément d'accouplement pour relier deux éléments de renforcement longitudinal
WO2010070181A3 (fr) * 2008-12-17 2010-11-04 Airbus Operations, S.L. Ferrure de nervure
RU2446986C2 (ru) * 2006-10-03 2012-04-10 Эйрбас Оперейшнз Лимитед Соединительный элемент
EP2965983A1 (fr) * 2014-07-08 2016-01-13 Airbus Operations Limited Attache pour nervures et traverses dans une structure d'avion

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2993856B1 (fr) * 2012-07-30 2015-09-18 Airbus Operations Sas Element de structure de fuselage d'aeronef a section evolutive
GB2528080A (en) * 2014-07-08 2016-01-13 Airbus Operations Ltd Structure
GB2528076B (en) * 2014-07-08 2020-07-29 Airbus Operations Ltd Rib foot
GB2538098A (en) * 2015-05-07 2016-11-09 Airbus Operations Ltd A structural component
US11180238B2 (en) * 2018-11-19 2021-11-23 The Boeing Company Shear ties for aircraft wing

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US4744846A (en) * 1977-06-20 1988-05-17 Isovolta Method of shaping resin laminate sheet
US4784920A (en) * 1986-05-06 1988-11-15 Terufumi Machida Thin fiber-reinforced plastic composite plate and method of molding the same
EP0594096A1 (fr) * 1992-10-19 1994-04-27 T.T.K. KUNSTSTOFF-TECHNOLOGIE GmbH Procédé et dispositif pour déformer, notamment pour plier des objets essentiellement plats
NL1003167C2 (nl) * 1996-05-20 1997-11-21 Dsm Nv Werkwijze en inrichting voor het vouwen van vezelversterkte kunststof- platen en hiermee verkregen voorwerpen.
WO2003008265A1 (fr) * 2001-07-21 2003-01-30 Bae Systems Plc Procede d'assemblage d'elements composites
WO2003022677A1 (fr) * 2001-09-13 2003-03-20 Bae Systems Plc Structure en materiau composite

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US4338808A (en) * 1980-02-25 1982-07-13 Weiss Jacob B Eavestrough corner bracket
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JPH03154674A (ja) * 1989-11-10 1991-07-02 Somar Corp 表面に樹脂層を有する金属加工物の製造方法

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US2183984A (en) * 1935-11-08 1939-12-19 Republie Rubber Company Process and apparatus for a formed mat
US4744846A (en) * 1977-06-20 1988-05-17 Isovolta Method of shaping resin laminate sheet
US4784920A (en) * 1986-05-06 1988-11-15 Terufumi Machida Thin fiber-reinforced plastic composite plate and method of molding the same
EP0594096A1 (fr) * 1992-10-19 1994-04-27 T.T.K. KUNSTSTOFF-TECHNOLOGIE GmbH Procédé et dispositif pour déformer, notamment pour plier des objets essentiellement plats
NL1003167C2 (nl) * 1996-05-20 1997-11-21 Dsm Nv Werkwijze en inrichting voor het vouwen van vezelversterkte kunststof- platen en hiermee verkregen voorwerpen.
WO2003008265A1 (fr) * 2001-07-21 2003-01-30 Bae Systems Plc Procede d'assemblage d'elements composites
WO2003022677A1 (fr) * 2001-09-13 2003-03-20 Bae Systems Plc Structure en materiau composite

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Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007110586A1 (fr) * 2006-03-27 2007-10-04 Airbus Uk Limited élément d'aéronef
JP2009531224A (ja) * 2006-03-27 2009-09-03 エアバス・ユ―ケ―・リミテッド 航空機構成材
US8186622B2 (en) 2006-03-27 2012-05-29 Airbus Operations Limited Aircraft component
RU2446986C2 (ru) * 2006-10-03 2012-04-10 Эйрбас Оперейшнз Лимитед Соединительный элемент
US8267354B2 (en) 2006-10-03 2012-09-18 Airbus Operations Limited Fitting
WO2008067460A3 (fr) * 2006-11-30 2008-07-10 Boeing Co Barre de cisaillement composite
WO2008094528A3 (fr) * 2007-01-29 2008-12-31 Polystrand Inc Liaison structurelle composite
WO2009062712A1 (fr) * 2007-11-13 2009-05-22 Airbus Deutschland Gmbh Élément d'accouplement pour relier deux éléments de renforcement longitudinal
US8353479B2 (en) 2007-11-13 2013-01-15 Airbus Operations Gmbh Arrangement of two fuselage sections of an aircraft and a connecting structure for connecting fuselage skins
RU2479466C2 (ru) * 2007-11-13 2013-04-20 Эрбус Оперейшнс Гмбх Система из двух секций фюзеляжа самолета и соединительной структуры для соединения обшивок фюзеляжа
CN102282068A (zh) * 2008-12-17 2011-12-14 空客运营有限公司 肋接头
WO2010070181A3 (fr) * 2008-12-17 2010-11-04 Airbus Operations, S.L. Ferrure de nervure
EP2965983A1 (fr) * 2014-07-08 2016-01-13 Airbus Operations Limited Attache pour nervures et traverses dans une structure d'avion
US9862477B2 (en) 2014-07-08 2018-01-09 Airbus Operations Limited Aircraft structure

Also Published As

Publication number Publication date
EP1536938A1 (fr) 2005-06-08
US20050241358A1 (en) 2005-11-03
AU2003267546A1 (en) 2004-03-11
GB0219451D0 (en) 2002-09-25

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