Apparatus and method for joining dissimilar materials to form a structural support member
AssigneeLockheed Martin Corporation
InventorElbert Lee McKague, Jr.
Life of this patent
Estimating the term…
Abstract
A preformed component or “preform” for a structural member has a planar base with two longitudinal legs extending in parallel from the base. A channel is defined between the legs for insertion of a flat panel that forms the web of the structural member. The preform is a composite material having continuous filaments of woven or braided fiber. The preform is impregnated with a thermoset resin that bonds the web to the flange of the structural member. The preform provides excellent structural support even if the web and the flange are formed from dissimilar materials such as metallic and composite. The resin is structurally reinforced with oriented fibers in such a manner as to provide coupling strength between the joined members.
Claims24
A structural member, comprising:
- a web formed from one of a metallic material and a composite material, the web having a pair of longitudinal edges extending in an axial direction;
- a flange formed from the other of the metallic and composite materials;
- a preform formed from composite materials and having a base with a pair of axially elongated legs extending therefrom to define a channel therebetween, wherein the preform is formed from filaments that extend through the base and legs;
- and wherein
- one of the longitudinal edges of the web is bonded in the channel of the preform and the flange is bonded to a surface of the base of the preform.
A structural member, comprising:
- a web formed from one of a metallic material and a composite material, the web having a pair of longitudinal edges extending in an axial direction;
- a flange formed from the other of the metallic and composite materials;
- a generally pi-shaped preform formed from composite materials and having a base with a pair of axially elongated legs extending therefrom to define a channel therebetween, the preform being formed from axial filaments that extend through the base and legs, wherein the axial filaments are oriented parallel to the axial direction and a continuous length of the preform, and the axial filaments minimize a difference in thermal expansion coefficients of the web and the flange;
- and wherein
- one of the longitudinal edges of the web is bonded in the channel of the preform and the flange is bonded to a surface of the base of the preform.
A method for fabricating a structural member, comprising the steps of:
- (a) providing a web formed from one of a metallic material and a composite material and having a longitudinal edge extending in an axial direction, and a flange formed from the other of the metallic and composite materials;
- (b) forming a preform from composite materials, the preform having a base with a pair of legs extending therefrom to define a channel therebetween, wherein the preform has filaments that extend through the base and the legs;
- (c) positioning boundary tooling on the preform, web, and flange and heating the structural member;
- (d) bonding the longitudinal edge of the web in the channel of the preform such that the legs of the preform closely receive the web;
- and
- (e) bonding the base of the preform to the flange to form a structural member.
Dependencies are inferred from the claim text.