# US 9,039,858 B2 · Composite strip

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- Number: US 9,039,858 B2
- Document ID: US9039858B2
- Status: Granted
- Kind: B2
- Application number: 13/074,430
- Filed: 2011-03-29
- Published: 2011-08-11
- Granted: 2015-05-26
- Earliest claimed: 2007-08-02
- Assignees: The Boeing Company
- Applicants: Kenneth M. Dull; William H. Ingram
- Inventors: Kenneth M. Dull; William H. Ingram
- Web page: https://patentgrep.com/patent/US9039858B2

## CPC

- B29C 70/342: {using isostatic pressure}
- B29C 66/532: {Joining single elements to the wall of tubular articles, hollow articles or bars}
- B29C 70/446: {Moulding structures having an axis of symmetry or at least one channel, e.g. tubular structures, frames}
- B29C 70/549: {Details of caul plates, e.g. materials or shape}
- B29C 70/68: by incorporating or moulding on preformed parts, e.g. inserts or layers {, e.g. foam blocks (mould constructions therefor B29C33/12; joining preformed parts by moulding B29C65/70)}
- B29C 37/02: Deburring or deflashing {(thermal deburring in general B23D79/005)}
- B29C 39/00: Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor (B29C41/00 takes precedence)
- B29C 65/02: by heating, with or without pressure
- B29C 65/48: using adhesives {, i.e. using supplementary joining material; solvent bonding}
- B29C 65/5057: {positioned between the surfaces to be joined (B29C65/5035 takes precedence)}
- B29C 66/1122: {Single lap to lap joints, i.e. overlap joints (B29C66/45, B29C66/472, B29C66/52272 take precedence)}
- B29C 66/522: {Joining tubular articles (B29C66/53241 takes precedence)}
- B29C 66/5326: {said single elements being substantially flat}
- B29C 66/71: {characterised by the composition of the plastics material of the parts to be joined (welding bar compositions B29C65/125)}
- B29C 66/721: {Fibre-reinforced materials (B29C66/729 takes precedence)}
- B29C 66/7212: {characterised by the composition of the fibres}
- B29C 66/72141: {Fibres of continuous length}
- B29C 66/723: {being multi-layered (B29C66/7292, B29C66/72941 take precedence)}
- B29C 66/73751: {the to-be-joined area of at least one of the parts to be joined being uncured, i.e. non cross-linked, non vulcanized}
- B29C 66/73753: {the to-be-joined area of at least one of the parts to be joined being partially cured, i.e. partially cross-linked, partially vulcanized}
- B29C 66/7394: {characterised by the material of at least one of the parts being a thermoset}
- B29C 66/73941: {characterised by the materials of both parts being thermosets}
- B29L 2031/3082: {Fuselages}
- B32B 17/04: bonded with or embedded in a plastic substance
- B32B 19/04: next to another layer of {the same or of} a {different material (next to a glass layer B32B17/067)}
- B32B 37/00: Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B 37/02: characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
- B32B 2037/1253: {curable adhesive}
- B32B 2305/076: Prepregs
- B32B 2309/10: linear, e.g. length, distance, width
- Y10T 156/10: Methods of surface bonding and/or assembly therefor
- Y10T 156/1093: with covering of discrete laminae with additional lamina
- Y10T 428/24752: Laterally noncoextensive components
- Y10T 428/2476: Fabric, cloth or textile component
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A composite strip and a method of manufacturing a pre-cured composite strip. A pre-cured composite strip having a thermoset resin may be placed on a surface of a portion of a composite component where a caul plate seam may be expected. Caul plates may be placed on the composite component after placing the pre-cured composite strip to form the caul plate seam. The composite component may be cured after placing the caul plates on the composite component.

## Claims

### Claim 1

A method of manufacturing a pre-cured composite strip for use with a composite part, the method comprising:
laying up a composite strip comprising a set of fibers and a thermoset resin on a base plate, the composite strip characterized by a longitudinal axis, the set of fibers oriented substantially perpendicular to the longitudinal axis;
curing the composite strip on the base plate to form the pre-cured composite strip, the thermoset resin configured not to melt or soften after curing;
applying the pre-cured composite strip to a surface comprising a fiber reinforced composite material of the composite part, wherein the pre-cured composite strip has a width and a length and wherein the pre-cured composite strip has a thickness that tapers towards opposing edges of the width of the pre-cured composite strip; and
placing a first caul plate and a second caul plate over the composite material and the composite strip, the first caul plate and the second caul plate defining a seam that overlies the composite strip.

### Claim 2 (depends on 1)

The method of claim 1, further comprising a forming step including:
placing a layer of composite tape over a first layer of composite fabric, the composite tape comprising a plurality of fibers oriented substantially perpendicular to the longitudinal axis; and
placing a second layer of composite fabric over the layer of composite tape to form composite layers.

### Claim 3 (depends on 2)

The method of claim 2, wherein the forming step further comprises:
placing a first layer of peel ply over the composite layers; and
placing a second layer of peel ply under the composite layers.

### Claim 4 (depends on 2)

The method of claim 2, wherein the first layer of the composite fabric has a first width, the layer of the composite tape has a second width that is less than the first width, and the second layer of the composite fabric has a third width that is less than the second width.

### Claim 5 (depends on 2)

The method of claim 2, wherein the composite tape, the first layer of the composite fabric, and the second layer of the composite fabric include thermoset resins.

### Claim 6 (depends on 3)

The method of claim 3 further comprising:
replacing the first layer of peel ply with an adhesive layer after curing the pre-cured composite strip; and
replacing the second layer of peel ply with a surface layer after curing the pre-cured composite strip.

### Claim 7 (depends on 2)

The method of claim 2, wherein the thermoset resin does not melt or soften if subjected to a second curing process.

### Claim 8 (depends on 1)

The method of claim 1, wherein the base plate is substantially flat.

### Claim 9 (depends on 1)

The method of claim 1, wherein the base plate comprises a curvature that substantially matches an outer mold line for the composite strip.

### Claim 10

A method of applying a pre-cured composite strip for use with a composite part, the method comprising:
placing a first peel ply layer on a base plate;
placing a first composite fabric layer on the first peel ply layer, the first composite fabric layer comprising a fiber material and a thermoset resin;
placing a tape layer on the first composite fabric layer, the tape layer comprising a plurality of unidirectional fibers and the thermoset resin, the tape layer characterized by a longitudinal axis, the plurality of unidirectional fibers oriented substantially perpendicular with respect to the longitudinal axis;
placing a second composite fabric layer on the tape layer, the second composite fabric layer comprising a fiber material and the thermoset resin; and
curing the first composite fabric layer, the tape layer, and the second composite fabric layer to form the pre-cured composite strip, the thermoset resin in the first composite fabric layer, the tape layer, and the second composite fabric layer configured not to melt or soften after curing;
placing the pre-cured composite strip on a surface comprising a fiber reinforced composite material of the composite part;
bonding the pre-cured composite strip onto the surface of the composite part with an adhesive;
placing a first caul plate and a second caul plate over the surface of the composite part such that a seam between the first caul plate and the second caul plate overlies the pre-cured composite strip; and
curing the composite part.

### Claim 11 (depends on 10)

The method of claim 10 further comprising removing the first peel ply layer so as to expose a surface of the first composite fabric layer.

### Claim 12 (depends on 11)

The method of claim 11 further comprising placing an adhesive on the surface of the first composite fabric layer; and bonding the surface of the first composite fabric layer with the adhesive to the composite component.

### Claim 13 (depends on 10)

The method of claim 10 further comprising placing a second peel ply layer on the second composite fabric layer.

### Claim 14 (depends on 10)

The method of claim 10 further comprising placing an additional tape layer on the tape layer.

### Claim 15 (depends on 10)

The method of claim 10, wherein the first composite fabric layer has a first width; the tape layer has a second width that is smaller than the first width; and the second composite fabric layer has a third width that is smaller than the second width.

### Claim 16 (depends on 10)

The method of claim 10, wherein at least one of the first composite fabric layer and the second composite fabric layer is a prepreg layer.

### Claim 17

A method of manufacturing a pre-cured composite strip for a composite part, the pre-cured composite strip oriented with respect to a longitudinal axis of a composite part, the method comprising:
placing a first peel ply layer on a base plate;
placing a first composite fabric layer on the first peel ply layer, the first composite fabric layer comprising a fiber material and a thermoset resin;
placing a tape layer on the first composite fabric layer, the tape layer comprising a plurality of unidirectional fibers and the thermoset resin;
placing a second composite fabric layer on the tape layer, the second composite fabric layer comprising a fiber material and the thermoset resin;
curing the first composite fabric layer, the tape layer, and the second composite fabric layer to form the pre-cured composite strip, the thermoset resin in the first composite fabric layer, the tape layer, and the second composite fabric layer configured not to melt or soften after curing;
removing the first peel ply layer so as to expose a surface of the first composite fabric layer;
placing an adhesive on the surface of the first composite fabric layer;
bonding the surface of the first composite fabric layer with the adhesive to a surface comprising a fiber reinforced composite material of the composite part, the composite part characterized by a longitudinal axis, the composite strip positioned such that the plurality of unidirectional fibers in the tape layer are oriented substantially perpendicular with respect to the longitudinal axis of the composite part, the composite part comprising a fiber reinforced with resin composite material; and
placing a first caul plate and a second caul plate over the composite material and the composite strip, the first caul plate and the second caul plate defining a seam that overlies the composite strip.

### Claim 18 (depends on 17)

The method of claim 17, wherein the first composite fabric layer has a first width; the tape layer has a second width that is smaller than the first width; and the second composite fabric layer has a third width that is smaller than the second width.