# US 9,040,138 B2 · Composite article including composite to metal interlock and method of fabrication > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,040,138 B2 - Document ID: US9040138B2 - Status: Granted - Kind: B2 - Application number: 13/872,317 - Filed: 2013-04-29 - Published: 2014-10-30 - Granted: 2015-05-26 - Earliest claimed: 2013-04-29 - Assignees: General Electric Company - Applicants: General Electric Company - Inventors: Shatil Sinha; Scott Roger Finn; Nicholas Joseph Kray; Peggy Lynn Baehmann; Dong Jin Shim; Gregory Carl Gemeinhardt - Web page: https://patentgrep.com/patent/US9040138B2 ## CPC - B32B 7/08: by mechanical means - B29C 37/0082: {Mechanical anchoring (B29C66/303 takes precedence)} - B29C 70/72: Encapsulating inserts having non-encapsulated projections, e.g. extremities or terminal portions of electrical components {(B29C70/742 takes precedence)} - B29C 70/745: {Filling cavities in the preformed part (for joining B29C70/84)} - B29C 70/86: Incorporated in coherent impregnated reinforcing layers, {e.g. by winding} - B29K 2705/00: Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts - B29L 2031/08: Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers - B29L 2031/7504: {Turbines} - Y10T 428/19: Sheets or webs edge spliced or joined - Y10T 428/24033: including stitching and discrete fastener[s], coating or bond - Y10T 428/24331: including nonapertured component - Y10T 428/249923: Including interlaminar mechanical fastener - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - 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) - 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 - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A composite article including a composite component, a metallic component and one or more interlock components. The composite component including a plurality of composite plies and extending heightwise from a component base to a component tip and lengthwise between spaced apart component first and second edges, the composite. The metallic component including a first surface and a second surface and a plurality of openings formed therein extending from the first surface to the second surface. The metallic component including at least a portion substantially or fully embedded in the composite component. The one or more interlock components is interwoven through one or more of the plurality of openings in the metallic component and extending into and at least partially embedded in the composite component to provide an interlocking system between the composite component and the metallic component. A method of fabrication of a composite article is also provided. ## Claims ### Claim 1 A composite article comprising: a composite component extending heightwise from a component base to a component tip and lengthwise between spaced apart component first and second edges, the composite component including a plurality of plies; a metallic component including a first surface and a second surface, the metallic component including a plurality of openings formed therein and extending from the first surface to the second surface, the metallic component including a first portion extending heightwise from below the component base up through the component base into the composite component and a second portion at an upper end of the metallic component, wherein the second portion is substantially or fully embedded in the composite component, the second portion including heightwise spaced apart base and tip, and one or more interlock components, each of the one or more interlock components interwoven through at least two of the plurality of openings in the metallic component and extending across one of a substantial width or substantial length of the second portion of the metallic component and into and at least partially embedded in the composite component to provide an interlocking system between the composite component and the metallic component. ### Claim 2 (depends on 1) The composite article as claimed in claim 1, wherein the one or more interlock components are oriented relative to the metallic component to optimize a given load condition. ### Claim 3 (depends on 2) The composite article as claimed in claim 2, wherein the one or more interlock components is comprised of one or more fiber tows. ### Claim 4 (depends on 2) The composite article as claimed in claim 2, wherein the one or more interlock components is comprised of a textile. ### Claim 5 (depends on 2) The composite article as claimed in claim 2, wherein the one or more interlock components support a resin injection process. ### Claim 6 (depends on 2) The composite article as claimed in claim 2, wherein the one or more interlock components support a pre-preg laminate construction. ### Claim 7 (depends on 1) The composite article as claimed in claim 1, wherein the composite component includes a composite material lay-up of a plurality of filament reinforced composite plies. ### Claim 8 (depends on 7) The composite article as claimed in claim 7, wherein the plurality of filament reinforced composite plies comprise a fiber filament ply woven composite material in the form of at least one of a tape, a braid, or a weave. ### Claim 9 (depends on 1) The composite article as claimed in claim 1, wherein the composite component is an airfoil and the metallic component is a spar mount. ### Claim 10 (depends on 1) The composite article as claimed in claim 1, wherein the plurality of openings in the metallic component are substantially circular in geometry and provide interweaving of the one or more interlock components therethrough to form a pre-threaded metallic component. ### Claim 11 (depends on 1) The composite article as claimed in claim 1, wherein the plurality of openings in the metallic component are substantially oval in geometry and provide interweaving of the one or more interlock components therethrough to form a pre-threaded metallic component. ### Claim 12 (depends on 1) The composite article as claimed in claim 1, wherein the metallic component includes a first portion and a second portion and wherein the plurality of openings are formed in the second portion. ### Claim 13 A composite article comprising: composite component extending heightwise from a component base to a component tip and lengthwise between spaced apart component first and second edges, the composite component including a composite material lay-up of a plurality of filament reinforced composite plies, wherein each of the plurality of filament reinforced plies have widthwise spaced apart ply sides and ply edges therebetween; and a pre-threaded metallic component including a first surface and a second surface, the pre-threaded metallic component including a plurality of openings formed therein and extending from the first surface to the second surface, the pre-threaded metallic component including one or more interlock components, each of the one or more interlock components interwoven through at least two of the plurality of openings in the pre-threaded metallic component, wherein the one or more interlock components extend from one of a tab forward edge to a tab aft edge or a tab base to a tab tip of the pre-threaded metallic component and into and at least partially embedded in the composite component to provide an interlock system between the composite component and the pre-threaded metallic component, and wherein the composite component and the pre-threaded metallic component are co-cured. ### Claim 14 (depends on 13) The composite article as claimed in claim 13, wherein the pre-threaded metallic component includes a first portion extending heightwise from below the component base up through the component base into the composite component and a second portion at an upper end of the first portion, wherein the second portion is substantially or fully embedded in the composite component, the second portion including heightwise spaced apart base and tip. ### Claim 15 (depends on 13) The composite article as claimed in claim 13, wherein the one or more interlock components is oriented within the pre-threaded metallic component to optimize a given load condition. ### Claim 16 (depends on 13) The composite article as claimed in claim 13, wherein the one or more interlock components is comprised of one or more fiber tows. ### Claim 17 (depends on 13) The composite article as claimed in claim 13, wherein one or more interlock components is comprised of a textile. ### Claim 18 (depends on 13) The composite article as claimed in claim 13, wherein the composite component is an airfoil and the metallic component is a spar mount. ### Claim 19 A method of fabricating a composite article comprising: laying up a plurality of filament reinforced composite plies formed from a composite material, wherein each of the plurality of filament reinforced composite plies have widthwise spaced apart ply sides and ply edges therebetween; inserting a pre-threaded metallic component, into the plurality of filament reinforced composite plies during the laying up of the plurality of filament reinforced composite plies to form a composite to metallic interface; and co-curing the plurality of filament reinforced composite plies and the pre-threaded metallic component to form a composite article including an interlock system for the composite to metallic interface, wherein the pre-threaded metallic component includes a first surface and a second surface and a plurality of openings formed therein and extending from the first surface to the second surface, the pre-threaded metallic component further including one or more interlock components, wherein each of the interlock components is interwoven through at least two of the plurality of openings, and wherein the one or more interlock components extend across one of a substantial width or substantial length of the pre-threaded metallic component and into and at least partially embedded in the plurality of filament reinforced composite plies to provide an interlock system between the plurality of filament reinforced composite plies and the pre-threaded metallic component. ### Claim 20 (depends on 19) The method of fabricating a composite article as claimed in claim 19, wherein the one or more interlock components is comprised of one or more fiber tows or a textile.