U.S. patent application number 10/904802 was filed with the patent office on 2006-06-01 for determinant assembly features for vehicle structures.
This patent application is currently assigned to THE BOEING COMPANY. Invention is credited to Thomas R. Berkel, Michael P. Renieri, Jeffrey H. Wood.
Application Number | 20060115320 10/904802 |
Document ID | / |
Family ID | 36001269 |
Filed Date | 2006-06-01 |
United States Patent
Application |
20060115320 |
Kind Code |
A1 |
Wood; Jeffrey H. ; et
al. |
June 1, 2006 |
DETERMINANT ASSEMBLY FEATURES FOR VEHICLE STRUCTURES
Abstract
A determinant assembly feature for a joint assembly is provided.
The joint assembly includes a structure, a web connected to the
structure. The structure includes a base, a pair of axially
elongated legs extending from the base to define a channel
therebetween, and one or more location control receiving element in
either axially elongated leg. The web includes one or more location
control element, wherein the location control element of the web is
correspondingly matched to the location control receiving element
of the structure, whereby an assembly location control is achieved.
A method of assembling a joint assembly of the present invention is
also provided.
Inventors: |
Wood; Jeffrey H.; (Eureka,
MO) ; Renieri; Michael P.; (St. Peters, MO) ;
Berkel; Thomas R.; (Troy, IL) |
Correspondence
Address: |
ARTZ & ARTZ, P.C.
28333 TELEGRAPH RD.
SUITE 250
SOUTHFIELD
MI
48034
US
|
Assignee: |
THE BOEING COMPANY
100 North Riverside
Chicago
IL
|
Family ID: |
36001269 |
Appl. No.: |
10/904802 |
Filed: |
November 30, 2004 |
Current U.S.
Class: |
403/232.1 |
Current CPC
Class: |
Y02T 50/40 20130101;
Y10T 403/1624 20150115; Y10T 403/75 20150115; F16B 2200/10
20180801; Y10T 403/73 20150115; Y10T 403/472 20150115; B64C
2001/0081 20130101; F16B 5/0012 20130101; Y10T 29/49826 20150115;
B64C 1/06 20130101; B64C 2001/0072 20130101; Y10T 403/7096
20150115 |
Class at
Publication: |
403/232.1 |
International
Class: |
F16D 1/00 20060101
F16D001/00 |
Claims
1. A joint assembly comprising: a structure comprising a base, a
pair of axially elongated legs extending from the base to define a
channel therebetween, and one or more location control receiving
element in either axially elongated leg; and a web coupled to said
structure, said web comprising one or more location control
element, wherein the location control element of said web is
correspondingly matched to the location control receiving element
of said structure, whereby a assembly location control is
achieved.
2. The joint assembly according to claim 1, wherein the location
control receiving element is a slot.
3. The joint assembly according to claim 1, wherein the one or more
location control receiving element is one or more pair of location
control receiving elements in the pair of axially elongated legs,
and the location control element is correspondingly matched to the
pair of location control receiving elements.
4. The joint assembly according to claim 3, wherein the pair of
location control receiving elements is a slot concentrically
located in the pair of axially elongated legs.
5. The joint assembly according to claim 1, wherein the assembly
location control comprises a linear position control or a vertical
depth position control.
6. The joint assembly according to claim 1, wherein the assembly
location control element of said web is a locating pin or a
boss.
7. The joint assembly according to claim 1, wherein the assembly
location control element of said web is a raised resin boss.
8. The joint assembly according to claim 3, wherein the assembly
location control element of said web is a cross pin or a concentric
pair of boss.
9. The joint assembly according to claim 3, wherein the cross pin
is hollow, whereby the hollow cross pin may act as a conduit to
pass wires, hydraulic lines, fluid between sealed bays, or fuel
transport from bay to bay.
10. The joint assembly according to claim 1, wherein said web is a
panel, a nonporous panel, or a flat panel.
11. The joint assembly according to claim 1, wherein said structure
has a pi-shaped cross-section.
12. The joint assembly according to claim 1, wherein said structure
has an angled pi-shaped cross-section.
13. The joint assembly according to claim 1, further comprising an
adhesive fixedly bonding said web to said structure.
14. The joint assembly according to claim 13, wherein the adhesive
is an epoxy adhesive.
15. The joint assembly according to claim 1, wherein said web
further comprises a bondline thickness control element, whereby
spacing between said web and said structure is controlled.
16. The joint assembly according to claim 15, wherein the bondline
thickness control element is a spacer, a wire or a rail.
17. The joint assembly according to claim 15, wherein the bondline
thickness control element provides a minimum distance of at least
0.02 inches between said web and said structure.
18. The joint assembly according to claim 1, wherein said web is a
metallic material or a composite material, and said structure is a
metallic material or a composite material.
19. The joint assembly according to claim 18, wherein the composite
material is a high-modulus carbon fiber fabric infused with
toughened epoxy resin.
20. The joint assembly according to claim 5, wherein said web
includes a leading side, a trailing side, a top side and a lower
side, said structure is coupled to the lower side of said web, and
further comprising a second pi structure coupled to the upper side
of said web.
21. The joint assembly according to claim 20, wherein the linear
position control is in the general direction of the leading side
and the trailing side, and the vertical depth position control is
in the general direction of the top side and the lower side.
22. A joint assembly for a vehicle comprising: a structure having a
base, a pair of axially elongated legs extending from the base to
define a channel therebetween, and at least one first determinant
assembly feature in either axially elongated leg; and a web
determinately coupled to the structure, the web having at least one
second determinant assembly feature, wherein a linear position
control or a vertical depth position control is attained between
said structure and said web.
23. The joint assembly for a vehicle according to claim 22, wherein
the first determinant assembly feature of said structure is a slot,
and the second determinant assembly feature of said web is a pin, a
boss, a nub, or a raised resin boss.
24. The joint assembly for a vehicle according to claim 22, wherein
said web is a panel and said structure has a pi-shaped
cross-section.
25. The joint assembly for a vehicle according to claim 22, further
comprising an adhesive fixedly bonding said web to said
structure.
26. The joint assembly for a vehicle according to claim 22, wherein
said web further comprises a thickness control element, wherein a
spacing position control is attained between said structure and
said web.
27. The joint assembly for a vehicle according to claim 26, wherein
the thickness control element is a spacer, a wire or a rail,
providing the spacing position control of at least 0.02 inches
between said web and said structure.
28. A joint assembly for an aircraft comprising: a panel having at
least one hole; at least one determinant assembly element coupled
to the hole of said panel; and a structure having a base, a pair of
axially elongated legs extending from the base to define a channel
therebetween, and at least one determinant assembly feature in
either axially elongated leg, wherein said panel with said
determinant assembly element is determinately coupled to the
structure.
29. The joint assembly for an aircraft according to claim 28,
further comprising a thickness control element coupled between said
structure and said panel.
30. The joint assembly for an aircraft according to claim 29,
wherein the determinant assembly feature of said structure is a
slot, said determinant assembly element is a pin, a cross pin or a
boss, and said thickness control element is a spacer, a wire or a
rail, wherein a linear position control, a vertical depth position
control or a spacing position control is attained between said
panel and said structure.
31. The joint assembly for an aircraft according to claim 28,
further comprising an adhesive fixedly bonding said panel to said
structure.
32. The joint assembly for an aircraft according to claim 28,
wherein said panel is a non-porous flat panel or said structure has
a pi-shaped cross-section.
33. A joint assembly for an aircraft comprising: a web; at least
one determinant assembly element coupled to the web; at least one
bondline thickness control element coupled to the web; and a
structure having a base, a pair of axially elongated legs extending
from the base to define a channel therebetween, and at least one
determinant assembly feature in either axially elongated leg,
wherein said web with said determinant assembly element is
determinately coupled to said structure, and said bondline
thickness control element determinately spacing said web between
the pair of axially elongated legs of said structure.
34. The joint assembly for an aircraft according to claim 33,
wherein the determinant assembly feature of said structure is a
slot, said determinant assembly element is a pin, a boss, a nub or
a raised resin boss, and said bondline thickness control element is
a spacer, a wire or a rail.
35. The joint assembly for an aircraft according to claim 33,
further comprising an epoxy adhesive fixedly bonding said web to
said structure.
36. The joint assembly for an aircraft according to claim 28,
wherein said web is a porous panel or a flat panel and said
structure has an angled cross-section or a pi-shaped
cross-section.
37. A method of assembling a joint assembly comprising: providing a
structure comprising a base, a pair of axially elongated legs
extending from the base to define a channel therebetween, and one
or more location control receiving element in either axially
elongated leg; providing a web comprising one or more location
control elements; and inserting said web into said structure,
wherein the location control element of said web is correspondingly
matched to the location control receiving element of said
structure, whereby a determinant assembly is achieved.
38. The method of assembling a joint assembly according to claim
37, further comprising filling an adhesive between said web and
said structure.
39. A method of assembling a joint assembly comprising: providing a
web; providing at least one determinant assembly element; providing
at least one thickness control element; providing a structure
having a base, a pair of axially elongated legs extending from the
base to define a channel therebetween, and at least one determinant
assembly feature in either axially elongated leg; coupling said
determinant assembly element to said web; coupling said thickness
control element to said web or said determinant assembly element;
and inserting said web, said determinant assembly and said
thickness control element into said structure, wherein said web
with said determinant assembly element is determinately coupled to
said structure, and said thickness control element determinately
spacing said web between the pair of axially elongated leg of said
structure.
40. The method of assembling a joint assembly according to claim
39, further comprising filling an adhesive between said web and
said structure, and waiting for a cure time.
41. The method of assembling a joint assembly according to claim
40, further comprising removing said determinant assembly element
or said thickness control element after said cure time thereby
forming a void, and filling an adhesive into said void.
Description
TECHNICAL FIELD
[0001] The present invention relates generally to a joint assembly
and method thereof, and more particularly, to determinant assembly
features for a joint assembly.
BACKGROUND DESCRIPTION
[0002] Adhesive connected joint assemblies are beginning to be more
prevalent as the choice for assembling two structural elements
together, whether or not the structure is a static or dynamic
structure, such as is a structure used on an airplane. More
importantly, the adhesively connected joint assembly provides a way
by which structural components are bound together without requiring
mechanical fasteners, especially when the material of each
component of the joint is either a composite-to-composite or a
composite-to-metallic type connection and would otherwise require
excessive material waste to fashion a typical flange joint
connection out of one of the parts capable of receiving mechanical
fasteners. By utilizing the adhesively connected joint to connect
structural elements, the weight of the overall structure may be
reduced and the structural strength in a particular application may
be increased.
[0003] One such adhesively connected joint is the pi-joint assembly
used for aircraft structures which includes the PI structure, known
for its shape resembling the mathematical .pi. symbol. The pi-joint
assembly includes a web, a pi member and a skin. An adhesive is
then typically filled in the gap formed between the web and the
pi-member in such a way as to secure the two members. Other pi
members may be joined to the other sides of the web in order to
complete a given structure, thereby allowing structures like a wing
of an airplane to be formed by multiple pi-joint assemblies.
Historically, aircraft structures were bent-up sheet metal with
crude tolerance control bolted to supporting structures. This
necessitated the use of assembly jigs for final location of the
mating aircraft structure utilizing shims between the mating parts
to accommodate the manufacturing tolerance inaccuracies. The
adhesively connected joint or pi-joint is an improvement upon
traditional aircraft structures. However, pi-joint has created a
disadvantage by necessitating the need to use shims and other
assembly jigs for final location and assembly of the joint. The
flat panel or web location must be controlled within the pi-member
to assure that an adequate adhesive bondline thickness is provided
on all sides of the web inside the joint. If the web shifts to one
side preventing adhesive from that surface, joint failure can
occur. Another disadvantage of such joints is the complicated
assembly procedures required in order to properly align the parts
prior to applying the adhesive to secure the web to the
pi-member.
[0004] One known process to assemble the parts is by utilizing
holes located in the parts, whereby the parts are located and
aligned during assembly. The holes are then drilled to size after
the parts are assembled, which necessitates the requirement of
subsequently disassembling the parts to remove drill lubricant,
chips and other foreign matter introduced between the parts during
the drilling process. The cleaned parts are then reassembled and
fasteners or jigs are installed along the part to "hold" the parts
in alignment with each other while the adhesive is injected into
the parts and while it cures. The alignment process may include
shims or wires that are positionally located along and between the
parts in order to insure a bondline thickness. The minimum bondline
thickness is required in order to insure maximum attachment
strength between the adhesively joined parts. After the adhesive
starts to set or has partially cured, the shims and wires are
removed. The voids that are created by removal of the shims and
wires are then filled with additional adhesive. The additional
steps of locating, drilling, cleaning, reassembly, fastening,
shimming, unfastening, unshimming, and filling voids as mentioned
above are a disadvantage because time and money are lost due to the
additional albeit necessary steps for the present method of
assembly. Therefore, there is a need to have an improved method of
assembly that reduces or eliminates the current steps. Also, there
is a need to have an improved assembly that reduces or eliminates
some of the assembly steps, assembly cycle time or assembly costs.
Moreover, it would be advantageous to develop parts that reduces
the dependency on tooling during the assembly process, reduces
variation for part-to-part indexing and improves product
repeatability and consistency. Lastly, it would be advantageous to
eliminate the need for shims and/or wires to achieve the minimum
bond thickness on a pi-joint and it would be advantageous to
eliminate or reduce some of the associated assembly steps required
by the shimming.
[0005] It may be beneficial to use Determinant Assembly (DA)
technology in a novel and inventive way to solve or improve the
uncertainty of locating and aligning pi-assembly members. It may
also be beneficial to use DA technology features in order to
provide an improved method of joint assembling. With the advent of
close tolerance N/C machines, designers can now create accurately
mated net-fit structures that can self locate on the mating parts.
Features can be designed and built into the mating parts to assure
prescribed locations. This practice is known as Determinant
Assembly (DA) since the location of each detail is "determined" by
features on the mating details of the assembly. Coupled with the
increasing use of fastener-free bonded composite aircraft
structural joints, there is an ever-increasing need to take
advantage of the DA practice. This will provide increased accuracy
of part locations, elimination of assembly jigs, and rapid
production rates. Therefore it may be desirable to utilize DA
technology, DA concepts and DA features on the parts in order to
provide an improved adhesively bonded joint and method of
assembling thereof.
SUMMARY OF THE INVENTION
[0006] Accordingly, determinant assembly features for a joint
assembly and method of assembly thereof is provided that
advantageously utilizes DA technology, DA concepts and DA
features.
[0007] For metallic members the DA features may be precisely
machined into each constituent part or parts.
[0008] For composite members the DA feature may be precisely
machined into each constituent part or parts, or the DA feature may
be fabricated or formed into each constituent part or parts. One
method that the composite members may be fabricated or formed that
comprise the assembled structural joint are typically fabricated
using either impregnated composite constituents (prepreg) placed on
a shaped one-sided mold and cured in an autoclave or utilize dry
composite fabric placed an a one-sided mold with subsequent room
temperature infusion of resin in a process known as Vacuum Assisted
Resin Transfer Molding (VARTM). Another less common practice is a
method in which the composite members may be fabricated or formed
is a matched-metal closed mold where the dry fabric is installed
into the mold then infused with resin in a process known as Resin
Transfer Molding (RTM).
[0009] In a first embodiment, determinant assembly features for a
joint assembly is provided. The determinant assembly features for a
joint assembly of the present invention is provided by utilizing DA
concepts as mentioned above in creating a novel and inventive joint
assembly. The joint assembly includes a structure and a web
connected to the structure. The structure includes a base, a pair
of axially elongated legs extending from the base to define a
channel therebetween, and one or more location control receiving
element in either axially elongated leg. The web includes one or
more location control element, wherein the location control element
of the web is correspondingly matched to the location control
receiving element of the structure, whereby an assembly location
control is achieved.
[0010] Other embodiments of the joint assembly are presented
below.
[0011] A method of assembling a joint assembly of the present
invention is also provided. The method of assembling a joint
assembly includes providing a structure comprising a base, a pair
of axially elongated legs extending from the base to define a
channel therebetween, and one or more location control receiving
element in either axially elongated leg, providing a web comprising
one or more location control element, and inserting the web into
the structure, wherein the location control element of the web is
correspondingly matched to the location control receiving element
of the structure, whereby a determinant assembly is achieved. The
method of assembling a joint may also include filling an adhesive
between the web and the structure.
[0012] Another method of assembling a joint assembly of the present
invention is also provided below.
[0013] Other aspects and advantages of the present invention will
become apparent upon the following detailed description and
appended claims, and upon reference to the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is an exploded isomeric view of a joint assembly for
an aircraft in accordance with the present invention being used to
advantage.
[0015] FIG. 2A is a partial exploded view of a joint assembly in
accordance with a second embodiment of the present invention being
used to advantage.
[0016] FIG. 2B is an assembled view of the joint assembly of FIG.
2A.
[0017] FIG. 3A is a partial exploded view of a joint assembly in
accordance with a third embodiment of the present invention being
used to advantage.
[0018] FIG. 3B is an assembled view of the joint assembly of FIG.
3A.
[0019] FIG. 4A is a partial exploded view of a joint assembly in
accordance with a fourth embodiment of the present invention being
used to advantage.
[0020] FIG. 4B is an assembled view of the joint assembly of FIG.
4A.
[0021] FIG. 5 is a partial cross-sectional view of the joint
assembly of FIG. 1.
[0022] FIG. 6 is a partial cross-sectional view of the joint
assembly in accordance with a fifth embodiment of the present
invention being used to advantage.
DETAILED DESCRIPTION OF THE INVENTION
[0023] In the following figures the same reference numerals will be
used to identify the same components of a given embodiment.
[0024] FIG. 1 shows an exploded isomeric view of a joint assembly
10 for an aircraft 11 in accordance with the present invention
being used to advantage. The joint assembly 10 is made from the
assembly of a panel or web 16 and a structure 12 coupled to the web
16. This embodiment also shows an additional structure 14 coupled
to the web 16. Simultaneous reference may be made to FIG. 5, which
shows a partial cross-sectional view of the joint assembly of FIG.
1.
[0025] The web 16 may include a front side, a back side, a lower
side 39, an upper side 38, a leading side 36 and a trailing side
37. The web 16 also includes six pins or cross pins 30, 31, 32, 33,
34, 35. The cross pins 30, 31, 32, 33, 34, 35 extend through holes
in the web 16 and concentrically extend above the front side and
the back side. The cross pins 30, 31, 32, 33, 34, 35 of the web 16
each form a location control element or a determinant assembly
element in the present embodiment.
[0026] The pins 30, 31, 32, 33, 34, 35 of the present embodiment
each have a cylindrical peg shape, however a person having skill in
the art would recognize that various other shapes may be used and
that each pin may have a different shape. The web 16 may have any
number of pins or pair of pins, even though six cross pins are
presented in the present embodiment.
[0027] Alternatively, the pins may form a determinant assembly
feature when the pin is formed or machined into the web. The pin
when formed or machined into the web may be a nub or a boss.
[0028] Each of the location control elements of the web 16
identifies a precise location to which a corresponding part, i.e.
the structure 12 or the structure 14 of the present embodiment, may
be positionally placed without guess as to either location or
alignment thereby achieving linear position control or vertical
depth position control in at least one direction. Optionally, it is
recognized that as many as one pin may achieve linear position
control or vertical depth position control in at least two
directions on a single web forming a determinant assembly
structure.
[0029] The structure 12 of the present embodiment includes a base,
a pair of axially elongated legs 20, 22 that extend from the base
and define a channel 21 therebetween. The structure 12 further
includes the slots 24, 25, 26, 27, 28, 29. The slots 24, 26, 28 are
formed or machined in the leg 20 and the slots 25, 27, 29 are
formed or machined in the leg 22, thereby forming pairs of slots
concentrically aligned in the pair of legs, respectively. The slots
24, 25, 26, 27, 28, 29 of the structure 12 each form a location
control receiving element or a determinant assembly feature in the
present embodiment.
[0030] The slots 24, 25, 26, 27, 28, 29 of the present embodiment
each have an open cylindrical channel shape formed to connectively
receive the cross pins 30, 32, 34. However, a person having skill
in the art would recognize that various other shapes may be used
and that each slot may have a different shape consistent with the
pin to be connectively received. The structure 12 may have any
number of slots or concentric pairs of slots, even though six slots
are presented in the present embodiment. Additionally, the slots
may be positioned in various locations on each leg of the structure
and need not be concentrically located with the slots on the other
of the pair of axially elongated legs.
[0031] Each of the axially elongated legs 20, 22 include a first
channel side, a first rail side, a first leading side, a first
trailing side and a first outer side.
[0032] Each of the location control receiving elements of the
structure 12 identifies a precise location to which a corresponding
part, i.e. the web 16 of the present embodiment, may be
positionally placed without guess as to either location or
alignment thereby achieving linear position control or vertical
depth position control in at least one direction, see FIG. 5.
Optionally, it is recognized that as many as one slot may achieve
linear position control or vertical depth position control in at
least two directions on a single web forming a determinant assembly
structure.
[0033] As depicted in the partial cross-sectional view of FIG. 5,
vertical depth position control is achieved where cross pin 32 of
the web 16 is concentrically connected to the slots 26, 27 of the
structure 12, whereby the assembled relationship between the web 16
and the structure 12 is obtained in at least one direction. The
joint assembly 10 further includes an adhesive 18 dispersed through
the gap formed by the web 16 and the structure 12 in order to bond
the two structures together as required. The adhesive 18 in the
present embodiment is an epoxy adhesive. Alternately, the joint may
be fixedly attached by fasteners or adhesives as would be
recognized by one of skill in the art.
[0034] Returning to FIG. 1, the location control elements, i.e.,
the cross pins 30, 32, 34, of the web 16 are correspondingly
matched to the location control receiving elements, i.e., the slots
24, 25, 26, 27, 28, 29, of the structure 12, whereby assembly
location control is achieved.
[0035] In the present embodiment the joint assembly 10, the lower
side 39 of the web 16 is coupled into the channel 21 of the
structure 12. Also, a pi structure 14 may be coupled to the upper
side 38 of the web 16. However, it is recognized that a single
structure being connected as herein described to the web 16 shows
the novel aspects including the determinant assembly features of
the present invention.
[0036] Alternately, the location control element may be hollow,
whereby the hollow location control element may act as a conduit to
pass wires, hydraulic lines, electrical control or supply lines,
fluid between sealed bays, fuel transport from bay to bay, or for
other suitable applications requiring access from one side of the
joint assembly to the other side of the joint assembly.
[0037] It is recognized that the web may also be a panel, including
flat panel or other recognized structures such as lattices. The web
may also be non-porous.
[0038] It is recognized that the structure 12 has a pi-shaped cross
section, but may also have other cross sections consistent with the
present invention such as angled cross section, a tilted pi
section, an angled pi-shaped cross section, or an offset cross
section having a base and two legs forming a channel
therebetween.
[0039] The web 16 of the present embodiment is finish-machined from
a composite material. The structure 12 of the present embodiment is
finish-machined from a composite material. The pins 30-35 are made
from a composite material.
[0040] Alternatively, the structure, the location control element,
or the web may each be made from various materials including
metallic material, a composite material or other materials
compatible with the claims of the present invention. Also, the
parts of the present invention need not be machined, but may be
made with other acceptable manufacturing methods for the selected
material, wherein the location and orientation of the location
control element, location control feature, or location control
receiving element are determinately positioned.
[0041] The metallic material may be of any composition, but is
anticipated to be a high strength aluminum alloy or titanium
because of the preferable weight per unit strength relationship.
The composite material may be of any composition known to be
suitable for joint structures. One composite material composition
may be from the carbon fiber fabric infused with resin family. Also
a high-modulus carbon fiber fabric infused with toughened epoxy
resin may be more suitable for the present embodiment. It is also
recognized that the structure, the location control element or the
web may each have different materials. Moreover, if the materials
are different for each part care may be taken to insure dimensional
stability between the parts or care may be taken to select material
properties compatible one to another.
[0042] FIG. 2A shows a partial exploded view of a joint assembly 50
in accordance with a second embodiment of the present invention
being used to advantage. FIG. 2B shows an assembled view of the
joint assembly 50 shown in FIG. 2A. The joint assembly 50 is made
from the assembly of a panel or web 57, and a structure 51 coupled
to the web 57 using determinant assembly methods, elements and
features. The joint assembly 50 includes the web 57, the structure
51, a peg 59, and two spacers 60, 61.
[0043] The web 57 may include a hole 58, a lower side 62, and a
leading side 63. The hole 58 is precisely located within the web 57
for receiving and releasably retaining the peg 59. The peg 59
concentrically extends above the front side and the back side of
the web 57. Each spacer 60, 61 is releasably connected to the peg
59 on opposite sides of the web 57, respectively.
[0044] The peg 59 forms a location control element or a determinant
assembly element in the present embodiment. Optionally, there may
be one or more pegs in the web. The peg 59 of the present
embodiment has a cylindrical shape, however a person having skill
in the art would recognize that various other shapes may be used
and that each peg may have a different shape.
[0045] The web 57 has a single hole 58 having a sectional shape
capable of receiving the peg 59. However, it is recognized that the
hole may have other form fitting shapes capable of receiving other
peg shapes. Moreover, the web 57 may have one or more holes.
[0046] The spacers 60, 61 each form a bondline thickness control
element or a thickness control element. Optionally, there may be
only one spacer on each peg, may be alternate spacers on each peg
or be connected directly to the lower area of the web 57. The
spacers 60, 61 of the present embodiment have a hollow cylindrical
shape, however a person having skill in the art would recognize
that various other shapes may be used and that each spacer may have
a different shape.
[0047] Alternatively, the pins and or the spacers may form a
determinant assembly feature when formed or machined into the web.
The pins or the spacers when formed or machined into the web may be
a nub, a boss, a resin boss, or a resin rail.
[0048] Each of the location control element, i.e. the peg 59,
together with the web 57 identifies a precise location to which a
corresponding part, i.e. the structure 51 of the present
embodiment, may be positionally placed without guess as to either
location or alignment thereby achieving linear position control 65
or vertical depth position control 64 in at least one direction.
Optionally, it is recognized that as many as one pin may achieve
linear position control or vertical depth position control in at
least two directions on a single web forming a determinant assembly
structure.
[0049] Each of the thickness control element, i.e. the spacers 60,
61, together with the web 57 identifies a precise location to which
a corresponding part, i.e. the structure 51 of the present
embodiment, may be positionally placed without guess as to either
location or alignment thereby achieving side to side or gap
position control in at least one direction.
[0050] The structure 51 of the present embodiment includes a base,
a pair of axially elongated legs 52, 53 that extend from the base
and define a channel 54 therebetween. The structure 51 further
includes the slots 55, 56. The slot 55 is formed or machined in the
leg 52 and the slot 56 is formed or machined in the leg 53, thereby
forming pairs of slots concentrically aligned in the pair of legs,
respectively. The slots 55, 56 of the structure 51 each form a
location control receiving element or a determinant assembly
feature in the present embodiment.
[0051] The slots 55, 56 of the present embodiment each have an open
cylindrical channel shape formed to connectively receive the peg
59, however, a person having skill in the art would recognize that
various other shapes may be used and that each slot may have a
different shape consistent with the peg to be connectively
received. The structure 51 may have any number of slots or pair of
slots, even though two slots are presented in the present
embodiment. Additionally, the slots may be positioned in various
locations on each leg of the structure and need not be
concentrically located with the slots on the other of the pair of
axially elongated legs.
[0052] Each of the axially elongated legs 52, 53 includes a first
channel side, a first rail side, a first leading side, a first
trailing side and a first outer side.
[0053] Each of the location control receiving elements of the
structure 51 identifies a precise location to which a corresponding
part, i.e. the location control element together with the web 57 of
the present embodiment, may be positionally placed without guess as
to either location or alignment thereby achieving linear position
control 65 or vertical depth position control 64 in at least one
direction. Optionally, it is recognized that as many as one slot
may achieve linear position control or vertical depth position
control in at least two directions on a single web forming a
determinant assembly structure.
[0054] Also, the thickness control elements, i.e. the spacers 60,
61, together with the web 57 identifies a precise location to which
a corresponding part, i.e. the structure 51 of the present
embodiment, may be positionally placed without guess as to either
location or alignment thereby achieving side to side or gap
position control in at least one direction within the channel 54 of
the structure 51.
[0055] The joint assembly 50 may further include an adhesive
dispersed through the gap within the channel 54 formed by the web
57 and the structure 51 in order to bond the two structures
together.
[0056] The web 57 of the present embodiment is finish-machined from
a composite material. The structure 51 of the present embodiment is
finish-machined from a composite material. The peg 59 and the
spacers 60, 61 are made from a composite material.
[0057] Alternatively, the structure, the location control element,
or the web may each be made from various materials including
metallic material, a composite material or other materials
compatible with the claims of the present invention. Also, the
parts of the present invention need not be machined, but may be
made with other acceptable manufacturing methods for the selected
material, wherein the location and orientation of the location
control element, location control feature, or location control
receiving element are determinately positioned.
[0058] FIG. 3A shows a partial exploded view of a joint assembly 70
in accordance with a third embodiment of the present invention
being used to advantage. FIG. 3B shows an assembled view of the
joint assembly 70 shown in FIG. 3A. The joint assembly 70 is made
from the assembly of a panel or web 77, and a structure 71 coupled
to the web 77 using determinant assembly methods, elements and
features. The joint assembly 70 includes the web 77, the structure
71, a peg 79, and a thickness control element or wire 80.
[0059] The web 77 includes a hole 78, a lower side 82, and a
leading side 83. The hole 78 is precisely located within the web 77
for receiving and removeably retaining the peg 79. The peg 79
extends above the front side and the back side of the web 79.
Alternatively the peg 79 may extend above a single side of the web
79. The wire 80 is releasably connected to the web 77 from the
front side around the lower side 82 to the back side.
[0060] The peg 79 forms a location control element or a determinant
assembly element in the present embodiment.
[0061] The wire 80 forms a bondline thickness control element or a
thickness control element. Optionally, there may be more than one
wire connected directly to the lower area of the web 77. The wire
80 of the present embodiment has a flattened U shape, however, a
person having skill in the art would recognize that various other
shapes may be used and that each spacer may have a different shape
in order to provide thickness control for applying adhesive. It is
recognized that the wire 80 may be made from metal, however the
wire may also be made from a compatible material with that of the
other parts such as an epoxy filament.
[0062] Each of the location control element, i.e. the peg 79,
together with the web 77 identifies a precise location to which a
corresponding part, i.e. the structure 71 of the present
embodiment, may be positionally placed without guess as to either
location or alignment thereby achieving linear position control 85
or vertical depth position control 84 in at least one direction.
Optionally, it is recognized that as many as one pin may achieve
linear position control or vertical depth position control in at
least two directions on a single web forming a determinant assembly
structure.
[0063] Each of the thickness control element, i.e. the wire 80,
together with the web 77 identifies a precise location to which a
corresponding part, i.e. the structure 71 of the present
embodiment, may be positionally placed without guess as to either
location or alignment thereby achieving side to side or gap
position control in at least one direction when the web 77 is
placed into the channel of the structure 71.
[0064] The structure 71 of the present embodiment includes a base,
a pair of axially elongated legs 72, 73 that extend from the base
and define a channel 74 therebetween. The structure 71 further
includes the slots 75, 76. The slot 75 is formed or machined in the
leg 72 and the slot 76 is formed or machined in the leg 73, thereby
forming pairs of slots concentrically aligned in the pair of legs,
respectively. The slots 75, 76 of the structure 71 each form a
location control receiving element or a determinant assembly
feature in the present embodiment.
[0065] The slots 75, 76 of the present embodiment each have an open
cylindrical channel shape formed to connectively receive the peg
79, however, a person having skill in the art would recognize that
various other shapes may be used and that each slot may have a
different shape consistent with the peg to be connectively
received. The structure 71 may have any number of slots or pair of
slots, even though two slots are presented in the present
embodiment. Additionally, the slots may be positioned in various
locations on each leg of the structure and need not be
concentrically located with the slots on the other of the pair of
axially elongated legs.
[0066] Each of the axially elongated legs 72, 73 include a first
channel side, a first rail side, a first leading side, a first
trailing side and a first outer side.
[0067] Each of the location control receiving elements of the
structure 71 identifies a precise location to which a corresponding
part, i.e. the location control element together with the web 77 of
the present embodiment, may be positionally placed without guess as
to either location or alignment thereby achieving linear position
control 85 or vertical depth position control 84 in at least one
direction.
[0068] Also, the thickness control element, i.e. wire 80, together
with the web 77 identifies a precise location to which a
corresponding part, i.e. the structure 71 of the present
embodiment, may be positionally placed without guess as to either
location or alignment thereby achieving side to side or gap
position control in at least one direction within the channel 74 of
the structure 71.
[0069] The joint assembly 70 may further include an adhesive
dispersed through the gap within the channel 74 formed by the web
77 inserted into the structure 71 in order to bond the two
structures together. Moreover, The thickness control element may
provide a minimum distance in which the adhesive may bond the two
structures. The minimum distance may be 0.02 inches thick.
[0070] FIG. 4A shows a partial exploded view of a joint assembly 86
in accordance with a fourth embodiment of the present invention
being used to advantage. FIG. 4B shows an assembled view of the
joint assembly 86 shown in FIG. 4A. The joint assembly 86 is made
from the assembly of a panel or web 93, and a structure 87 coupled
to the web 93 using determinant assembly methods, elements or
features. The joint assembly 86 includes the web 93 and the
structure 87.
[0071] The web 93 includes a nub or boss 94 and the rails 95, 96,
97, 98. The boss 94 is precisely located on the web 93. The rails
95, 96, 97, 98 are positionally spaced and located in the lower
area of the web 93. The boss 94 extends above the front side of the
web 57.
[0072] The boss 94 forms a location control element or a
determinant assembly feature upon the web 93 in the present
embodiment. Optionally, there may be one or more boss formed on the
web. The boss 94 of the present embodiment has a cylindrical shape
extending from the side of the web 93, however a person having
skill in the art would recognize that various other shapes may be
used and that each boss may have a different shape. Also, each of
the one or more boss may extend from any side of the web 93.
[0073] The rails 95, 96, 97, 98 each form a bondline thickness
control element or a thickness control feature. Optionally, there
may be a single rail formed directly in the lower area of the web
93. It is recognized that each rail may be formed on the front
side, lower side or back side of the web 93. The rails 95, 96, 97,
98 of the present embodiment have a pencil shape, however, a person
having skill in the art would recognize that various other shapes
may be used and that each spacer may have a different shape.
Moreover the rails may have a shape that is similar to the boss,
but having a lower profile conducent for thickness control.
[0074] Optionally, the boss 94 or the rails 95, 96, 97, 98 when
formed or machined into the web 93 may be a nub, a boss, a rail, a
resin nub, a resin boss, or a resin rail.
[0075] Each of the location control element, i.e. the boss 94, on
the web 93 identifies a precise location to which a corresponding
part, i.e. the structure 87 of the present embodiment, may be
positionally placed without guess as to either location or
alignment thereby achieving linear position control 100 or vertical
depth position control 99 in at least one direction. Optionally, it
is recognized that as many as one boss may achieve linear position
control or vertical depth position control in at least two
directions on a single web forming a determinant assembly
structure.
[0076] Each of the thickness control element, i.e. rails 95, 96,
97, 98, on the web 57 identifies a thickness location to which a
corresponding part, i.e. the structure 51 of the present
embodiment, may be positionally placed without guess as to either
location or alignment thereby achieving side to side or gap
position control in at least one direction.
[0077] The structure 87 of the present embodiment includes a base,
a pair of axially elongated legs 88, 89 that extend from the base
and define a channel 90 therebetween. The structure 87 further
includes the slots 91, 92. The slot 91 is formed or machined in the
leg 88, thereby forming a receivable slot. The slots 91, 92 of the
structure 87 each form a location control receiving element, a
determinant assembly element or a determinant assembly feature in
the present embodiment.
[0078] The slots 91, 92 of the present embodiment each have an open
cylindrical channel shape formed to connectively receive the boss
94, however, a person having skill in the art would recognize that
various other shapes may be used and that each slot may have a
different shape consistent with the boss to be connectively
received. The structure 87 may have any number of slots or pair of
slots, even though two independent slots are presented in the
present embodiment. Additionally, the slots may be positioned in
various locations on each leg of the structure and need not be
concentrically located with the slots on the other of the pair of
axially elongated legs.
[0079] Each of the axially elongated legs 88, 89 include a first
channel side, a first rail side, a first leading side, a first
trailing side and a first outer side.
[0080] Each of the location control receiving elements of the
structure 87 identifies a precise location to which a corresponding
part, i.e. the location control feature of the web 93 of the
present embodiment, may be positionally placed without guess as to
either location or alignment thereby achieving linear position
control 100 or vertical depth position control 99 in at least one
direction. Optionally, it is recognized that as many as one boss
may achieve linear position control or vertical depth position
control in at least two directions on a single web forming a
determinant assembly structure.
[0081] Also, the thickness control elements, i.e. the rails 95, 96,
97, 98 on the web 93 identifies a gap location to which a
corresponding part, i.e. the structure 87 of the present
embodiment, may be positionally placed without guess as to either
location or alignment thereby achieving side to side or gap
position control in at least one direction within the channel 90 of
the structure 87.
[0082] The joint assembly 86 may further include an adhesive
dispersed through the gap within the channel 90 formed by the web
93 and the structure 87 in order to bond the two structures
together.
[0083] The web 93 of the present embodiment may be finish-machined
from a composite material. The structure 87 of the present
embodiment is finish-machined from a composite material.
Optionally, the web 93 or the structure 87 may be precision molded
from carbon impregnated fabric with diffused epoxy resin in
precision form from a mold having DA features precisely formed
within the mold.
[0084] FIG. 6 is a partial cross-sectional view of the joint
assembly 40 in accordance with a fifth embodiment of the present
invention being used to advantage. The present embodiment is
consistent with the features presented in the other embodiments.
Accordingly, optional features are presented.
[0085] The peg 46 is hollow having interior wall 47, whereby the
peg 46 may act as a conduit.
[0086] The structure 40 may include a tilt 42. In the present
embodiment, the tilt 42 forms an angled pi-structure.
[0087] A method of assembling a joint assembly of the present
invention is also provided. The method of assembling a joint
assembly includes providing a structure comprising a base, a pair
of axially elongated legs extending from the base to define a
channel therebetween, and one or more location control receiving
element in either axially elongated leg, providing a web comprising
one or more location control element, and inserting the web into
the structure, wherein the location control element of the web is
correspondingly matched to the location control receiving element
of the structure, whereby a determinant assembly is achieved. The
method of assembling a joint may also include filling an adhesive
between the web and the structure.
[0088] When inserting the web to the structure, location control
element of the web is connected to the location control receiving
element of the structure.
[0089] An additional method of assembling a joint assembly of the
present invention is also provided. The method of assembling a
joint assembly includes providing a web, providing at least one
determinant assembly element; providing at least one thickness
control element, providing a structure having a base, a pair of
axially elongated legs extending from the base to define a channel
therebetween, and at least one determinant assembly feature in
either axially elongated leg, coupling the determinant assembly
element to the web, coupling the thickness control element to the
web or the determinant assembly element, and inserting the web, the
determinant assembly and the thickness control element into the
structure, wherein the web with the determinant assembly element is
determinately coupled to the structure, and the thickness control
element determinately spacing the web between the pair of axially
elongated legs of the structure. The method of assembling a joint
may also include waiting for a cure time after filling the
adhesive. Also, the method of assembling a joint assembly may also
include filling an adhesive into a void formed by removing the
determinant assembly element or the thickness control element.
[0090] For metallic members the DA features may be precisely
machined into each constituent part or parts.
[0091] For composite members the DA features may be precisely
machined into each constituent part or parts, or the DA features
may be fabricated or formed within the mold that is used to make
each constituent part or parts. A method by which a composite
members may be fabricated or formed is by using either impregnated
composite constituents (prepreg) placed on a shaped one-sided mold
and cured in an autoclave or utilize dry composite fabric placed an
a one-sided mold with subsequent room temperature infusion of resin
in a process known as Vacuum Assisted Resin Transfer Molding
(VARTM). Another method that the composite members may be
fabricated or formed is by using a matched-metal closed mold where
the dry fabric is installed into the mold then infused with resin
in a process known as Resin Transfer Molding (RTM).
[0092] The VARTM and autoclaved components are trimmed to net size
due to excess material and rough edges created by these
manufacturing processes. During the machining process for trimming,
features may be machined in by the accurate N/C machining center
that may act as location features in the assembly process.
[0093] Since RTM parts are fabricated net shape and do not require
a trimming process, features may be machined into the matched-metal
mold that, after infusion of resin into the mold, create resin
bosses or rails for DA features to facilitate the assembly
process.
[0094] The flat panel web of the assembly may be drilled to receive
a cross pin at a location specific from the panel edge. The PI
component of the assembly may be machined with a slot in the ends
of the PI legs at a depth specific from the bottom of the PI
flange. The slot may receive the cross pin that was installed in
the flat panel and position the panel in the desired depth location
within the PI legs. The cross pins can either be bonded in place
for permanent installation or removed after the adhesive is
cured.
[0095] For an RTM part, a shallow round hole may be machined into
the matched-metal mold at locations matching those of the slots in
the mating PI structure. These holes will fill with resin during
the infusion process and provide a resin rich pin-type locator.
[0096] The side-to-side location may be achieved by either a
polymer string (fishing line) of a prescribed diameter draped down
inside the channel of the PI legs or by using a shim spacer on
either side of the panel when installed within the PI structure.
The shim spacer material may be compatible with the composite and
adhesive system.
[0097] For an RTM part, the matched-metal mold may have pockets or
voids machined in appropriate locations that will fill with resin
during the infusion process forming rails or bosses. The height of
each rail will equal the adhesive thickness requirements to assure
that adhesive is introduced into the joint on all sides of the flat
panel within the joint assembly.
[0098] While the invention has been described in connection with
one or more embodiments, it should be understood that the invention
is not limited to those embodiments. On the contrary, the invention
is intended to cover all alternatives, modifications, and
equivalents, as may be included within the spirit and scope of the
appended claims.
* * * * *