U.S. patent application number 11/973532 was filed with the patent office on 2008-10-30 for laminate with mutually offset layers.
Invention is credited to Abdoel Faziel Rajabali, Willem Jan Nicolaas ter Steeg.
Application Number | 20080268222 11/973532 |
Document ID | / |
Family ID | 33550498 |
Filed Date | 2008-10-30 |
United States Patent
Application |
20080268222 |
Kind Code |
A1 |
Rajabali; Abdoel Faziel ; et
al. |
October 30, 2008 |
Laminate with mutually offset layers
Abstract
A method for the production under elevated pressure and
temperate of a laminate (1, 1') consisting of a pack with
alternating metal layers (2) and plastic bonding layers (3),
comprises stacking a first series (8) of layers on top of one
another in a mould, then stacking at least a second series (7, 7')
of layers on top of the first series (8) of layers, with the
formation of the pack of layers such that at at least one edge of
the pack at least one (7 7') of the series is stepped back with
respect to the other series (8), an auxiliary tool (12) being
placed alongside the stepped-back series (7, 7') and on the other,
non-stepped-back series (8) and a gap (13) being formed between the
stepped-back series (7, 7') and that side (14)of the auxiliary tool
(12) facing said series, raising the temperature and the pressure
on the pack and the auxiliary (12) tool such that the binder in the
plastic bonding layers (3) is made to flow and some of the binder
present in the stepped-back series (7, 7') collects in said gap
(13).
Inventors: |
Rajabali; Abdoel Faziel;
(Alphen Aan De Rijn, NL) ; ter Steeg; Willem Jan
Nicolaas; (Pulheim, DE) |
Correspondence
Address: |
COOPER & DUNHAM, LLP
1185 AVENUE OF THE AMERICAS
NEW YORK
NY
10036
US
|
Family ID: |
33550498 |
Appl. No.: |
11/973532 |
Filed: |
October 8, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10912355 |
Aug 5, 2004 |
7279062 |
|
|
11973532 |
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Current U.S.
Class: |
428/221 ;
428/411.1 |
Current CPC
Class: |
B32B 2605/18 20130101;
B32B 37/10 20130101; Y10T 428/31504 20150401; Y10T 428/249921
20150401; Y10T 428/12493 20150115; Y10T 428/12201 20150115; B32B
15/08 20130101; B32B 15/14 20130101 |
Class at
Publication: |
428/221 ;
428/411.1 |
International
Class: |
B32B 5/02 20060101
B32B005/02; B32B 9/04 20060101 B32B009/04 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 8, 2003 |
NL |
1024077 |
Claims
1-3. (canceled)
4. Laminate (1, 1') comprising a first series (8) of layers, at
least a second series (7, 7') of layers on the first series (8) of
layers forming a pack such that at least one edge of the pack (7,
7') of the series of layers is indented with respect to the other
series (8), the edge (10) of the indented series (7, 7') of layers
being covered by a layer (16) of a binder.
5. Assembly comprising two laminates of claim 4 attached to one
another.
6. Assembly according to claim 5, wherein, in the direction
traverse to the surface of the laminates, at least one stepped-back
series (7, 7') of the one laminate is next to a non-stepped-back
series (8) of the other laminate.
7. Assembly according to claim 5, wherein, in the direction
traverse to the seam defined between the laminates, at least one
non-stepped-back series (8) of layers is opposite a stepped-back
series (7) of layers.
8. Laminate consisting of a pack with alternating metal layers and
plastic bonding layers, wherein said plastic bonding layers contain
fiber layers and a binder, made under elevated temperature and
pressure by stacking a first series of layers on top of one another
in a mold, then stacking at least a second series of layers on top
of the first series of layers, forming the pack of layers such that
at least one edge of the pack of at least one of the series is
stepped back with respect to the other series, placing an auxiliary
tool alongside the stepped-back series and on the other, non
stepped-back series to form a gap between the stepped-back series
and a side of the auxiliary tool facing said stepped-back series,
raising the temperature and the pressure on the pack and the
auxiliary tool such that said binder in the plastic bonding layers
is made to flow and some of the binder present in the stepped-back
series collects in said gap, sealing the fiber layers so as to
prevent the penetration of moisture into the fibre layer and
forming a substantially un-rounded edge, wherein the laminate is
specifically used to form an aircraft body panel.
Description
[0001] This application is a divisional of U.S. Ser. No.
10/912,355, filed Aug. 5, 2004, which claims priority under 35
U.S.C. .sctn.119 of application No. 1024077 filed in The
Netherlands on Aug. 8, 2003, the entire contents of which are
incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The invention relates to the production of laminates that
can be attached to one another by means of edge regions made in the
form of steps. A portion of the layers of which the laminate
consists then protrudes with respect to the other layers, such that
the protruding layers form the actual joining region. The advantage
of such a join is that this is relatively smooth, which is
advantageous especially from the standpoint of aerodynamics.
[0003] However, the production of such laminates with edges made in
the form of steps presents problems. For instance, in the case of,
for example, plastic bonding layers that contain fibers, the fibers
can emerge on the outside under the influence of the elevated
pressure under which the laminate is produced. This is not
desirable because undesired phenomena can then arise in the
finished product, such as the penetration of moisture into the
fiber layer, corrosion and the like. The life of the laminate can
be seriously limited as a result.
[0004] In the aviation industry such joins occur in both the
longitudinal direction and in the circumferential direction of the
aircraft body. It is desirable to keep the body as smooth as
possible in the longitudinal direction and for this reason the
joins between the panels consisting of laminate are frequently made
with step-shaped edges. In the circumferential direction of the
body such joins are also frequently used with strips of different
thickness. Such joins can also be used when coupling together
strips made up of metal laminates, which may or may not be
fibre-reinforced and may or may not have different thicknesses,
which are usually used in panel couplings in the circumferential
direction of an aircraft body.
SUMMARY OF THE INVENTION
[0005] The aim of the invention is to provide a method for the
production of a laminate that is suitable for use with such joins
and that does not have the abovementioned disadvantages. Said aim
is achieved by means of a method for the production under elevated
pressure and temperature of a laminate consisting of a pack with
alternating metal layers and plastic bonding layers, comprising
stacking a first series of layers on top of one another in a mould,
then stacking at least a second series of layers on top of the
first series of layers, with the formation of the pack of layers
such that at at least one edge of the pack at least one of the
series is stepped back with respect to the other series, an
auxiliary tool being placed alongside the stepped-back series and
on the other, non-stepped-back series and a gap being formed
between the stepped-back series and that side of the auxiliary tool
facing said series, raising the temperature and the pressure on the
pack and the auxiliary tool such that the binder in the plastic
bonding layers is made to flow and some of the binder present in
the stepped-back series collects in said gap.
[0006] With the method according to the invention it is ensured
that the edge boundary of the series of layers that is indented has
a smooth finish as a consequence of the amount of binder that has
run into the gap between the indented layers and the tool.
Furthermore, the edge of the tool facing these layers acts as a
forming mould for said edge boundary, such that the desired shape
thereof can be ensured by selection of the shape of said edge of
the tool. Furthermore, any fibres that have become detached will be
embedded well in the binder that has flowed into the gap.
[0007] As is known the fibres in the fibre-reinforced plastic
layers can have different orientations. If at least one of the
plastic bonding layers contains fibre layers which have an
orientation parallel to the edge of the pack, the method according
to the invention comprises making said fibre layer indented with
respect to the metal layers located next to it. In said indented
position the fibres have hardly any opportunity to emerge between
the metal layers, as a result of which the quality of the laminate
is further improved.
[0008] If, however, at least one of the plastic bonding layers
contains fibres which have an orientation perpendicular to said
edge, said fibres can be allowed to continue to essentially in line
with the adjacent metal layers.
[0009] The invention furthermore relates to a laminate comprising a
first series of layers, a second series of layers on the first
series of layers with the formation of a pack such that at at least
one edge of the pack one of the series of layers is indented with
respect to the other series, the edge of the stepped-back series of
layers being covered by a layer of binder.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention will be explained in more detail below with
reference to the laminates shown in the figures.
[0011] FIG. 1 shows the production of the laminate according to the
invention in accordance with a first possibility.
[0012] FIG. 2 shows a second possible production method.
[0013] FIG. 3 shows one embodiment of the laminate according to the
invention.
[0014] FIGS. 4 and 5 show two possible assemblies obtained with the
laminate according to FIG. 3.
[0015] FIGS. 6 and 7 show two assemblies of a laminate with two
stepped-back series.
[0016] FIG. 8 shows an assembly of a laminate with a stepped-back
series and a laminate with two stepped-back series.
DETAILED DESCRIPTION OF THE INVENTION
[0017] In FIG. 1 a laminate is shown that is indicated in its
entirety by 1 and consists of metal layers 2 and fibre-reinforced
bonding layers 3 incorporated between them. These fibre reinforced
bonding layers 3 each consist of, in turn, two layers 4, 5, but
this number is of no further importance for the invention.
[0018] When carrying out the method according to the invention, a
first series of layers 7 is stacked on the forming mould 6. A
second series of layers 8 is then stacked on top of this. The edge
9 of the second series of layers 8 protrudes with respect to the
edge 10 of the first series of layers 7. The finished laminate 1
produced in this way can be joined by the protruding portion 11,
which borders on the edge 9, with, for example, a corresponding
protruding portion 11 of another laminate.
[0019] When producing such a laminate problems can arise in that
the fibres become detached from the fibre layers at the edge 10.
This can constitute a problem especially in the case of fibres that
run parallel to the edge 10. The layer 5 contains such fibres and
therefore terminates some distance before the edge 10. The layer 4,
on the other hand, contains fibres that run perpendicularly to the
edge 10. There is no risk of detachment in the case of these
fibres, so said layer does continue as far as the edge 10.
[0020] The auxiliary tool 12 is used in the production of the
laminate, which, as is known, takes place under elevated pressure
and temperature. This auxiliary tool is positioned with respect to
the first series of layers 7 such that a gap 13 remains between the
edge 10 and the edge 14 of the auxiliary tool 12.
[0021] As a consequence of the elevated temperature and pressure,
some of the binder with which the fibre layers 4, 5 have been
impregnated runs out of the gap between the metal layers 2 and
passes into the gap 13 that has remained between said series of
layers 7 and the auxiliary tool 12. The edge 10 of the series of
layers 7 is then covered with a layer of binder 16.
[0022] As a consequence of this the end of the series of layers 7
acquires a straight, smooth boundary 16 that is defined by the end
edge 14 of the tool 12. Any fibres that have become detached are
embedded in the amount of binder 16 that is at that end of the
series of layers 7.
[0023] In the representation in FIG. 2 it is shown that the series
of layers 8 can also be placed with the protruding portion directly
on the forming mould, whilst the series of layers 7 that is stepped
back is located on top of said series of layers 8. The forming tool
12 is then also located on the protruding portion of the series of
layers 8. Binder that has become fluid under the influence of heat
then collects under pressure in the gap 13 between the end 10 of
the series of layers 7 and the edge 14 of the auxiliary tool
12.
[0024] The laminate obtained is shown in FIG. 3, in which the
amount of binder 16 that now forms the end limit of the series of
layers 7 is shown.
[0025] FIG. 4 shows a first assembly of two laminates according to
FIG. 3. The stepped-back layers 7, in particular the boundaries
formed from binder 16 thereof, are directly opposite on another,
whilst in each case one non-stepped-back series 8 of the one
laminate 1 lies over the stepped-back series 7 of the other
laminate 1. The laminates 1 can be attached to one another at the
location of the holes shown diagrammatically by an axis 12 by means
of, for example, rivets or bolted joints.
[0026] In the variant in FIG. 5 the assembly is made flat in that
in each case one non-stepped-back series 8 of the one laminate 1 is
opposite the stepped-back series 7 of the other laminate 1.
[0027] The variants in FIGS. 6, 7 and 8 each contain a laminate 1'
with two stepped-back series 7, 7'. The series 7 is stepped back
with respect to the non-stepped-back series 8, whilst the
stepped-back series 7', in turn is stepped back with respect to the
stepped-back series 7.
[0028] In the embodiment in FIG. 6 in each case one
non-stepped-back series 8 lies over the second stepped-back series
7' of the other laminate 1'.
[0029] In the variant in FIG. 7 the non-stepped-back series 8 of
the one laminate 1' is in each case opposite the second
stepped-back series 7' of the other laminate. With this arrangement
the first stepped-back series 7 are opposite one another. A smooth
assembly is obtained in this way.
[0030] In the variant in FIG. 8 a laminate 1 with a stepped-back
series 7 and a second laminate 1' with two stepped-back series 7,
7' are used. The non-stepped-back series 8 of the first laminate 1
is opposite the second stepped-back series 7' of the second
laminate 1'. The stepped-back series 7 are opposite one another. An
assembly that is smooth on one side is obtained by this means.
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