Over-molding of load-bearing composite structures

1. An assembly comprising a composite structure connected to a support body, said assembly comprising:

1) said composite structure comprising:

a) a load-bearing element comprising continuous reinforcing fibers and a resin matrix, said load bearing and a resin matrix, said load-bearing element having an attachment portion for connection to said support body, said attachment portion comprising an end surface having an end surface area, a first side surface having a first side surface area, a second side surface having a second side surface area, a top surface having a top surface area, and a bottom surface having a bottom surface area, said attachment portion comprising at least one bond enhancement surface that provides an increase in surface area of said attachment portion said bond-enhancement surface defining a hole in said attachment portion, said hole having a diameter;

b) a connection element comprising a plurality of chips comprising unidirectional fibers in a resin matrix wherein said chips have a size defined by the width, length, and thickness of said chips, said connection element comprising a first portion that is molded over said end surface area, said first side surface area, said second side surface area, said top surface area, and said bottom surface area so that said attachment portion of said load-bearing element is embedded in said connection element and wherein the size of said is such that said hole in said attachment portion is substantially filled with said chips, said connection element comprising a second portion for connection to said support body wherein the second portion of said connection element comprises at least two non-parallel surfaces that have been machined to provide at least two non-parallel machined mating surfaces for connecting said composite structure directly to said support body; and

2) said support body comprising at least two non-parallel mating surfaces that are in direct mating contact with said corresponding at least two non-parallel machined mating surfaces of said connection element wherein at least two non-parallel machined mating surfaces form a machined connection surface to which said support body has been attached for direct mating engagement and wherein the second portion of said connection element further comprising a machined connection pin surface defining a hole that has been machined into said second portion and wherein said support body comprises a connection pin surface defining a hole in said support body that is aligned with the machined connection pin surface in said connection element, said assembly further comprising a connection pin having a surface, said connection pin being located in the aligned holes of said connection element and support body such that the surface of said connection pin is in direct contact with the machined connection pin surface of the second portion of said connection element.

2. An assembly according to claim 1 wherein said continuous reinforcing fibers are unidirectional.

3. An assembly according to claim 1 wherein the width of said chips is from 0.2 to 2.5 centimeters, the length of said chips is from 1.3 to 5.1 centimeters and the thickness is from 0.01 to 0.03 centimeters.

4. An assembly according to claim 1 wherein said continuous reinforcing fibers are carbon fibers and said chips comprise unidirectional carbon fibers.

5. An assembly according to claim 4 wherein said resin matrix in said load-bearing element and said resin matrix in said connection element are both a thermoplastic-toughened epoxy resin.

6. An assembly according to claim 3 wherein said resin matrix in said load-bearing element and said resin matrix in said connection element are both a thermoplastic-toughened epoxy resin and wherein said continuous reinforcing fibers are carbon fibers and said chips comprise unidirectional carbon fibers.

7. An assembly according to claim 1 wherein said machined connection surface forms an opening in said second portion into which said support body has been inserted.

8. An assembly according to claim 1 wherein said support body is part of an aircraft.

9. An assembly according to claim 8 wherein said load-bearing element is a wing spar, propeller blade, strut, floor beam, blocker door link, frame, intercostal, aircraft skin, aircraft panel, jet engine blade or jet engine vane.

10. A method for making an assembly comprising a composite structure connected to a support body, said method comprising the steps of:

1) providing said composite structure comprising:

a) a load-bearing element comprising continuous reinforcing fibers and a resin matrix, said load bearing and a resin matrix, said load-bearing element having an attachment portion for connection to said support body, said attachment portion comprising an end surface having an end surface area, a first side surface having a first side surface area, a second side surface having a second side surface area, a top surface having a top surface area, and a bottom surface having a bottom surface area, said attachment portion comprising at least one bond enhancement surface that provides an increase in surface area of said attachment portion said bond-enhancement surface defining a hole in said attachment portion, said hole having a diameter;

b) a connection element comprising a plurality of chips comprising unidirectional fibers in a resin matrix wherein said chips have a size defined by the width, length, and thickness of said chips, said connection element comprising a first portion that is molded over said end surface area, said first side surface area, said second side surface area, said top surface area, and said bottom surface area so that said attachment portion of said load-bearing element is embedded in said connection element and wherein the size of said is such that said hole in said attachment portion is substantially filled with said chips, said connection element comprising a second portion for connection to said support body wherein the second portion of said connection element comprises one or more surfaces that have been machined to provide at least two non-parallel machined mating surfaces for connecting said composite structure directly to said support body and wherein the second portion of said connection element further comprises a machined connection pin surface defining a hole that has been machined into the second portion;

2) providing said support body comprising at least two non-parallel mating surfaces and a connection pin surface defining a hole in said support body;

3) connecting said support body to the machined connection surface of said connection element so that said at least two non-parallel mating surfaces of said support body are in direct mating contact with said at least two non-parallel machined mating surfaces of said connection element

4) aligning the connection pin surface in said support body with the machined connection pin surface in said connection element;

5) providing a connection pin having a surface; and

6) locating said connection pin in the aligned holes of said connection element and support body such that the surface of said connection pin is in direct contact with the machined connection pin surface of the second portion of said connection element.

11. A method for making an assembly composite structure according to claim 10 wherein said continuous reinforcing fibers are unidirectional.

12. A method for making an assembly according to claim 10 wherein the width of said chips is from 0.2 to 15 centimeters, the length of said chips is from 1.3 to 5.1 centimeters and the thickness is from 0.01 to 0.03 centimeters.

13. A method for making an assembly according to claim 10 wherein said continuous reinforcing fibers are carbon fibers and said chips comprise unidirectional carbon fibers.

14. A method for making an assembly according to claim 13 wherein said matrix resin in said load-bearing element and said resin matrix in said connection element are both a thermoplastic-toughened epoxy resin.

15. A method for making an assembly according to claim 12 wherein said resin matrix in said load-bearing element and said resin matrix in said connection element are both a thermoplastic-toughened epoxy resin and wherein said continuous reinforcing fibers are carbon fibers and said chips comprise unidirectional carbon fibers.

16. A method for making an assembly according to claim 10 wherein said machined connection surface forms an opening in said second portion into which said support body has been inserted.

17. A method for making an assembly according to claim 10 wherein said support body is part of an aircraft.

18. A method for making an assembly according to claim 17 wherein said load-bearing element is a wing spar, propeller blade, strut, floor beam, blocker door link, frame, intercostal, aircraft skin, aircraft panel, jet engine blade or jet engine vane.