Composite material structures with integral composite fittings and methods of manufacture
Composite material structures prepared from at least one reinforcement material and at least one matrix material are disclosed. The invention provides a simple solution for combining two or more components made of a composite material into a monolithic “fastener free” structure of a composite material having a smooth contour. The composite material structure includes a main frame with at least one load bearing beam having at least one beam surface. To this beam surface at least one composite material fitting is integrally attached. The main frame and the composite material fitting are conjoined by at least one matrix material. In addition, the disclosed technique provides for methods of production of a composite material structure with fittings made of a composite material.
1. A composite material structure comprising at least one reinforcement material and at least one matrix material, said composite material structure comprising:
a main frame with at least one load bearing beam having at least one beam surface to which at least one composite material fitting is integrally attached, said at least one composite material fitting comprising:
at least one mount portion comprising a bore for receiving a tubular bushing; and
an anchoring structure extending from or coupled with said at least one mount portion, said anchoring structure is integrally attached with said main frame; wherein said anchoring structure is comprised of at least one anchoring surface, at least one of said at least one anchoring surfaces is locally aligned with a beam surface and at least one of said at least one anchoring surfaces being substantially parallel to a center axis of said bore; wherein said at least one anchoring surface being substantially parallel to a center axis of said bore is permanently attached to said main frame; wherein said composite material fitting is prepared from at least one reinforcement material and at least one matrix material and wherein said main frame is prepared from at least one reinforcement material and at least one matrix material; and wherein said main frame and said composite material fitting are conjoined by at least one matrix material.
2. A composite material structure according to claim 1 , wherein said main frame comprises at least one main frame surface to which at least one anchoring surface is locally aligned.
3. A composite material structure according to claim 1 , for use in an aircraft.
4. A composite material structure according to claim 1 , for use in a vehicle.
5. A composite material structure according to claim 1 , formed in a structure selected from the list consisting of: a wing, a control surface, a flap, an aileron, a spoiler, a rudder, a stabilizer, an external fuel tank sections or a complete external fuel tank, an airplane cabin door, an airplane barrel section, a nacelle section, a body or chassis section and a fairing or a cover.
6. A composite material structure according to claim 1 that comprises at least one reinforcement material which is a fabric.
7. A composite material structure according to claim 1 wherein said at least one reinforcement material is selected from the list consisting of: glass, carbon, silicon carbide, aramid and a high strength polyethylene fiber.
8. A composite material structure according to claim 1 , wherein said at least one matrix material is a thermoplastic or a thermoset polymer.
9. A composite material structure according to claim 1 wherein said composite material structure comprises a matrix material which is selected from the list consisting of: epoxy, phenolic, polyester, silicone, bismaleimide, polyimide and polybenzimidazole.
10. A composite material structure according to claim 1 wherein said composite material structure is manufactured by any one of the production methods selected from the list consisting of: closed mold RTM, compression molding, autoclave processing, open mold R1 (resin infusion), vacuum bag molding and filament winding of tows or tapes.
11. A composite material structure according to claim 1 wherein said at least one mount portion further comprises a metal plate.
12. A composite material structure according to claim 1 wherein said fitting comprises a tubular bushing made of metal.
13. A composite material structure according to claim 1 wherein said composite material structure is a control surface and wherein the configuration of said control surface is characterized by at least one of:
(a) at least one protection element embedded in said control surface to create a closed structure; and
(b) at least one co-bonded protection element which covers a portion of said control surface.
14. A composite material structure according to claim 1 wherein said main frame is constructed from layers of reinforcement material, and wherein said layers of reinforcement material are draped over a portion of said fitting.
15. A composite material structure according to claim 14 wherein said layers of reinforcement material constructing said main frame are separated such that in between them said composite material fitting is positioned.
16. A composite material structure according to claim 1 wherein said at least one composite material fitting comprises at least one anchoring surface which is locally aligned with a beam surface, being substantially perpendicular to a center axis of said bore.
17. A composite material structure according to claim 1 wherein one of said at least one anchoring surfaces is in an angle in a range of between 70 to 110 degrees with respect to a center axis of said bore.