Hot joint fastener

Abstract

A method for joining together different components or different sections of a single component, wherein at least one of the components is a thermoplastic fiber composite component, by using a threaded fastener. Heat is used for softening the thermoplastic fiber composite component to be joined together with the threaded fastener. A joined-together fiber composite component of a vehicle, aircraft or spacecraft, can be obtained by the disclosed method.

Claims

1. A method for joining together different components or different sections of a single component, comprising the steps of: a) providing one or more components, wherein at least one of the components is a thermoplastic fiber composite component, to be joined together at one or more positions, and a fastener comprising a thread, or at least one fastener component, which comprises a thread, wherein the fastener is a screw and the at least one fastener component, which comprises a thread, is an insert of a rivet, b) positioning said one or more components, or sections of a single one of the one or more components, on top of each other, c) heating at least one of at least a portion of the one or more components, and optionally also portions of other of the one or more components to be joined, at one or more positions where the thermoplastic fiber components are to be joined, or said fastener or said at least one fastener component, and d) screwing said fastener, or said at least one fastener component, into at least a bottom thermoplastic fiber component at the one or more positions, wherein a further fastener component is fixed to said at least one fastener component, to join the one or more thermoplastic fiber components together, wherein the further fastener component is a bolt or a nut, wherein step (c) is performed at least one of prior to or during step (d).

2. The method according to claim 1, wherein the one or more thermoplastic fiber composite components includes a thermoplastic material selected from the group consisting of polyamide (PA), polyphenylene sulfide (PPS), polyetherketoneketone (PEKK), polyetheretherketone (PEEK), polypropylene (PP), polyethylene (PE), poly(styrene-butadiene-styrene) (SBS), polyethyleneimine (PEI), preferably polyphenylene sulfide, polyetherketoneketone, and polyetheretherketone.

3. The method according to claim 1, wherein the one or more thermoplastic fiber composite components comprise continuous fibers.

4. The method according to claim 1, wherein said fastener, said at least one fastener component and said further fastener component is predominantly made of a metal or a metal alloy.

5. The method according to claim 1, wherein said one or more thermoplastic fiber composite components have a flat form, at least at the positions where they are to be joined to each other when they are stacked over each other in step (b).

6. The method according to claim 1, wherein the heating in step (c) is performed with at least one of ultrasound, hot air, microwave radiation, laser radiation, electric current, electromagnetic induction, or infrared radiation.

7. The method according to claim 1, wherein the heating is performed at at least one of: (i) one surface or opposing surfaces of the one or more thermoplastic fiber composite components, which are positioned on top of each other, at positions where the components are to be joined; or (ii) at an inner part of one or more of said one or more thermoplastic fiber composite components which are to be joined.

8. The method according to claim 1, wherein said further fastener component is a bolt.

9. The method according to claim 1, wherein the thread of said fastener or of said at least one fastener component is dimensioned: to extend through all thermoplastic fiber composite components which are positioned on top of each other, or to extend into only in the bottom thermoplastic fiber composite component and optionally further thermoplastic fiber composite components, but not in a top thermoplastic fiber composite component, leaving an unthreaded part at least in said top thermoplastic fiber composite component.

10. The method according to claim 1, wherein said at least one fastener component is screwed into all thermoplastic fiber composite components which are positioned on top of each other, or is screwed only into the bottom thermoplastic fiber composite component.

11. The method according to claim 1, wherein said fastener, said at least one fastener component and said further fastener component, extends through all thermoplastic fiber composite components.

12. The method according to claim 1, wherein the method does not include drilling of a hole into the one or more thermoplastic fiber composite components prior to or during step (d).

13. The method according to claim 1, wherein said fastener, or said further fastener component comprises a head at one end and an opposing end which can be deformed.

14. The method according to claim 1, wherein at least one of the one or more thermoplastic fiber composite components comprises a carbon-fiber-reinforced plastic material.

15. The method according to claim 1, wherein the joined components are components of a vehicle, aircraft or spacecraft.

16. The method according to claim 1, wherein the joined components are structural components selected from the group consisting of: skin, stiffening elements, doubles/reinforcements, window frames, floor structure components, seat rails, Z-struts, X-paddles, door frames, intercostals, lintel and a mix of different parts thereof.

17. The method according to claim 1, wherein the number of joined thermoplastic fiber composite components is at least two.

18. An assembly of one or more different components or different sections of a single one of the one or more components, comprising: at least one of the one or more components is a thermoplastic fiber composite component, the at least one thermoplastic fiber composite component is joined together at one or more positions with a fastener comprising a thread, or at least one fastener component, which comprises a thread, wherein the fastener is a screw and the at least one fastener component, which comprises a thread, is an insert of a rivet, wherein a further fastener component is fixed to said at least one fastener component, to join the one or more thermoplastic fiber components together, wherein the further fastener component is a bolt or a nut.

19. The assembly according to claim 18, wherein said further fastener component is a bolt.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Preferred embodiments of the method, use and joined components of the present invention are described in greater detail with reference to the attached schematic drawings in the following.

(2) FIG. 1 shows the joined together component 10, wherein a fastener 13 is screwed into components 11 and 12. The fastener is shown in its final position. If desirable, the fastener can be cooled after reaching its final position.

(3) FIG. 2 shows the embodiment of FIG. 1 after the fastener 13 is positioned but before it is screwed into components 11 and 12.

(4) FIG. 3 shows the embodiment of FIGS. 1 and 2, wherein fastener 13 is heated before and optionally during screwed into components 11 and 12 in order to indirectly heat components 11 and 12 at the positions where they are to be joined. The arrows point to the heated part of fastener 13.

(5) FIG. 4 shows the embodiment of FIGS. 1-3, wherein an inner part of components 11 and 12 (indicated by the arrows) is heated at positions where components 11 and 12 are to be joined. Heating can be performed before and/or during the screwing step.

(6) FIG. 5 shows the embodiment of FIGS. 1-4, wherein a pressure force is applied onto the head 14 of the fastener 13 towards the position where the components are to be joined (indicated by the arrow which is perpendicular to components 11 and 12), and wherein a torque/momentum force is applied to fastener 13 (indicated by the bent arrow).

(7) FIG. 6a shows an enlarged view on a thermoplastic fiber composite component after conventional drilling, wherein a drilled hole/through hole 17 has been formed. Composite fibers 15 and 16 are running perpendicular to each other and are cut by the drilling step and cut fibers 18 remain.

(8) FIG. 6b shows an enlarged view on a thermoplastic fiber composite component after a fastener has been screwed into it, wherein moved fibers 19 remain, which are still (essentially) continuous, i.e., are not cut but are pushed aside by the fastener (not shown).

(9) FIG. 7a shows two components 11 and 12, to be joined by fixed by a bolt and insert combination, wherein a threaded insert 113 (i.e., a component of the fastener comprising a thread) is screwed into component 12. The bolt has not yet been fully inserted.

(10) FIG. 7b shows the embodiment of FIG. 7, wherein the bolt 120 has been fully inserted.

(11) FIG. 8a shows a fastener in the form of a screw 13 with a countersink head 14, wherein the thread is in both components 11 and 12.

(12) FIG. 8b shows a fastener in the form of a screw 13 with a spherical head 14, wherein the thread is in both components 11 and 12.

(13) FIG. 8c shows a fastener in the form of a screw 13 with a polyhedron head 14, wherein the thread is in both components 11 and 12.

(14) FIG. 9a shows a fastener in the form of a screw 13 with a countersink head 14 and a thread only in component 12.

(15) FIG. 9b shows a fastener in the form of a screw 13 with a polyhedron head 14 and a thread only in component 12.

(16) FIG. 9c shows a fastener in the form of a screw 13 with a spherical head 14 and a thread only in component 12.

(17) FIG. 10a shows a fastener in the form of a screw 13 with a countersink head 14, wherein the screw 13 goes through both components 11 and 12 and even protrudes beyond them.

(18) FIG. 10b shows the embodiment of FIG. 10a with a polyhedron head 14.

(19) FIG. 10c shows the embodiment of FIG. 10a with a spherical head 14.

(20) FIG. 11a shows two components 11 and 12, to be joined by screwing of bolts, wherein a component 113 of the fastener comprising a thread is screwed into component 12 to join it with component 11 by inserting bolt 120, which is not yet fully inserted (i.e., a further component of the fastener not comprising a thread), wherein the threaded component 113 protrudes beyond the components.

(21) FIG. 11b shows the embodiment of FIG. 11a, wherein the bolt 120 has been fully inserted.

(22) FIG. 12a shows two components 11 and 12, to be joined by a blind fastener/blind rivet, wherein a component 113 of the fastener comprising a thread which is screwed into components 11 and 12 and the fastener is fixed by inserting bolt 120 (i.e., a further component of the fastener not comprising a thread), which is not yet fully fixed.

(23) FIG. 12b shows the embodiment of FIG. 12a, wherein the bolt 120 has been fully fixed.

(24) FIG. 13a shows a fastener with two components, wherein one component 113 comprises a thread and is screwed into the bottom component 12, and a further component 120 which is a bolt with a countersink head 121.

(25) FIG. 13b shows the embodiment of FIG. 13a with a spherical head 121.

(26) FIG. 13c shows the embodiment of FIG. 13a with a polyhedron head 121.

(27) FIG. 14a shows a fastener (insert) 113 which is screwed into component 12 and is fixed with a bolt 120 having a countersink head 121.

(28) FIG. 14b shows the embodiment of FIG. 14a with a different head 121 and bolt 120 variant.

(29) FIG. 14c shows the embodiment of FIG. 14a with a different head 121 and bolt 120 variant.

(30) FIG. 14d shows the embodiment of FIG. 14a with a different head 121 and bolt 120 variant.

(31) FIG. 15a shows a fastener 13, wherein arrow A shows the slot(s) in the fastener head 14.

(32) FIG. 15b shows different slot variants/forms of head 14 of FIG. 15a, i.e., biangle, triangle, square, pentagon, hexagon and polygon.

(33) FIG. 16a shows a fastener 13, wherein arrow B shows the slot(s) in the fastener head 14.

(34) FIG. 16b shows different slot variants/star forms of head 14 of FIG. 16a.

(35) FIG. 17a shows a fastener 13, wherein arrow C shows the slot(s) in the fastener head 14.

(36) FIG. 17b show different slot variants/forms, being a mix of the forms of head 14 of FIGS. 15 and 16.

(37) FIG. 18a shows a fastener 113, wherein arrow D shows the location of a partial inner thread at the location.

(38) FIG. 18b shows the top view of FIG. 18a on the partial inner thread.

(39) FIG. 18c shows a cross-section of the fastener 113 of FIGS. 18a and 18b.

(40) FIG. 19a shows a cross-section of fastener 113 of FIGS. 18a-18c with a bolt 120 before being fully inserted.

(41) FIG. 19b shows the embodiment of FIG. 19a with the bolt 120 being fully inserted.

(42) FIG. 20a shows a fastener 113, wherein arrow F shows the location of an inner thread at the location.

(43) FIG. 20b shows the top view of FIG. 20a on the inner thread.

(44) FIG. 20c shows a cross-section of fastener 113 of FIGS. 20a and 20b.

(45) FIG. 21a shows a cross-section of the fastener 113 of FIGS. 20a-20c with a bolt 120 before being fully inserted.

(46) FIG. 21b shows the embodiment of FIG. 21a with the bolt 120 being fully inserted.

(47) FIG. 22a shows a fastener 13 inserted in components 1 and 2 with a head 14, pointed to by arrow A.

(48) FIG. 22b shows different head variants/forms, i.e., biangle, triangle, square, pentagon, hexagon and polygon of head 14 of FIG. 22a.

(49) FIG. 23a shows a fastener 13 inserted in components 1 and 2 with a head 14, pointed to by arrow B.

(50) FIG. 23b shows different head variants/star forms of head 14 of FIG. 23a.

(51) FIG. 24a shows a fastener 13 inserted in components 1 and 2 with a head 14, pointed to by arrow C.

(52) FIG. 24b shows different head variants/forms based on mixtures of the forms of head 14 of FIGS. 22 and 23.

(53) FIG. 25 shows a prior art self-piercing rivet.

(54) FIG. 26a shows a prior art fastener with cutting edges which is inserted into a component, thereby forming a through hole.

(55) FIG. 26b shows a prior art fastener showing that the cutting edges are removed/not present according to the present application.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(56) The following detailed description of the schematic drawings focuses on the illustrated implementation variants of a method of the invention, the use of the invention and the joined-together components of the invention. The present disclosure is not limited to the above and below described embodiments, but includes combinations thereof.

(57) FIGS. 1-5 show the fastener 13 in the form of a screw. In FIG. 2, the screw has been brought into position, i.e., is positioned above the components at the location where these are to be joined. Components 11 and 12 have been positioned on top of each other. The use of a single component which is bent or folded to provide an overlapping section can provide the same setup as shown in FIGS. 1-5.

(58) FIG. 6 shows the difference between prior art drilling methods (FIG. 6a) and the method of the present invention (FIG. 6b). When comparing the figures, the structural differences between prior art products and the products of the present invention, resulting from the processes of joining according to the invention, become apparent. These differences may be determined by microscopy, e.g., scanning electron microscopy.

(59) FIGS. 7a and 7b show two components 11 and 12, to be joined by a bolt and insert combination. Component 11 is joined with component 12 by inserting bolt 120 (i.e., a further component which can optionally also comprise a thread) into the insert 113. The bolt can be screwed or hammered into the insert.

(60) FIGS. 11a and 11b show an embodiment which is similar to the embodiment of FIGS. 7a and 7b. However, in FIGS. 11a and 11b, the threaded component 113 protrudes beyond the components.

EXAMPLE

(61) A test was performed with PPS (polyphenylene sulfide) material. This material is used in A350 clips and cleats. The material PPS had a melting temperature of about 285 C. A woodscrew having a length of 16 mm and a cross recess was inserted by using a manual screwdriver and a blowtorch for heating. The temperature of the sheet was controlled by distance temperature measurement by means of IR measurement with laser steering (range: 50 C. up to 900 C.). Upon heating to a temperature of about 200 C. it was possible to screw with minimal forces without destroying the fibers. After removal of the screw a good quality of the holes were observed.

(62) While at least one exemplary embodiment of the present invention(s) is disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. This disclosure is intended to cover any adaptations or variations of the exemplary embodiment(s). In addition, in this disclosure, the terms comprise or comprising do not exclude other elements or steps, the terms a or one do not exclude a plural number, and the term or means either or both. Furthermore, characteristics or steps which have been described may also be used in combination with other characteristics or steps and in any order unless the disclosure or context suggests otherwise. This disclosure hereby incorporates by reference the complete disclosure of any patent or application from which it claims benefit or priority.

REFERENCE LIST

(63) 10 joined-together components 11 component to be joined 12 component to be joined 13 fastener comprising a thread 14 fastener head 15 composite fiber 16 composite fiber 17 drilled hole/through hole 18 cut fibers 19 moved fibers 113 fastener in form of a threaded insert 120 bolt 121 bolt head