COMPONENT COMPRISING CONNECTED FIBER COMPOSITE MATERIAL SUB-ELEMENTS AND METHOD AND APPARATUS FOR CONNECTING THE SUB-ELEMENTS

Abstract

Connections of sub-elements formed at least partly from fiber composite materials of a component for an aircraft with relatively low manufacturing complexity and the same or improved reliability and improved sealing, by providing different seam connections between the sub-elements. For this purpose, at least an edge region, formed from fiber composite material, of the first sub-element is formed to give a foldover that engages with an edge region of the other sub-element. Preferably, the forming is effected especially with use of thermoplastic materials while heating preferably the entire edge region.

Claims

1. A component for a vehicle, comprising: a first sub-element made of a fiber composite material, and a second sub-element, wherein the second sub-element has been connected to the first sub-element by means of a seam connection having a foldover at an edge of the first sub-element.

2. The component according to claim 1, wherein the second sub-element is formed from a fiber composite material, or the second sub-element is formed from a metallic material.

3. The component according to claim 1, wherein the fiber composite material has a thermoplastic matrix material.

4. The component according to claim 1, wherein the seam connection is selected from a group consisting of a standing seam connection, a flat lock seam connection, a double lock seam connection, a cap strip seam connection, an external seam connection, an internal seam connection or groove seam connection, a Pittsburgh lock seam connection and a snaplock seam connection.

5. The component according to claim 1, wherein at least one of: at least one of the sub-elements is a panel element; at least one of the sub-elements is or includes a reinforcing element for a panel; at least one of the sub-elements has been formed by laminating layers of fiber composite material; a stiffening element for a panel has been formed by at least a sub-region of the seam connection; the component is a component for an aircraft; the component has a third sub-element connected to at least one of the first or second sub-element by means of a seam connection; the component has a third sub-element composed of fiber composite material which has been connected to at least one of the first or second sub-element by means of a seam connection; the second and a third sub-element are connected via the seam connection by means of the first sub-element, where the first sub-element is selected from a group consisting of a connecting element, a reinforcing element, a reinforcing element with a projecting flange, a reinforcing element with a projecting reinforcement fin and an angled reinforcing element; the fiber composite material is selected from a group of fiber composite materials consisting of CF/PPS composite material, CF/PEKK composite material, CF/PEEK composite material, CF/PA composite material, fiber composite material with carbon fibers in a thermoplastic matrix, fiber composite material with embedded metal mesh, fiber composite material with embedded bronze mesh, fiber weave in a plastic matrix, unidirectional fibers of a plastic matrix, fibers in a PEEK matrix, fibers in a PA matrix, composite material comprising a mixture of thermoplastic materials with metallic materials, composite material comprising a mixture of thermoplastic materials with aluminum materials, composite material comprising a mixture of thermoplastic materials with titanium materials; carbon fiber weave in a PPS matrix, unidirectional carbon fibers in a PPS matrix, PEKK-impregnated carbon fiber weave, carbon fiber weave in a PEKK matrix, unidirectional carbon fibers in a PEKK matrix, PEKK-embedded carbon fibers with bronze mesh and combinations of the aforementioned materials; the fiber composite material includes fibers from a group of fibers consisting of carbon fibers, glass fibers, aramid fibers, synthetic fibers, fibers in a fiber weave, fibers in a fiber scrim and unidirectional fibers, and combinations of the fibers mentioned; the fiber composite material has a matrix material from a group of matrix materials consisting of PE, PP, PA, POM, PET, PC, a transparent plastic, a transparent thermoplastic, transparent PC, PETG, PMMA, plastic alloys, thermoplastic alloys, a high-temperature plastic, a high-temperature thermoplastic, PTFE, PVDF, PEI, PEEK and PEKK.

6. The component according to claim 1, wherein a filler material has been inserted in at least one foldover of the seam connection.

7. A method of connecting a first sub-element, formed from a fiber composite material, of a component for a vehicle to a second sub-element of the component, comprising a) providing the first sub-element having an at least partly deformable edge region; c) producing a seam connection for connecting of the first and second sub-elements by means of folding the at least partly deformable edge region to form a foldover.

8. The method according to claim 7, wherein step a) comprises at least one of the following steps: a1) producing the first sub-element from fibers and a thermoplastic matrix; a2) producing the first sub-element by laminating plies of fiber composite material; a3) producing the first sub-element from a fiber composite material selected from a group of fiber composite materials consisting of CF/PPS composite material, CF/PEKK composite material, CF/PEEK composite material, CF/PA composite material, fiber composite material with carbon fibers in a thermoplastic matrix, fiber composite material with embedded metal mesh, fiber composite material with embedded bronze mesh, fiber weave in a plastic matrix, unidirectional fibers of a plastic matrix, fibers in a PEEK matrix, fibers in a PA matrix, composite material comprising a mixture of thermoplastic materials with metallic materials, composite material comprising a mixture of thermoplastic materials with aluminum materials, composite material comprising a mixture of thermoplastic materials with titanium materials; carbon fiber weave in a PPS matrix, unidirectional carbon fibers in a PPS matrix, PEKK-impregnated carbon fiber weave, carbon fiber weave in a PEKK matrix, unidirectional carbon fibers in a PEKK matrix, PEKK-embedded carbon fibers with bronze mesh and combinations of the aforementioned materials; a4) producing the first sub-element from a fiber composite material comprising fibers from a group of fibers consisting of carbon fibers, glass fibers, aramid fibers, synthetic fibers, fibers in a fiber weave, fibers in a fiber scrim and unidirectional fibers and combinations of the fibers mentioned; a5) producing the first sub-element from a fiber composite material comprising a matrix material from a group of matrix materials consisting of PE, PP, PA, POM, PET, PC, a transparent plastic, a transparent thermoplastic, transparent PC, PETG, PMMA, plastic alloys, thermoplastic alloys, a high-temperature plastic, a high-temperature thermoplastic, PTFE, PVDF, PEI, PEEK and PEKK; a6) providing the first sub-element having a soft deformable forming region of the edge region to be folded; a7) providing the first sub-element in such a way that the entire edge region is soft and deformable; a8) providing the first sub-element made of a thermoplastic fiber composite material and heating at least regions of a region to be formed of the edge region; a9) providing the first sub-element made of a thermoplastic fiber composite material and heating the entire edge region; a10) heating at least a sub-region of the edge region by means of a heat source selected from a group of heat sources consisting of a burner, a Bunsen burner, an infrared heat radiation source, a laser, a maser, an induction heat source, conduction of heat, a plasma heat source, a heating element embedded into at least one sub-element, a copper heating element, a steel heating element, an aluminum heating element, a carbon heating element, a carbon fiber heating element and combinations of the above heat sources or heating elements; or a11) heating at least a sub-region of the edge region by at least one of a group of heating methods consisting of convection heating, radiation heating, infrared heating, laser heating, maser heating, induction heating, heating by means of heat conduction, plasma heating, resistance heating by means of embedded elements, resistance heating by means of embedded copper elements, resistance heating by means of embedded steel elements, resistance heating by means of embedded aluminum elements, resistance heating by means of embedded carbon elements and resistance heating by means of embedded carbon fiber elements.

9. The method according to claim 7, wherein step c) comprises at least one, more than one or all of the following steps: c1) folding the edge region, c2) forming a foldover at the edge region of the first sub-element and inserting an edge region of the second sub-element into the foldover; c3) forming a foldover at the edge region of the first sub-element, forming a foldover at an edge region of the second sub-element and engaging the foldovers of the first and second sub-elements with one another; c4) co-forming the edge region of the first sub-element and an at least partly deformable edge region of the second sub-element; c5) producing the seam connection as a seam connection selected from a group consisting of a standing seam connection, a flat lock seam connection, a double lock seam connection, a cap strip seam connection, an external seam connection, an internal seam connection or groove seam connection, a Pittsburgh lock seam connection and a snaplock seam connection; c6) connecting the second and a third sub-element by means of the first sub-element which is connected to the second sub-element and the third sub-element by a seam connection in each case; c7) connecting the second and a third sub-element by means of the first sub-element selected from a group consisting of a connecting element, a reinforcing element, a reinforcing element with a projecting flange, a reinforcing element with a projecting reinforcement fin and an angled reinforcing element; c8) exerting pressure on the seam connection; c9) at least one of consolidating or curing the regions of the first and second sub-elements that form the seam connection; c10) inserting a filler material into a foldover that forms the seam connection; c11) inserting a filler material into the seam connection; c12) inserting a filler material from a group of filler materials consisting of a material for sealing, a sealant material, a material for forming an edge guard, a material for improving electrical conductivity, an electrically conductive material and materials for achieving defined mechanical properties of the seam connection; c13) preforming the edge region of the first sub-element, joining first sub-element and second sub-element, finally forming the seam connection; c14) holding the sub-element in a holding device such that the edge region protrudes therefrom, and bending the edge region; c15) folding the entire edge region in one step; or c16) folding the edge region in a continuously advancing manner across its extent.

10. The method according to claim 7, including the further steps: ba) providing the second sub-element made of fiber composite material, or bb) providing the second sub-element made of a metallic material.

11. The method according to claim 10, wherein step ba) comprises at least one of the following steps: ba1) providing the second sub-element having an at least partly deformable edge region; ba2) producing the second sub-element from fibers and a thermoplastic matrix; ba3) producing the second sub-element by laminating plies of fiber composite material; ba4) producing the second sub-element from a fiber composite material selected from a group of fiber composite materials consisting of CF/PPS composite material, CF/PEKK composite material, CF/PEEK composite material, CF/PA composite material, fiber composite material with carbon fibers in a thermoplastic matrix, fiber composite material with embedded metal mesh, fiber composite material with embedded bronze mesh, fiber weave in a plastic matrix, unidirectional fibers of a plastic matrix, fibers in a PEEK matrix, fibers in a PA matrix, composite material comprising a mixture of thermoplastic materials with metallic materials, composite material comprising a mixture of thermoplastic materials with aluminum materials, composite material comprising a mixture of thermoplastic materials with titanium materials; carbon fiber weave in a PPS matrix, unidirectional carbon fibers in a PPS matrix, PEKK-impregnated carbon fiber weave, carbon fiber weave in a PEKK matrix, unidirectional carbon fibers in a PEKK matrix, PEKK-embedded carbon fibers with bronze mesh and combinations of the aforementioned materials; ba5) producing the second sub-element (18) from a fiber composite material comprising fibers from a group of fibers consisting of carbon fibers, glass fibers, aramid fibers, synthetic fibers, fibers in a fiber weave, fibers in a fiber scrim and unidirectional fibers and combinations of the fibers mentioned; ba6) producing the second sub-element from a fiber composite material comprising a matrix material from a group of matrix materials consisting of PE, PP, PA, POM, PET, PC, a transparent plastic, a transparent thermoplastic, transparent PC, PETG, PMMA, plastic alloys, thermoplastic alloys, a high-temperature plastic, a high-temperature thermoplastic, PTFE, PVDF, PEI, PEEK and PEKK; ba7) providing the second sub-element having a soft deformable forming region to be folded at an edge region to be connected to the first sub-element; ba8) providing the second sub-element such that an entire edge region to be connected to the first sub-element is soft and deformable; ba9) providing the second sub-element made of a thermoplastic fiber composite material and heating at least regions of a region to be formed of an edge region to be connected to the first sub-element; ba10) providing the second sub-element made of a thermoplastic fiber composite material and heating the entire edge region to be connected to the first sub-element; ba11) heating at least a sub-region of an edge region to be connected to the first sub-element by means of a heat source selected from a group of heat sources consisting of a burner, a Bunsen burner, an infrared heat radiation source, a laser, a maser, an induction heat source, conduction of heat, a plasma heat source, a heating element embedded into at least one sub-element, a copper heating element, a steel heating element, an aluminum heating element, a carbon heating element, a carbon fiber heating element and combinations of the above heat sources or heating elements; or ba12) heating at least a sub-region of an edge region to be connected to the first sub-element by at least one of the heating methods of convection heating, radiation heating, infrared heating, laser heating, maser heating, induction heating, heating by means of heat conduction, plasma heating, resistance heating by means of embedded elements, resistance heating by means of embedded copper elements, resistance heating by means of embedded steel elements, resistance heating by means of embedded aluminum elements, resistance heating by means of embedded carbon elements and resistance heating by means of embedded carbon fiber elements.

12. An apparatus for connecting a first sub-element formed from a fiber composite material of a component for a vehicle to a second sub-element of the component, comprising a forming preparation device configured to provide the first sub-element having an at least partly deformable edge region; and a seam connection device configured to produce a seam connection for connecting the first and second sub-elements by means of folding the at least partly deformable edge region to give a foldover.

13. The apparatus according to claim 12, wherein at least one of: the forming preparation device comprises at least one of: a providing device configured to provide a first sub-element formed at least from fibers and a thermoplastic matrix; or a heating device for heating at least a sub-region to be formed of the edge region; the seam connection device comprises at least one of: a holding device for holding the first sub-element; or a bending device for bending the edge region of the first sub-element.

14. A product made by the process according to claim 7 comprising at least one of: a longitudinal connection across a structural component of an aircraft; a peripheral connection that extends in circumferential direction of a structural component of an aircraft; a coupling of frame elements of a structure of a vehicle or aircraft to one another; a coupling of reinforcing elements to skin elements of a structure component for a vehicle or an aircraft; a coupling of system components or cabin components of a vehicle or aircraft to one another; a coupling of a system component to a structure of a vehicle or aircraft; a coupling of cabin components to a structure of a vehicle or aircraft; an integration of a reinforcing element into a structure of a vehicle or aircraft; an integration of a frame element into a structure of a vehicle or aircraft; a connection or integration of a floor constituent, a crash element, a securing clip or a bracket or a pressure dome to or into a structure or into or to another sub-element of a vehicle or aircraft; connections to vehicles, aircraft, airplanes, helicopters, rockets, spaceships, satellites, in satellite technology, to flying automobiles or to land-based automobiles.

15. A product made by utilizing the apparatus of claim 12 comprising at least one of: a longitudinal connection across a structural component of an aircraft; a peripheral connection that extends in circumferential direction of a structural component of an aircraft; a coupling of frame elements of a structure of a vehicle or aircraft to one another; a coupling of reinforcing elements to skin elements of a structure component for a vehicle or an aircraft; a coupling of system components or cabin components of a vehicle or aircraft to one another; a coupling of a system component to a structure of a vehicle or aircraft; a coupling of cabin components to a structure of a vehicle or aircraft; an integration of a reinforcing element into a structure of a vehicle or aircraft; an integration of a frame element into a structure of a vehicle or aircraft; a connection or integration of a floor constituent, a crash element, a securing clip or a bracket or a pressure dome to or into a structure or into or to another sub-element of a vehicle or aircraft; connections to vehicles, aircraft, airplanes, helicopters, rockets, spaceships, satellites, in satellite technology, to flying automobiles or to land-based automobiles.

16. An aircraft comprising the component according to claim 1.

17. An aircraft comprising a seam connection formed by the method according to claim 7.

18. An aircraft comprising the product according to claim 14.

19. An aircraft comprising the product according to claim 15.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0262] The invention is elucidated in detail hereinafter with reference to the appended drawings. The drawings show:

[0263] FIG. 1 is a perspective, part-sectional view of a fuselage segment of an aircraft in which various components have sub-elements connected by means of seam connections;

[0264] FIG. 2 is a section through a connection site between a first sub-element and a second sub-element of a component with a first embodiment of a seam connection;

[0265] FIG. 3 is a section through a connection site between sub-elements of a component with a second embodiment of a seam connection;

[0266] FIG. 4 is a schematic view of an edge region of a first sub-element of the component to illustrate a first step of a process for producing a seam connection;

[0267] FIGS. 5-8 are side views of an edge region of the first sub-element during different steps of a method of producing the seam connection;

[0268] FIGS. 9-11 are cross-sectional views of different sub-elements that are folded to form seam connections;

[0269] FIGS. 12-15 are section views of edge regions to be bonded of a first sub-element and a second sub-element to form the seam connection shown in FIG. 2;

[0270] FIG. 16 is a photograph of a connection site between a first sub-element and a second sub-element, bonded by means of the seam connection according to FIG. 2;

[0271] FIGS. 17-20 are profile views of a first sub-element, a second sub-element and a third sub-element during different steps of a method of producing the seam connection of FIG. 3;

[0272] FIG. 21 is a photograph of an example of a seam connection formed according to FIG. 3 between sub-elements formed from fiber composite materials;

[0273] FIGS. 22-28 are perspective views of different working examples of folded structures and seam connections formed thereby;

[0274] FIGS. 29a-29b are profile views of a first sub-element and a second sub-element during different phases for formation of an embodiment of a seam connection;

[0275] FIGS. 30a-30c are profile views of a first sub-element and a second sub-element during different phases for formation of a further embodiment of the seam connection;

[0276] FIGS. 31a-31b are profile views of a first sub-element and a second sub-element during different phases for formation of a further embodiment of the seam connection;

[0277] FIGS. 32a-32b are profile views of a first, a second, and a third sub-element during different phases for formation of a further embodiment of the seam connection;

[0278] FIGS. 33a-33b are profile views of a first sub-element and a second sub-element for formation of a further embodiment of the seam connection;

[0279] FIGS. 34a-34b are profile views of a first, second and third sub-element during different phases for formation of a further embodiment of the seam connection and

[0280] FIGS. 35a-35b are profile views of a first sub-element, a second sub-element and a third sub-element during different phases for formation of a further embodiment of the seam connection.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0281] FIG. 1 shows, in part-perspective and part-sectional view, a fuselage segment 11 with different working examples of components 10 of an aircraft 12, in which at least a first sub-element 16 and a second sub-element 18 are connected at a connection site 14 by means of a seam connection 20.

[0282] At least the first sub-element 16 is formed from a fiber composite material. The fiber composite material preferably has carbon fibers in a thermoplastic matrix.

[0283] The connection site 14 with the seam connection 20 is, for example, a longitudinal connection 22 between skin elements 23 of the fuselage segment 11 that take the form of sheet elements or panel elements. Such mutually connected skin elements 23 are thus a first example of the sub-elements 16, 18 of a component 10 of the aircraft 12 that are connected by means of the seam connection 20. In that case, component 10 takes the form, for example, of a structural component 24 for formation of a fuselage 26 of the aircraft 12.

[0284] Other examples of the connection site 14 are connections 28 that run in circumferential direction between the skin elements, which form sub-elements 16, 18 of the component 10 in the form of a structural component 24 that are connected by means of the seam connection 20.

[0285] In addition, the connection site 14 may be provided between a cabin component 30for example the floor of a cabinand the structure component 24. Here, the cabin component 30 forms one of the sub-elements 16, 18 and the structural component 24 the other of the sub-elements 16, 18.

[0286] Further examples of the sub-elements 16, 18 that are connected to one another by means of the seam connection 20 to give a component are a skin element 23 of the structure component 24 as one of the sub-elements 16, 18 and a reinforcing element 32, for example a stringer or a frame element, as the other of the sub-elements 16, 18.

[0287] Also shown in FIG. 1 is a fluid conduit 34 as an example of a system component of a functional system of an aircraft 12, wherein the fluid conduit 34 is connected at a connection site 14 by means of the seam connection 20. Here, in that case, different regions of the fluid conduit 34 that are to be bonded to one another at their edges constitute further examples of the sub-elements 16, 18.

[0288] In all these examples, in each case, at least a first sub-element 16 made of a fiber composite material is bonded to a second sub-element 18 by means of a seam connection 20 in order thus to form a component 10 of a vehicle, especially aircraft 12.

[0289] FIGS. 2 and 3 show different preferred working examples of the seam connection 20.

[0290] In all the working examples of the seam connection shown here, and especially the working examples shown in FIGS. 2 and 3, at least the first sub-element 16 as elucidated above is made of a fiber composite material. At least the first sub-element 16 has a foldover 38 at an edge region 36 to form a seam connection 20.

[0291] In the embodiment of the seam connection 20 shown in FIG. 2, the first sub-element 16 and the second sub-element 18 are directly connected by the seam connection 20. For this purpose, the second sub-element 18 also has a further foldover 42 at the edge region 40 to be connected to the first sub-element 16. The sub-elements 16, 18 are mutually engaged by their foldovers 38, 42 and consolidated.

[0292] In the embodiment of the seam connection 20 according to FIG. 3, the first sub-element 16 takes the form of a connecting element 44 and is especially formed as a bar-like connecting element 44 having the foldover 38 at each of the two longitudinal edges. Similar seam connections formed by means of a connecting element 44 are also referred to in metal connection technology as a cap strip connection. The connecting element 44 forms a cap strip seam 45 that covers and protects the formed edge regions 36, 40, 50.

[0293] The second sub-element 18 provided with a foldover 42 can be connected to a third sub-element 46 by means of the first sub-element 16 in the form of a connecting element 44. The third sub-element 46 may also have a foldover 48 at the edge region 50 to be bonded to the second sub-element 18.

[0294] The second sub-element 18 and the third sub-element 46 may be formed from the same material or from different materials from the first sub-element 16. Preferably all sub-elements 16, 18, 46 are made of a fiber composite material and more preferably made of a fiber composite material with a thermoplastic matrix.

[0295] In some embodiments, the fiber composite material contains carbon fibers, glass fibers, aramid fibers and/or synthetic fibers.

[0296] In some embodiments, the fiber composite material contains a thermoplastic material as matrix. In some embodiments, the matrix material comprises at least one of the following thermoplastic materials:

[0297] a. a standard material, for example

[0298] i. PE (polyethylene)

[0299] ii. PP (polypropylene)

[0300] b. a construction plastic, for example

[0301] i. PA (polyamide, especially PA 6/PA 6 C/PA 66/PA 46/PA 12)

[0302] ii. POM (polyoxymethylene)

[0303] iii. PET (polyethylene terephthalate)

[0304] iv. PC (polycarbonate)

[0305] c. a transparent plastic, for example

[0306] i. PC (polycarbonate)

[0307] ii. PETG (polyethylene terephthalate glycol)

[0308] iii. PMMA (polymethylmethacrylate)

[0309] d. a plastic alloy

[0310] e. a high-temperature plastic, for example

[0311] i. PTFE (polytetrafluoroethylene)

[0312] ii. PVDF (polyvinylidene fluoride)

[0313] iii. PEI (polyetherimide)

[0314] iv. PEEK (polyetheretherketone)

[0315] v. PEKK (polyetherketoneketone)

[0316] Preferred composite materials are, for example:

[0317] CF/PPS composite material,

[0318] CF/PEKK composite material,

[0319] CF/PEEK composite material,

[0320] CF/PA composite material,

[0321] fiber composite material with carbon fibers in a thermoplastic matrix,

[0322] fiber composite material with embedded metal mesh,

[0323] fiber composite material with embedded bronze mesh,

[0324] fiber weave in a plastic matrix,

[0325] unidirectional fibers of a plastic matrix,

[0326] fibers in a PEEK matrix,

[0327] fibers in a PA matrix,

[0328] composite material comprising a mixture of thermoplastic materials with metallic materials,

[0329] composite material comprising a mixture of thermoplastic materials with aluminum materials,

[0330] composite material comprising a mixture of thermoplastic materials with titanium materials,

[0331] carbon fiber weave in a PPS matrix,

[0332] unidirectional carbon fibers in a PPS matrix,

[0333] PEKK-impregnated carbon fiber weave,

[0334] carbon fiber weave in a PEKK matrix,

[0335] unidirectional carbon fibers in a PEKK matrix,

[0336] PEKK-embedded carbon fibers with bronze mesh, and

[0337] combinations of the aforementioned materials.

[0338] In some embodiments, composite materials with nonconductive fibers, for example glass fibers, are used in at least one of the sub-elements 15, 18, 46, especially to form regions with electrical insulation, for example in the case of system constituents.

[0339] The second sub-element 18 and the third sub-element 46 may also be formed from materials other than the first sub-element 16, for example from metal as well. For instance, a tight connection of simple construction of a fiber composite material sub-element 16 to a metal part, for example made of aluminum material or a titanium material, is also possible.

[0340] In some embodiments, accordingly, the second sub-element 18 and/or optionally the third sub-element 46 are formed from a metallic material. In some embodiments, the second sub-element and/or the third sub-element, for this purpose, is formed from a metallic material from the group comprising

[0341] a. aluminum

[0342] b. titanium

[0343] c. steel, especially stainless steel

[0344] d. magnesium

[0345] e. copper

[0346] and alloys of the metals a) to e) mentioned.

[0347] The seam connection 20 may be formed in the manner known for seam connections in the field of connection to sheet metal parts. Unlike in the case of sheet metal seam connections, however, it is not a metal but an edge region 36 of fiber composite material that is folded over.

[0348] For forming of the seam connection 20, the edge regions 36, 40, 50 to be formed in each case should be prepared such that they can be formed correspondingly. For this purpose, preferably, the sub-elements 16, 18, 46 are formed from a thermoplastically formable material, i.e., for example, from fibersespecially in a weave or unidirectional fibersin a thermoplastic matrix. It is of course also possible for further materials to be present as well in the sub-elements 16, 18, 46. More particularly, it is also possible for heating elementsnot described here in detailor other functional elements to be embedded.

[0349] For forming of the corresponding edge regions 36, 40, 50, when they are in the form of thermoplastic materials, they are preferably heated correspondingly prior to the forming and/or during the forming

[0350] To form the seam connection 20 according to FIGS. 2 and 3, the edge regions 36, 40, 50 are preferably first correspondingly formed, then the sub-elements 16, 18 or 16, 18, 46 are joined with their foldovers engaging or intermeshing with one another. Subsequently, there is preferably final forming of the seam connection 20 by ultimate forming of the foldovers 38, 42, 48, for example by application of heat and compressing. Thereafter, the connection site 14 is left to cure in order thus to form the firm seam connection 20.

[0351] The component 10 formed from the sub-elements 16, 18 and optionally 46 may at first take the form, for example, of a pre-form and then subsequently be ultimately formed to give a structural component 24, the combination of cabin component 30 and structural component 24, or to give the fluid conduit 34.

[0352] In another embodiment, the component 10 is already complete apart from the joining of the sub-elements 16, 18, 46 and is merely assembled by production of the seam connection 20.

[0353] The seam connection 20 may be used instead of or in addition to connection techniques used to date by means of drilling of holes and riveting and/or instead of or in addition to welding of the sub-elements 16, 18, 46.

[0354] Elucidated in detail hereinafter, with reference to the representation in FIGS. 4 to 15, are the steps for production of the seam connection 20 according to the different embodiments. More particularly, FIGS. 4 to 8 show the production of the foldover 38 at the edge region 36 of the first sub-element 16. With appropriate technology, it is also possible to produce the foldovers 42, 48 of the other sub-elements 18, 46. The further figures, FIGS. 9 to 15, show edge forms producible by this forming method and further steps for completion of the seam connection 20.

[0355] More particularly, FIGS. 4 to 8 and FIGS. 14 and 15 show, in schematic form, different devices of an apparatus 51 for connection of the first sub-element 16 to the second sub-element 18. The apparatus 51 has a forming preparation device 59 for providing the first sub-element 16 with a deformable edge region 36 and a seam connection device 64 for production of the seam connection 20.

[0356] FIG. 4 shows the forming preparation device 59 and illustrates a step of providing the first sub-element 16 with a soft deformable edge region 36 which is performable thereby. For this purpose, the forming preparation device 59 has at least one heating device 52 for heating the edge region 36. The heating device 52 may have, for example, one or more of the following heat sources:

[0357] a burner, e.g., a Bunsen burner,

[0358] an infrared heat radiation source,

[0359] a laser,

[0360] a maser,

[0361] an induction heat source,

[0362] conduction of heat,

[0363] a plasma heat source,

[0364] a heating element embedded or inserted into the sub-element 16, especially

[0365] made of copper,

[0366] made of steel,

[0367] made of aluminum,

[0368] made of carbon, especially carbon fiber.

[0369] Moreover, the forming preparation device 59 may have a provision device (not shown in detail) for providing the first sub-element 16, for example by supplying the sub-element 16 from a manufacturing site, and a support 54 or another device for fixing of the first sub-element 16.

[0370] In the forming preparation step, the first sub-element 16 is fixed on the support 54 and then heated by the heating device 52 at least in the edge region to be folded over. Especially when the sub-elements 16, 18, 46 are formed from multilayer fiber composite material, the edge region 50 overall is heated by means of the heating device 52. The edge region 50 is thus heated not just in its forming region but up to the edge 56. The heating is effected to softening temperature at which the matrix material of the edge region is plastically deformable but not yet liquefied.

[0371] The seam connection device 64 especially has, as indicated in FIGS. 5 and 6, a holding device 62 for holding the first sub-element 16 and a bending device 60 for bending the edge region 36.

[0372] FIG. 5 shows a first embodiment of a step for forming the edge region 36, in order thus to form the foldover 38. In FIG. 5, for this purpose, an insert 58 is placed onto the sub-element 16 resting on a support 54, and the deformable edge region 36 is formed around the insert 58 by means of the bending device 60.

[0373] The bending device 60 may have a beam element which extends along the edge region 50 and which is pivotable about a pivot axis that runs at right angles to the plane of the drawing. In another embodiment, the bending device 60 may have a forming surface that moves along the edge region 36 for bending of the edge region 40.

[0374] The insert 58 may, for example, be a forming element. In one configuration, the insert 58 may also be an already correspondingly creased edge region 40 of the other sub-element 18, 46 to be connected to the first sub-element 16.

[0375] The insert 58 and the support 54 may be part of the holding device 62.

[0376] FIG. 6 shows another working example of the fold connection device 64, where the holding device 62 includes the support 54 and an automatically movable holding jaw 66. The bending device 60 is designed to fold the edge region 36 to form the foldover 38 around the holding jaw 66. The holding jaw 66 thus serves solely to hold and form the interior of the foldover 38 and is removed after the forming of the foldover 38.

[0377] There are different options for the further procedure for forming of the seam connection 20. If the insert 58 is already formed by a foldover 42 or an edge region 40 of the other sub-element 18 of the seam connection 20, it is possible in a next step to consolidate the seam connection 20. In another variant executable especially with the configuration according to FIG. 6, it is first possible to consolidate a form of the foldover 38 of the first sub-element 16 that has been opened out to accommodate a foldover 42 or edge region 40 of the other sub-element.

[0378] FIGS. 7 and 8 show different configurations of a device for such a consolidation of the still opened-out form of the foldover 38 on its own, or even of the entire seam connection 20. The insert 58 may, as mentioned above, be a seam formed by an edge region 40 of the connection partnerfor example of the second sub-element 18or part of the foldover 42, 48 of the further sub-element 18 to be connected to the first sub-element 16. Rather than the insert 58, it is alternatively possible to introduce the inner mold that is then to be removed therefrom (for example in the form of holding jaw 66).

[0379] In the embodiment shown in FIG. 7, in open configuration, by means of a press element 68 with employment of pressure and optionally heat, the desired form of the foldover 38 of the first sub-element 16 to form the seam connection 20 is achieved.

[0380] FIG. 8 likewise shows an embodiment of the consolidation device 70 for consolidating the shape of the foldover 38 or even of the entire seam connection 20, wherein the consolidating is effected in a closed mold 72.

[0381] FIGS. 9 and 10 show different examples of the profile form of the first sub-element 16 in the region of the seam connection 20. The first sub-element 16 may have been provided with the foldover 38 on one side only, for example, as shown in FIG. 9. Especially in the case of design of the first sub-element 16 as connecting element 44, the foldover 38 is formed on the two opposite longitudinal edges of the first sub-element 16, as shown in FIG. 10. The further sub-element 18, 46 to be connected to the first sub-element 16 may, for example, have a shape as shown in FIG. 9 or else a shape as in FIG. 11.

[0382] In the connection of the sub-elements 16, 18, both of which have the configuration with a foldover 38, 42 shown in FIG. 9, the result is a double lock seam. However, it is also sufficient when the edge region 40 of the second sub-element 18 is introduced into the foldover 38 of the first sub-element 16 in order thus to form a single seam or a standing seam.

[0383] The forming of the double lock seam is elucidated in detail by FIGS. 12-16.

[0384] Here, both the first sub-element 16 and second sub-element 18 are each provided with the foldover 38, 42 by the forming operation having the steps according to FIGS. 4-8.

[0385] As shown in FIG. 13, the sub-elements 16, 18 are engaged with one another by their foldovers 38, 42 that are still in opened-out form.

[0386] Subsequently, in a compression device 74, the mutually engaged foldovers 38, 42 are compressed, in order thus to form the seam connection 20. The compression device 74 may have a first compression jaw 76 and a second compression jaw 78. At least one of the compression jaws 76, 78 may have a heated design. The compression presses the respective legs of the foldovers 38, 42 against one another, and the result is tight folding between the joining partners which thus engage with one another both in a form-fitting and frictionally engaged manner

[0387] FIG. 15 shows another variant of the compression step shown in FIG. 14 for final formation of the seam connection 20. In the configuration of FIG. 15, a filler material 80 is introduced into the seam connection to fill the gaps between the sub-elements 16, 18. The filler material 80 is selected to achieve desired properties of the seam connection, especially to achieve desired mechanical properties, for sealing purposes, for improving electrical conductivity, or the like.

[0388] FIG. 16 shows a photograph of a specific test example for the mutually intermeshed sub-elements 16, 18 shown in FIG. 13. It is possible here to clearly see the formation of the sub-elements 16, 18 from fiber composite material via mutually laminated fiber layers in a matrix.

[0389] FIGS. 17 to 20 show the corresponding steps and devices of the apparatus 51 as per FIGS. 12 to 15, except that they are configured here to form the embodiment of the seam connection 20 shown in FIG. 3. The design is analogous to the design of FIGS. 12 to 15, and so reference may be made to the above remarks. Here too, according to FIG. 20, the filler material 80 may be inserted to fill the gaps.

[0390] FIG. 21 correspondingly shows a photograph of the sub-elements 16, 18, 46 mutually engaged according to FIG. 18 by their foldovers 38, 42, 48. Here too, it is possible to clearly see the formation of the sub-elements 16, 18, 46 from fiber composite material.

[0391] FIGS. 22 and 23 show different possible embodiments of one of the sub-elements 16, 18 for forming the seam connection.

[0392] FIG. 22 shows the first or second sub-element 16, 18 in a configuration as was also encountered in the above-elucidated embodiments of the seam connection.

[0393] FIG. 23 shows a design of the foldover 38 in an angle region 82 angled away from the remaining extent of the first sub-element 16.

[0394] FIG. 24 shows a perspective view of the seam connection according to FIG. 2 composed of two sub-elements 16, 18 as shown in perspective view in FIG. 22.

[0395] FIG. 25 shows one configuration of the seam connection 20 composed of the first sub-element 16 in the configuration according to FIG. 23 and of the second sub-element 18 in the configuration according to FIG. 22. This results in a connection of the sub-elements 16, 18 in a corner connection.

[0396] FIGS. 26 and 27 show a further configuration of the seam connection 20, where the second sub-element 18 has an edge region 40 angled away as a standing seam 84, inserted into the foldover 38 of the first sub-element 16. This makes it possible to form, for example, a reinforcing element 32, which reinforces the component 10, at a corner region (FIG. 26) or else in a two-dimensional region of the component 10.

[0397] FIG. 28 shows one design of the flat lock seam connection 86. The flat lock seam 86 may, as shown in FIG. 28, be designed as a double lock seam and especially as a groove seam, meaning that, for example, the foldover of the first sub-element 16 has been inserted into the edge region 40 of the second sub-element 18 that has been provided with a foldover 42 and bent in the form of a groove from the plane of extension of the other sub-element 18.

[0398] FIGS. 29a and 29b show joining steps for production of a snaplock seam connection 87. In a snaplock seam connection 87, hook elements 88 on the edge regions 36, 40 of the sub-elements 16, 18 engage with one another and prevent pulling-apart. More particularly, the hook elements 88 engage with one another in the joining operation.

[0399] FIGS. 30a-30c show different steps for production of what is called a

[0400] Pittsburgh lock connection 90, where the second sub-element 18 has merely an angled edge region 40 and the foldover 38 of the first sub-element 16 is extended at one end. The extended end is bent over after insertion of the edge region 40.

[0401] FIGS. 31a and 31b show the steps for joining and production of a corner connection 94 with a flat lock seam 86.

[0402] FIGS. 32a and 32b show a flange connection 20 in a modification of the seam connection 20 shown in FIG. 3, where the first sub-element 16 in the form of a connecting element 44 has a reinforcement fin 96. For instance, a reinforcing element 32 can be integrated into the component 10 by the seam connection. The reinforcing element 32, in the configuration shown in FIGS. 32a and 32b, has a reinforcement fin 96.

[0403] In the joining technique shown in FIGS. 33a and 33b for forming a further embodiment of the flange connection 20 as well, it is possible to integrate a reinforcing element 32. Here, the seam connection as already indicated in FIG. 27 is created. Here, the reinforcing element 32 especially has a projecting flange 98 formed by the edge region 40 of the second sub-element 18 and the foldover of the first sub-element 16 that has been folded around it.

[0404] FIGS. 34a and 34b show the joining of the flange connection 20 according to the working example of FIG. 3.

[0405] FIGS. 35a and 35b show a modification of this configuration, where the connection of the second sub-element 18 and the third sub-element 46 is not made in a mutually aligned manner, but around a corner. For this purpose, the first sub-element 16 that acts as connecting element 44 has an angled design.

[0406] In general, it is possible by the technology described here for folding of sub-elements 16, 18, 46 and for forming of seam connections 20 at the corresponding foldovers 38, 42, 48 to produce seam connections 20 as also known in principle in the field of connection of metal sheets.

[0407] Working examples of component 10 find use especially in vehicles, such as aircraft 12 in particular. The aircraft 12 is especially an airplane or else a helicopter or some other aircraft, for example a flying automobile. In general, the technology proposed here finds use wherever fiber composite elements are to be bonded to one another or to elements made of other materials. This may also be the case in land-based vehicles, for example automobiles. Connections in space vehicles or other components or constituents for space technology may be executed by the technology proposed here.

[0408] The connecting technique proposed here can be used to assemble constituents of an assemblystructure, cabin, floor, function systemof a vehicle or aircraft from sub-elements. Also possible is the connection of constituents of an assembly to constituents of another assembly.

[0409] For example, by the connecting technique proposed here, it is possible to integrate and optionally couple floor constituents, crash elements, brackets, pressure domes and constituents thereof into structural elements, cabin elements or system elements.

[0410] The technology can also be used for cabin installations and the coupling of cabin components.

[0411] Different embodiments of a component 10 with connected fiber composite material sub-elements 16, 18, 46 and a method and device for connecting the sub-elements 16, 18, 46 have been proposed.

[0412] In order to create connections of sub-elements 16, 18 of a component 10 for a vehicle, especially aircraft 12, formed at least partly from fiber composite materials with relatively low manufacturing complexity and equal or improved reliability and improved sealing compared to connections in common use to date for fiber composite components, different seam connections 20 between the sub-elements 16, 18 are proposed here. For this purpose, an edge region 36 of the first sub-element 16 that has been formed from fiber composite material is formed to give a foldover 38 that encompasses an edge region 40 of the other sub-element 18. Preferably, the forming, especially in the case of use of thermoplastic materials, is effected with heating, preferably of the entire edge region 36.

[0413] 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.

LIST OF REFERENCE NUMERALS

[0414] 10 component [0415] 11 fuselage segment [0416] 12 aircraft [0417] 14 connection site [0418] 16 first sub-element [0419] 18 second sub-element [0420] 20 seam connection [0421] 22 longitudinal connection [0422] 23 skin element [0423] 24 structure component [0424] 26 fuselage [0425] 28 connections extending in circumferential direction [0426] 30 cabin component [0427] 32 reinforcing element [0428] 34 fluid conduit [0429] 36 edge region (first sub-element) [0430] 38 foldover (first sub-element) [0431] 40 edge region (second sub-element) [0432] 42 foldover (second sub-element) [0433] 44 connecting element [0434] 45 cap strip seam [0435] 46 third sub-element [0436] 48 foldover (third sub-element) [0437] 50 edge region (third sub-element) [0438] 51 apparatus [0439] 52 heating device [0440] 54 rest [0441] 56 edge [0442] 58 insert [0443] 59 forming preparation device [0444] 60 bending device [0445] 62 holding device [0446] 64 seam connection device [0447] 66 holding jaw [0448] 68 compression element [0449] 70 consolidation device [0450] 72 closed mold [0451] 74 compression device [0452] 76 first compression jaw [0453] 78 second compression jaw [0454] 80 filler material [0455] 82 angle region [0456] 84 standing seam [0457] 86 flat lock seam [0458] 87 snaplock seam connection [0459] 88 hook element [0460] 90 Pittsburgh lock connection [0461] 92 additional bend [0462] 94 corner connection [0463] 96 reinforcement fin [0464] 98 projecting flange