System and method of forming structural assemblies with 3-D woven joint pre-forms

DETAILED DESCRIPTION The present invention provides a co-bonded structural assembly for composite materials that substantially eliminates or reduces disadvantages and problems associated with previously developed systems and methods used for bonding composite materials.
More specifically, the present invention provides a system and method of forming structural assemblies with 3-D woven joint pre-forms.
The method of the present invention forms complex structural assemblies using pre-cured detail parts with the 3-D woven joint pre-form.
Adhesive is applied between the preformed structures and uncured 3-D woven textile pre-forms.
Then together the pre-cured structures and uncured resin impregnated 3-D woven textile are cured with heat and/or pressure to form the larger complex structural assemblies.
The present invention provides an important technical advantage over prior systems and methods of forming complex composite structures.
The present invention provides a robust joint between two pre-cured composites or metallic sub-assemblies.
By simultaneously co-bonding sub-assemblies to 3-D woven textile pre-forms structural strength is increased.
Additionally, the present invention provides another important technical advantage by eliminating the need for expensive tooling and fine tolerances to achieve uniform bondlines critical for structural performance.
Yet another technical advantage provided by the present invention is that pressure intensifiers or overpresses used can be inexpensively manufactured as an exact fit is not required as is needed by conventional bonding or co-curing.
Additionally, the present invention provides another important technical advantage by forcing uncured 3-D pre-forms to conform to the sub-assemblies or pre-cured details.
This allows the flexible uncured 3-D woven textile pre-forms to be forced against adjacent sub-assemblies thus conforming to severe contours and angles.
Yet another technical advantage provided by the present invention is that the 3-D woven textile pre-forms provide a structural strength that cannot be matched with a conventional 2-D textile composite material joints