当前申请(专利权)人地址：
6 Carlton Gardens, LONDON, SW1Y 5AD, United Kingdom
摘要：
A structural assembly and method of fabricating the same, the method comprising: producing a first member 106, using an additive manufacturing process, comprising a bond surface 800 and a plurality of protrusions 802 having a length less than or equal to 2mm (preferably less than or equal to 0.9mm); providing a second member 202 comprising a fibre-reinforced composite material comprising a plurality of fibres embedded in a polymer matrix; while the polymer matrix is in its plastic state, forcing the second member against the bond surface so as to cause the second member to form onto the bond surface and the protrusions; and thereafter causing the polymer matrix to harden, thereby fixing the first member to the bond surface of the second member. Preferably, the method comprises heating the second member to soften the polymer matrix. Preferably, the polymer matrix is a thermoplastic polymer such as polyaryletherketone and the first member comprises a titanium alloy. A layer of a bond compound 806 preferably the same as the polymer matrix may be provided between the second member and the bond surface. The first member is produced by an additive manufacturing process. The first member may be at least part of an aircraft door hinge assembly and the second member at least part of an aircraft door.
权利要求：
CLAIMS
1. ..- A method for fabricating a structural assembly, the method comprising:
producing a first member using an additive manufacturing process, the first member comprising a bond surface and a plurality of protrusions extending from the bond stirface, wherein a length of each of the protrusions from the bond surface is |éss than or equal to 2mm;
providing a second member, the second member comprising a fibre- reinforced composite material, ‘the fibre-reinforced composite material comprising a plurality of elongate fibres embedded in a polymer matrix:
while the polymer matrix is in its plastic state; forcing the second member against the bond surface and the protrusions of the first member so as to cause the second member to form onto the bond surface and the protrusions; and,
thereafter, causing the polymer matrix to harden, thereby fixing the first member to the bond surface of the second member.
2. The method according to claim 1, wherein:
the method further comprises heating the second member so as to cause the polymer matrix to soften;
the step of forcing the second member against the bond surface and the protrusions of the first member is performed during the step of heating; and
the step of causing the polymer matrix to harden comprises cooling the second member.
3. The method according to claim 1 or 2, wherein a length of each of the protrusions from the bond surface is less than or equal to 1mm.
4, The method according to any of claims 1 to 3, wherein the method further comprises, prior to the step of forcing, disposing a layer of a bond
wl.
compound “between the second ‘member and the bond surface and the protrusions of the first member, wherein the bond compound is a polymer.
5. The method according to claim 4, wherein
“ the method further comprises heating the second member and the bond compound. to cause both the polymer matrix and the bond compound to soften; and
the step of forcing the second member against the bond surface and the protrusions of the first member is performed during the step of heating .
6. The method according to claim 4 or 5, wherein the bond compound is the same material as the polymer matrix.
7. The method according to any of claims 1 to 6, wherein:
when the first member is fixed to the second member, the elongate fibres are spaced apart from the protrusions; and
the elongate fibres have lengths of greater than 50mm.
8. The method according to any of claims 1 to 6, wherein:
when the first member is fixed to the second member, at least some of the elongate fibres are positioned in gaps between the protrusions; and
the elongate fibres have iengths of less than or equal to 50mm.
9. The method according to any of claims 1 to 8, wherein the temperature to which the second member is heated is less than a melting point of the first member.
10. The method according to any of claims 1 to 9, wherein the polymer matrix is a thermoplastic polymer.
11. The method according to claim.10, wherein the polymer matrix is a polyaryletherketone.
12. The method according to any of claims 1 to 11, wherein the protrusions are pyramids. *
13. The method according to any of claims 1 to 12, wherein the first member comprises a titanium alloy.
14. A structural assembly comprising:
an additive layer manufactured first member comprising a bond surface and a plurality of protrusions extending from the bond surface, wherein a length of each of the protrusions from the bond surface is less than or equal to 2mm; and
a second member fixed to the bond surface and the protrusions of the first member, the second member comprising a fibre-reinforced composite material, the fibre-reinforced composite material comprising a plurality of elongate fibres embedded in a polymer matrix; wherein
the polymer matrix is moulded against the bond ‘surface and the protrusions.
15. A method according to any one of claims 1 to 13 or a structural assembly according to claim 14, wherein:
the first member is at least a part of an aircraft door hinge assembly; and
the second member is at least a part of an aircraft door.