Method for making a fiber reinforced composite rivet having an upset head

Abstract

A method for making a composite rivet and upsetting the composite rivet after the rivet has been inserted through (e.g., composite) structural members to be held together. The rivet includes a core having continuous and unidirectionally extending fibers that are reinforced by a thermoplastic resin. The core is surrounded by a braided jacket having fibers arranged in a criss-cross weave. A forming die guide having a containment opening extending therethrough is positioned so that the upstanding end of the composite rivet is received within the containment opening. A heated forming die having a forming cavity is moved into the containment opening of the forming die guide so as to lie in axial alignment with the upstanding end of the rivet. A ram forces the heated forming die through the containment opening so that the upstanding end of the rivet is softened and upset within the forming cavity. The ability of the upstanding end of the rivet to spread out under the heat and pressure generated by the heated forming die is limited by the containment opening of the forming die guide.

1 - 10 . (canceled)  
     
     
         11 . A method for making a composite rivet having an enlarged rivet head at one end and an upset head at the opposite end for holding structural members together, said method comprising the steps of: 
 providing a rivet preform including a composite core having a plurality of unidirectional fibers running continuously therethrough;    locating said rivet preform in an insert having a forming cavity such that a first end of said rivet preform projects into said forming cavity;    heating said insert and said rivet preform located therein;    applying pressure to the first end of said heated rivet preform for softening and shaping said first end within the forming cavity of said insert to form said enlarged rivet head;    cooling said rivet preform to produce said composite rivet with said enlarged rivet head having a shape corresponding to the shape of the forming cavity of said insert and then removing said composite rivet from said insert;    inserting said composite rivet through the structural members to be held together such that the enlarged rivet head of said composite rivet lies at one side of the structural members and the upstanding end of said composite rivet opposite the enlarged rivet head projects outwardly from the structural members to the opposite side thereof; and    forming said upset head by applying heat and pressure to the upstanding end of said composite rivet.    
     
     
         12 . The method for making recited in  claim 11 , including the additional step of surrounding the composite core of said rivet preform with a braided jacket comprising fibers arranged in a criss-cross weave.  
     
     
         13 . The method for making recited in  claim 11 , including the additional steps of locating a forming die within the forming cavity of said insert so as to lie in axial alignment with the first end of said heated rivet preform; and moving said forming die into contact with said first end for applying said pressure to said first end for softening and shaping said first end within the forming cavity of said insert.  
     
     
         14 . The method for making recited in  claim 13 , including the additional step of heating said forming die before the step of moving said forming die into contact with the first end of said heated rivet preform for applying said pressure thereto.  
     
     
         15 . The method for making recited in  claim 14 , including the additional steps of positioning said heated insert, said heated rivet preform located in said insert, and said heated forming die located within the forming cavity of said insert within a preheated mold base of a press; and closing said press against said heated forming die for moving said heated forming die into contact with the first end of said heated rivet preform for applying said pressure thereto.  
     
     
         16 . The method for making recited in  claim 11 , wherein said step of forming said upset head includes the additional steps of: 
 locating an upsetting die guide having a containment opening extending therethrough so that the upstanding end of the composite rivet is received in said containment opening;    moving an upsetting die having an upsetting cavity into the containment opening of said upsetting die guide for applying said pressure to the upstanding end of the composite rivet;    softening and shaping the upstanding end of the composite rivet within the upsetting cavity of said upsetting die; and    cooling the upstanding end of the composite rivet to form said upset head having a shape corresponding to the shape of said upsetting cavity.    
     
     
         17 . The method for making recited in  claim 16 , wherein said step of forming said upset head by applying heat to the upstanding end of said composite rivet includes heating said upsetting die for softening and shaping said upstanding end within the upsetting cavity of said upsetting die.  
     
     
         18 . The method for making recited in  claim 17 , including the additional steps of coupling a ram to said heated upsetting die; and moving said ram toward said upsetting die guide for forcing said heated upsetting die against the upstanding end of the composite rivet and thereby applying said pressure to said upstanding end when said upstanding end is softened and shaped within the upsetting cavity of said heated upsetting die.  
     
     
         19 . The method for making recited in  claim 16 , including the additional step of forming an indentation within the upset head of the composite rivet.  
     
     
         20 . The method for making recited in  claim 19 , including the additional step of forming said indentation within said upset head when said upsetting die is moved into the containment opening of said upsetting die guide by means of a tip carried by said upsetting die and projecting from within said upsetting cavity thereof.  
     
     
         21 . The method for making recited in  claim 11 , wherein the step of forming said upset head includes the additional steps of: 
 positioning a forming die guide having a containment opening extending therethrough such that the upstanding end of the composite rivet is located in said containment opening;    heating a forming die having a forming cavity at one end thereof and a tip projecting from said forming cavity;    moving said heated forming die towards said forming die guide such that the upstanding end of the fiber-reinforced composite rivet is received within the forming cavity of said heated forming die at the containment opening of said forming die guide so as to soften the upstanding end of the fiber-reinforced composite rivet within said forming cavity and prevent the softened end from spreading outside the containment opening of said forming die guide, the tip projecting from said forming cavity making an indentation in the softened rivet end for controlling the direction of the continuous fibers with which the rivet is reinforced; and    cooling the upstanding end of the fiber-reinforced composite rivet to form said upset head having a shape corresponding to the shape of said forming cavity where the continuous fibers flow around the indentation and into the upset head to maximize the strength of the composite rivet and said upset head thereof.    
     
     
         22 . The method for upsetting a composite rivet recited in  claim 21 , including the additional step of heating said forming die in a furnace for softening the upstanding end of the fiber-reinforced composite rivet within the forming cavity of said forming die.  
     
     
         23 . The method for upsetting a composite rivet recited in  claim 21 , including the additional step of applying pressure to said forming die when the upstanding end of the fiber-reinforced composite rivet is softened within the forming cavity of said forming die.  
     
     
         24 . The method for upsetting a composite rivet recited in  claim 23 , including the additional steps of coupling a ram to said forming die; and moving said ram towards said forming die guide so as to force said forming die against the upstanding end of the fiber-reinforced composite rivet for applying said pressure to said forming die when the upstanding end of the composite rivet is softened within the forming cavity of said forming die.  
     
     
         25 . The method for upsetting a composite rivet recited in  claim 24 , including the additional step of coupling said ram to said forming die by way of a guide pin projecting outwardly from said ram for receipt by said forming die.