# US 10,864,658 B2 · Mold with integral driver blocks > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,864,658 B2 - Document ID: US10864658B2 - Status: Granted - Kind: B2 - Application number: 15/042,972 - Filed: 2016-02-12 - Published: 2017-08-17 - Granted: 2020-12-15 - Earliest claimed: 2016-02-12 - Assignees: Rohr, Inc. - Applicants: Rohr, Inc. - Inventors: Michael Fiegl; Craig Robinson; Shawn Canela - Web page: https://patentgrep.com/patent/US10864658B2 ## CPC - B29C 33/12: with incorporated means for positioning inserts, e.g. labels {(positioning reinforcements B29C70/541)} - B29C 70/48: and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM] {, e.g. by vacuum} - B29D 99/0028: {hollow blades} - B64F 5/10: Manufacturing or assembling aircraft, e.g. jigs therefor - B29K 2307/04: Carbon - B29L 2031/3076: {Aircrafts (blades, propellers B29L2031/08)} - B29L 2031/3085: {Wings} - B64C 3/24: Moulded or cast structures - B64C 5/00: Stabilising surfaces - B64C 9/00: Adjustable control surfaces or members, e.g. rudders (trimming stabilising surfaces B64C5/10) - B64C 2001/0072: {from composite materials} - Y02T 50/40: Weight reduction - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00) - B64F: GROUND OR AIRCRAFT-CARRIER-DECK INSTALLATIONS SPECIALLY ADAPTED FOR USE IN CONNECTION WITH AIRCRAFT; DESIGNING, MANUFACTURING, ASSEMBLING, CLEANING, MAINTAINING OR REPAIRING AIRCRAFT, NOT OTHERWISE PROVIDED FOR; HANDLING, TRANSPORTING, TESTING OR INSPECTING AIRCRAFT COMPONENTS, NOT OTHERWISE PROVIDED FOR - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES - B64C: AEROPLANES; HELICOPTERS - Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION ## Abstract Aspects of the disclosure are directed to a toolset configured to fabricate a component of an aircraft, the toolset comprising: a mold base configured to seat at least one mandrel, a mold lid configured to be coupled to the mold base, and at least one driver block that is integral with the mold lid and projects from an interior surface of the mold lid. ## Claims ### Claim 1 A method for fabricating a component using a composite material, the method comprising: laying-up mandrels and skins in a mold base and a mold lid, wherein the mold base comprises a first mold base side surface, a second mold base side surface and a depression into the mold base formed laterally between the first mold base side surface and the second mold base side surface; assembling a mold by assembling the mandrels into the mold base and installing the mold lid onto the mold base, the assembled mold including at least one driver block that is integral with the mold lid such that the at least one driver block and the mold lid are configured as a single unitary body, wherein the at least one driver block projects vertically away from an interior surface of the mold lid, wherein the at least one driver block has a width that decreases as the at least one driver block projects from the interior surface of the mold lid towards a distal end of the at least one driver block, wherein a portion of a first of the mandrels is seated in the depression such that the portion of the first of the mandrels is laterally abutted against the first mold base side surface, wherein the at least one driver block projects vertically into the depression such that the at least one driver block is laterally between and laterally contacts the portion of the first of the mandrels and the second mold base side surface; closing the mold and placing the mold into a press; drawing a vacuum and injecting resin; curing the component at a curing temperature; removing the mold from the press; and removing the lid, with the at least one integral driver block, from the mold base, thereby automatically extracting the at least one driver block from the mold base. ### Claim 2 (depends on 1) The method of claim 1, wherein the lid is removed when the at least one driver block is at an elevated temperature. ### Claim 3 (depends on 1) The method of claim 1, wherein the composite material includes a carbon pre-preg material. ### Claim 4 (depends on 1) The method of claim 1, wherein the component includes at least a portion of a stabilizer of an aircraft. ### Claim 5 (depends on 1) The method of claim 1, wherein the component comprises at least a portion of a stabilator or an aircraft. ### Claim 6 (depends on 1) The method of claim 1, wherein the mold base includes a hard stop configured to prevent the first of the mandrels from being inserted into the mold base in an amount greater than a threshold. ### Claim 7 (depends on 6) The method of claim 6, wherein the hard stop is configured as an elevated portion of the mold base relative to a floor of the mold base. ### Claim 8 (depends on 1) The method of claim 1, wherein the at least one driver block is configured to locate at least one of the mandrels in the mold base in terms of at least two reference directions. ### Claim 9 (depends on 1) The method of claim 1, wherein the mold base includes a guide configured to couple the mold base and the mold lid. ### Claim 10 (depends on 1) The method of claim 1, wherein the at least one driver block includes a plurality of driver blocks. ### Claim 11 (depends on 1) The method of claim 1, wherein the component is configured as at least a portion of a control structure, an airfoil or a wing of an aircraft. ### Claim 12 (depends on 1) The method of claim 1, wherein the component comprises a first skin formed by the mold lid and a second skin formed by the mold base. ### Claim 13 (depends on 12) The method of claim 12, wherein the component comprises a spar formed by and between a pair of the mandrels. ### Claim 14 (depends on 1) The method of claim 1, wherein the at least one driver block includes a double angle and the first of the mandrels includes a matching angle to prevent a mold lock condition. ### Claim 15 (depends on 1) The method of claim 1, wherein the at least one driver block is configured to force and hold the composite material to a predetermined dimension during a curing of the component. ### Claim 16 (depends on 1) The method of claim 1, further comprising removing the mandrels from the component after the curing of the component. ### Claim 17 A method for fabricating a component using a composite material, the method comprising: laying-up mandrels and skins in a mold base and a mold lid, wherein the mold base comprises a first mold base side surface, a second mold base side surface and a depression into the mold base formed laterally between the first mold base side surface and the second mold base side surface; assembling a mold by assembling the mandrels into the mold base and installing the mold lid onto the mold base, the assembled mold including a tapered driver block that is integral with the mold lid such that the tapered driver block and the mold lid are configured as a single unitary body, wherein a portion of a first of the mandrels is seated in the depression, wherein the tapered driver block projects vertically into the depression such that (a) the tapered driver block is positioned laterally between and laterally contacts the portion of the first of the mandrels and the second mold base side surface and (b) the tapered driver block is configured to push the portion of the first of the mandrels laterally against the first mold base side surface; closing the mold and placing the mold into a press; drawing a vacuum and injecting resin; curing the component at a curing temperature; removing the mold from the press; and removing the lid, with the tapered driver block, from the mold base, thereby automatically extracting the tapered driver block from the mold base. ### Claim 18 (depends on 17) The method of claim 17, wherein the tapered driver block is configured to push the mandrels laterally together in order to apply lateral pressure to material located laterally between the mandrels. ### Claim 19 (depends on 1) The method of claim 1, wherein the width decreases as the at least one driver block projects from the interior surface of the mold lid to the distal end of the at least one driver block. ### Claim 20 (depends on 1) The method of claim 1, wherein the at least one driver block is configured to push the mandrels laterally together in order to apply lateral pressure to material located laterally between the mandrels.