# US 11,077,630 B1 · Molded laminated structure with negative draft angles and associated methods of manufacturing

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- Number: US 11,077,630 B1
- Document ID: US11077630B1
- Status: Granted
- Kind: B1
- Application number: 16/781,640
- Filed: 2020-02-04
- Published: 2021-08-05
- Granted: 2021-08-03
- Earliest claimed: 2020-02-04
- Assignees: The Boeing Company
- Applicants: The Boeing Company
- Inventors: Jeffrey Wirrick
- Web page: https://patentgrep.com/patent/US11077630B1

## CPC

- B29C 70/545: {Perforating, cutting or machining during or after moulding}
- B64F 5/10: Manufacturing or assembling aircraft, e.g. jigs therefor
- B29C 53/06: Forming folding lines by pressing or scoring
- B29C 53/066: {and joining the sides of the folding line, e.g. "Abkantschweissen"}
- B29C 66/02241: {Cutting, e.g. by using waterjets, or sawing (using heat B29C66/0246; cutting-off or cutting-out a part of a strip-like or sheet-like material, transferring that part and fixing it to an article B29C69/005)}
- B29C 66/7254: {honeycomb structures}
- B29C 69/001: {a shaping technique combined with cutting, e.g. in parts or slices combined with rearranging and joining the cut parts (for reinforced material B29C70/545; B29C49/4278, B29C51/268 take precedence)}
- B29C 70/30: Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C 70/682: {Preformed parts characterised by their structure, e.g. form}
- B29D 99/0003: {Producing profiled members, e.g. beams}
- B32B 1/00: Layered products having a non-planar shape
- B32B 3/12: characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
- B32B 3/30: characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)}
- B32B 5/02: characterised by structural features of a {fibrous or filamentary} layer {(layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02)}
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 27/06: as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08)}
- B32B 27/08: of synthetic resin
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/38: comprising epoxy resins
- B32B 27/42: comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
- B29C 2793/0054: partially cutting through the material
- B29C 2793/0072: combined with rearranging and joining the cut parts
- B29K 2309/08: Glass
- B29L 2031/3076: {Aircrafts (blades, propellers B29L2031/08)}
- B29L 2031/608: {Honeycomb structures}
- B32B 2250/03: 3 layers
- B32B 2260/023: Two or more layers
- B32B 2260/046: Synthetic resin
- B32B 2262/101: Glass fibres
- B32B 2262/106: Carbon fibres, e.g. graphite fibres
- B32B 2305/024: Honeycomb
- B32B 2307/732: Dimensional properties
- B32B 2605/18: Aircraft
- B64C 1/066: {Interior liners}
- B64D 11/003: {Stowage devices for passengers' personal luggage}
- 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)
- 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
- B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- 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
- B64D: EQUIPMENT FOR FITTING IN OR TO AIRCRAFT; FLIGHT SUITS; PARACHUTES; ARRANGEMENT OR MOUNTING OF POWER PLANTS OR PROPULSION TRANSMISSIONS IN AIRCRAFT

## Abstract

Disclosed herein is a molded laminated structure having negative draft angles and methods of manufacturing a molded laminated structure having negative draft angles. A preliminary structure having a first outer layer and a second outer layer is molded with a bend that divides the preliminary structure into two sections with an angle between the two sections of less than 180-degrees. Portions that extends from the sections are at positive draft angles. A groove is formed in the preliminary structure at the bend but not formed in a constant cross-section of the second outer layer. The preliminary structure is folding along the bend to at least partially close the groove and form a molded laminated structure with portions that extend at a negative draft configuration while retaining the second outer layer continuous throughout the molded laminated structure.

## Claims

### Claim 1

A method of manufacturing a molded laminated structure, the method comprising steps of:
molding a preliminary structure, wherein the preliminary structure comprises:
a first outer layer, defining a first outer surface;
a second outer layer, defining a second outer surface, wherein the first outer surface is opposite the second outer surface;
an intermediate portion, comprising a bend that divides the intermediate portion into a first section and a second section, wherein the first section, proximate the bend, is angled relative to the second section, proximate the bend, such that the second outer surface of the first section defines an angle with the second outer surface of the second section that is less than 180-degrees; and
a first portion, extending from the first section at a first positive angle relative to a horizontal plane; and
a second portion, extending from the second section away from the first portion at a second positive angle relative to the horizontal plane, wherein the first portion extends away from the second portion;
machining a groove into the first outer layer that extends across an entirety of the intermediate portion along the bend, wherein the groove is not formed in a constant cross-section of the second outer layer such that the second outer layer is continuous across a constant cross-section of the intermediate portion along the groove;
filling the groove with an adhesive; and
folding the intermediate portion at the bend to at least partially close the groove such that the first portion extends towards the second portion at a first negative draft angle relative to the horizontal plane and the second portion extends towards the first portion at a second negative draft angle relative to the horizontal plane.

### Claim 2 (depends on 1)

The method of claim 1, wherein:
the groove of the preliminary structure has a cross-section, along a plane perpendicular to the bend comprising:
a first wall, extending from the first outer surface and into the first outer layer;
a second wall, opposite the first wall, and extending from the first outer surface and into the first outer layer; and
an exposed section of the second outer layer between the first wall and the second wall; and
the step of folding the intermediate portion at the bend at least partially closes the groove by folding the first wall towards the second wall, and the second wall towards the first wall.

### Claim 3 (depends on 2)

The method of claim 2, wherein:
the exposed section of the second outer layer between the first wall and the second wall is radiused; and
a radius of the exposed section is at least 7 times a thickness of the second outer layer.

### Claim 4 (depends on 3)

The method of claim 3, wherein the radius of the exposed section is no more than 10 times the thickness of the second outer layer.

### Claim 5 (depends on 4)

The method of claim 4, further comprising filling a notch formed in the second outer surface and extending across an entirety of the intermediate portion along the bend with a filler material, wherein the notch is formed in the second outer surface, opposite the exposed section of the second outer layer, during the step of folding the preliminary structure at the bend.

### Claim 6 (depends on 2)

The method of claim 2, wherein:
the exposed section of the second outer layer between the first wall and the second wall is radiused; and
a radius of the exposed section is no more than 10 times a thickness of the second outer layer.

### Claim 7 (depends on 2)

The method of claim 2, further comprising filling a notch formed in the second outer surface and extending across an entirety of the intermediate portion along the bend with a filler material, wherein the notch is formed in the second outer surface, opposite the exposed section of the second outer layer, during the step of folding the preliminary structure at the bend.

### Claim 8 (depends on 1)

The method of claim 1, wherein:
the groove of the preliminary structure has a cross-section, along a plane perpendicular to the bend, that has a first V-shape; and
the step of folding the intermediate portion at the bend at least partially closes the groove such that the cross-section of the groove, after folding the intermediate portion at the bend, has a second V-shape different than the first V-shape.

### Claim 9 (depends on 1)

The method of claim 1, wherein the first outer layer and the second outer layer of the preliminary structure each comprises at least one of a glass-fiber-reinforced polymeric material or a carbon-fiber-reinforced polymeric material.

### Claim 10 (depends on 1)

The method of claim 1, wherein the preliminary structure is symmetrical.

### Claim 11 (depends on 1)

The method of claim 1, further comprising:
machining a second groove into the first outer layer that extends across an entirety of the intermediate portion along the bend, wherein the second groove is not formed in a constant cross-section of the second outer layer such that the second outer layer is continuous across a constant cross-section of the intermediate portion along the second groove;
filling the second groove with the adhesive; and
folding the intermediate portion at the bend to at least partially close the second groove such that the first portion extends towards the second portion at the first negative draft angle relative to the horizontal plane and the second portion extends towards the first portion at the second negative draft angle relative to the horizontal plane.

### Claim 12

A method of manufacturing a molded laminated structure, the method comprising steps of:
molding a preliminary structure, wherein the preliminary structure comprises:
a first outer layer, defining a first outer surface;
a second outer layer, defining a second outer surface, wherein the first outer surface is opposite the second outer surface;
a honeycomb core interposed between the first outer layer and the second outer layer;
an intermediate portion, comprising a bend that divides the intermediate portion into a first section and a second section, wherein the first section, proximate the bend, is angled relative to the second section, proximate the bend, such that the second outer surface of the first section defines an angle with the second outer surface of the second section that is less than 180-degrees;
a first portion extending from the first section at a first positive angle relative to a horizontal plane; and
a second portion extending from the second section, away from the first portion, at a second positive angle relative to the horizontal plane; wherein the first portion extends away from the second portion;
machining a groove into the first outer layer that extends across an entirety of the intermediate portion along the bend, wherein the groove is not formed in a constant cross-section of the second outer layer such that the second outer layer is continuous across a constant cross-section of the intermediate portion along the groove;
filling the groove with an adhesive; and
folding the intermediate portion at the bend to at least partially close the groove such that the first portion extends towards the second portion at a first negative draft angle relative to the horizontal plane and the second portion extends towards the first portion at a second negative draft angle relative to the horizontal plane.

### Claim 13 (depends on 12)

The method of claim 12, wherein:
the groove of the preliminary structure has a cross-section, along a plane perpendicular to the bend, comprising:
a first wall, extending from the first outer surface through the first outer layer and at least partially through the honeycomb core;
a second wall, opposite the first wall, and extending from the first outer surface through the first outer layer and at least partially through the honeycomb core; and
an exposed section of the honeycomb core between the first wall and the second wall; and
the step of folding the intermediate portion at the bend at least partially closes the groove by folding the first wall towards the second wall and the second wall towards the first wall.

### Claim 14 (depends on 13)

The method of claim 13, further comprising filling a notch formed in the second outer surface and extending across an entirety of the intermediate portion along the bend with a filler material, wherein the notch is formed in the second outer surface opposite of the exposed section of the honeycomb core during the step of folding the preliminary structure at the bend.

### Claim 15 (depends on 13)

The method of claim 13, wherein:
the exposed section of the honeycomb core between the first wall and the second wall is radiused; and
a radius of the exposed section is at least 7 times a thickness of the second outer layer.

### Claim 16 (depends on 15)

The method of claim 15, wherein the radius of the exposed section is no more than 10 times the thickness of the second outer layer.

### Claim 17 (depends on 13)

The method of claim 13, wherein:
the exposed section of the honeycomb core between the first wall and the second wall is radiused; and
a radius of the exposed section is no more than 10 times a thickness of the second outer layer.

### Claim 18 (depends on 12)

The method of claim 12, wherein the first outer layer and the second outer layer each comprises a glass-fiber-reinforced polymeric material.

### Claim 19 (depends on 12)

The method of claim 12, wherein the first outer layer and the second outer layer of the preliminary structure each comprises at least one of a glass-fiber-reinforced polymeric material or a carbon-fiber-reinforced polymeric material.

### Claim 20 (depends on 12)

The method of claim 12, further comprising:
machining a second groove into the first outer layer that extends across an entirety of the intermediate portion along the bend, wherein the second groove is not formed in a constant cross-section of the second outer layer such that the second outer layer is continuous across a constant cross-section of the intermediate portion along the second groove;
filling the second groove with the adhesive; and
folding the intermediate portion at the bend to at least partially close the second groove such that the first portion extends towards the second portion at the first negative draft angle relative to the horizontal plane and the second portion extends towards the first portion at the second negative draft angle relative to the horizontal plane.