Device for ultrasonically consolidating fiber reinforced composite structures
AssigneeFoster-Miller, Inc.
InventorsMargaret E. Roylance, John C. Player, Victor Leemon, Douglas T. Thomson
Life of this patent
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Abstract
A bi-directional device for ultrasonically consolidating a fiber reinforced composite structure including a horn which can be angled relative to the composite structure. The horn includes a tip at the distal end of the horn which terminates in a rounded face. The rounded face of the horn contacts the composite structure enabling the horn to be driven bi-directionally over the composite structure at an angle.
Claims28
A bi-directional device for ultrasonically consolidating a fiber reinforced composite structure, the device comprising:
- a horn which can be angled relative to the composite structure;
- and
- a tip at the distal end of the horn, the tip terminating in a rounded face which contacts the composite structure enabling the horn to be driven bi-directionally over the composite structure at an angle.
The bi-directional device of claim 7 in which the sides converge at an angle of between 10° and 40°.
A method of fabricating a fiber reinforced composite structure, the method comprising:
- assembling a stack of fiber reinforced material plies;
- engaging an ultrasonic horn with a rounded face with a top surface of the upper most ply such that the rounded face contacts the upper most ply;
- orienting the horn at an acute angle with respect to the top surface;
- energizing the horn to induce a shear wave in the plies to heat the plies;
- and
- providing relative motion between the horn and the stack such that the horn can be driven and pulled over the upper most ply to consolidate the plies.
A method of fabricating a fiber reinforced composite structure, the method comprising:
- assembling a stack of fiber reinforced material plies;
- engaging an ultrasonic horn with a tip at the distal end of the horn, the tip terminating in a rounded face which contacts a top surface of the upper most ply, the rounded face enabling the horn to be driven bi-directionally over the top surface of the upper most ply;
- orienting the horn at an acute angle with respect to the top surface;
- energizing the horn to induce a shear wave in the plies to heat the plies;
- and
- driving the horn bi-directionally over the top surface to consolidate the plies.
A method of fabricating a thermosetting matrix fiber reinforced composite structure, the method comprising:
- assembling a stack of fiber reinforced thermosetting resin material plies;
- engaging an ultrasonic horn with a tip at the distal end of the horn, the tip terminating in a rounded face which contacts a top surface of the upper most ply, the rounded face enabling the horn to be driven bi-directionally over the top surface of the upper most ply;
- orienting the horn at an acute angle with respect to the top surface;
- energizing the horn to induce a shear wave in the plies to heat the plies;
- providing relative motion between the horn and the stack such that the horn is driven and pulled over the upper most ply to consolidate the plies, the energy level applied by the horn sufficient to reduce the viscosity of the thermosetting resin to the point where the plies can be debulked but not high enough to fully cross-link the resin so that another ply can be cross-linked to the uppermost ply;
- and
- applying pressure to the plies as the horn moves relative to the plies to debulk the plies.
Dependencies are inferred from the claim text.