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US 2012/0258276 A1Published application
Method and apparatus for making contoured composite stiffeners
AssigneeThe Boeing Company
InventorANDREW E. MODIN
Life of this patent
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Abstract
A contoured composite part is made by assembling a preform charge, including aligning a plurality of plies along a preselected contour. The assembled aligned preform charge is then placed in a forming tool, where the charge is formed and cured.
Claims25
A method of making a contoured composite part, comprising:
- assembling a charge, including aligning a plurality of plies along a preselected contour;
- transferring the assembled aligned charge to a forming tool;
- forming the charge on the forming tool;
- and
- curing the formed charge.
2 more elements
A method of making a composite structural member having a web and at least one flange, comprising:
- assembling a multi-ply charge having at least one fiber reinforcement;
- clamping a first web portion of the charge in a tool;
- forming a second flange portion of the charge while the first web portion is clamped in the tool;
- and
- curing the formed charge.
2 more elements
Apparatus for making a composite structural member having at least one contour, comprising:
- an assembly tool for assembling a plurality of plies forming a charge;
- and
- a forming tool for forming the charge, the forming tool including a pair of relatively movable mandrels between which the assembled charge may be clamped.
Apparatus for making a composite member having a web with a compound contour and at least one flange, comprising:
- an assembly tool for pre-aligning a charge along a first contour;
- and
- a forming tool including a base and a pair of contoured mandrels on the base between which a web portion of the charge may be clamped and formed along a second contour.
A method of making a compound contoured composite blade stringer for aircraft, comprising:
- placing a resin distribution media on an assembly tool;
- placing a flat braided fiber preform on the assembly tool covering the resin distribution media to form a pre-form charge;
- aligning the resin distribution media and the preform charge relative to each other and along an alignment guide having a first contour;
- placing a blade height spacer over the pre-form charge;
- clamping a flange portion of the charge to maintain the alignment of the charge, including using the blade height spacer to control the placement of clamps on the charge;
- installing an inner vacuum bag over a forming tool;
- transferring the clamped charge to the forming tool;
- clamping a web portion of the charge in the forming tool, including inflating a bladder and using the inflation of the bladder to move a pair of mandrels into clamping engagement with the charge;
- removing the clamps from the flange portion of the charge while the web portion of the charge is clamped between the mandrels;
- forming a pair of stringer flanges by folding the flange portion of the charge down onto the mandrels;
- folding the inner bag back over the formed charge;
- placing an outer bag of the inner bag covering the charge;
- sealing the inner and outer bags;
- applying first and second vacuums respectively to the inner and outer bags;
- infusing the fiber preform with resin by introducing resin into the inner bag;
- curing the resin infused fiber preform on the forming tool;
- and
- removing the cured stringer from the forming tool following curing.
15 more elements
Apparatus for making a compound contoured composite stringer for aircraft having a web and a flange, comprising:
- an alignment and assembly tool, including—
- a flat surface on which a flat charge may be placed,
- an alignment fence having a first contour corresponding to one of the contours of the stringer and against which the charge may be aligned,
- a web height spacer for establishing the height of the stringer web;
- a plurality of clamps for clamping the charge and adapted to abut the web height spacer;
- a forming and cure tool, including—
- a tool base having a first contour which largely matches the contour of the alignment fence on the assembly tool, the tool base including an assembly of a base plate and spaced apart curved blocks,
- a pair of mandrels relatively slideable on the tool base toward and away from each other, the mandrels including a first set of opposing surfaces having a second contour for clamping a web portion of the charge therebetween, the mandrels further including a second set of tool surfaces onto which a flange portion of the charge may be formed;
- a first inner bag covering the formed charge;
- a second bag covering the charge and the first bag;
- first and second seals for sealing the first and second bags to the forming and cure tool;
- a resin infusion inlet for allowing resin to flow into the charge within the first bag;
- and
- at least one resin outlet for allowing resin to escape from the charge.
11 more elements
Dependencies are inferred from the claim text.