Methods And Systems For Forming Reinforced Composite Articles Having Variable Thickness Corners
AssigneeFiberforge Corporation
InventorDustin Louis Dequine
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Abstract
A method for making parts with variable thickness corners and parts with variable thickness corners are disclosed. The method includes laying up multiple plies to form a tailored blank, associating the blank with a convex and concave die, and applying pressure and heat so that material from at least one of the plies migrates towards a voided corner area formed between the dies.
Claims28
A method for manufacturing a composite part from a blank having a first ply oriented in a first direction and a second ply oriented in a second direction transverse to the first direction, the method comprising:
- positioning the blank between a convex die and a concave die, with the first ply oriented generally parallel to a longitudinal direction in which a corner of the concave die extends, and with the second ply oriented generally transverse to the longitudinal direction in which the corner of the concave die extends;
- and
- pressing the blank between the convex die and concave die such that a portion of the first ply migrates into the corner.
A method for manufacturing a composite part from a blank, having a first ply oriented in a first direction and a second ply oriented in a second direction, wherein the second direction is different from the first direction, the method comprising:
- positioning the blank between a convex die and a concave die, with the second ply oriented generally parallel to a longitudinal direction in which a corner of the concave die extends;
- and
- pressing the blank between the convex die and concave die such that the thickness of a portion of the second ply in the corner increases and the thickness of a portion of the first ply in the corner does not substantially change.
A composite part, comprising:
- a corner associated with the interface of a first adjacent section of the part and a second adjacent section of the part;
- the corner having a first thickness, wherein the first thickness is measured between an interior surface of the corner and an exterior surface of the corner;
- the first adjacent part and the second adjacent part having thicknesses greater than or equal to a second thickness;
- and
- wherein the first thickness is substantially greater than the second thickness.
Dependencies are inferred from the claim text.