Expandable tooling systems and methods
AssigneeThe Boeing Company
InventorsXiaoxi Wang, Gary Georgeson
Life of this patent
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Abstract
Prior to curing a composite workpiece assembly, an expandable element can be inserted into a cavity of the workpiece assembly. The expandable element is configured to expand when a predetermined change is produced in an attribute of the element. The attribute can be a temperature of the element. The element is expanded by producing the predetermined change, and the workpiece assembly is cured while the expanded element is in the cavity, so that the expanded element applies positive pressure to inner surfaces of the cavity during curing. The expanded element can be removed from the cavity after curing. The expanded element can comprise a plurality of expandable pellets.
Claims20
A method of manufacturing a first composite workpiece, the method comprising:
- inserting an unexpanded expandable first element into a cavity of an uncured composite workpiece assembly including at least the first composite workpiece, the unexpanded first element being configured to expand when a predetermined change is produced in an attribute of the unexpanded first element;
- expanding the unexpanded first element by producing the predetermined change in the attribute of the unexpanded first element;
- and
- curing the composite workpiece assembly while the expanded first element is in the cavity.
A method of manufacturing a part including a workpiece, the method comprising:
- positioning an unexpanded expandable first element within a cavity of a workpiece assembly including the workpiece;
- positioning the workpiece assembly within a mold;
- placing the mold against an outer surface of the workpiece assembly;
- and
- applying a positive pressure to an inner surface of the workpiece assembly forming the cavity by heating the unexpanded first element from a first temperature to a second temperature higher than the first temperature to expand the unexpanded first element to produce a predetermined pressure against the inner surface of the workpiece assembly.
A method of manufacturing an aircraft stiffener, the method comprising:
- inserting an unexpanded first element into a cavity of an uncured composite workpiece assembly including the stiffener, the unexpanded first element being configured to expand when heated by a predetermined amount;
- expanding the unexpanded first element by heating the first element by a predetermined amount from a first temperature;
- curing the composite workpiece assembly while the expanded first element is in the cavity;
- and
- removing the expanded first element from the cavity after curing the composite workpiece assembly.
Dependencies are inferred from the claim text.