Aerospace structure methods of manufacturing
AssigneeVenture Aerospace, LLC
InventorsVaughan Lennox Clift, Sasha Mela
Life of this patent
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Abstract
Methods of manufacturing of aerospace structures are disclosed. More specifically, methods of manufacturing relatively lightweight yet strong aerospace structures. In one embodiment, the method includes the addition of a volume of a rigid and flexible polyurethane mixture into a mold to create a composite structure. In one aspect, the method includes the integration of special structures within a larger structure to remove traditionally structurally weak or vulnerable areas.
Claims20
A method of manufacturing a composite structure comprising:
- providing a mold to operate at a minimum internal pressure, the mold comprising at least one fluid conduit;
- lining a mold interior surface with a release agent;
- forming a first epoxy layer over the release agent;
- forming a first epoxy layer over the release agent;
- forming a first non-stretching fiber layer over the epoxy layer, the first non-stretching fiber layer formed in a defined pattern;
- forming a second non-stretching fiber layer, the second non-stretching fiber layer disposed over the first non-stretching fiber layer and comprising a second epoxy layer;
- disposing a first volume of a rigid and flexible polyurethane mixture into the mold;
- closing the mold to form a closed mold;
- adding a second volume of the rigid and flexible polyurethane mixture into the closed mold through the at least one fluid conduit to form a second working structure from the first working structure;
- stabilizing the second working structure;
- and
- opening the closed mold;
- wherein:
- the second working structure is a composite structure.
The method of claim 6, further comprising the step of laying in at least one special structure in contact with the first working structure.
A method of manufacturing a composite structure comprising:
- providing a mold to operate at a minimum internal pressure, the mold comprising at least one fluid conduit;
- lining a mold interior surface with a release agent;
- forming a first epoxy layer over the release agent;
- forming a first epoxy layer over the release agent;
- forming a first non-stretching fiber layer over the epoxy layer, the first non-stretching fiber layer formed in a defined pattern;
- forming a second non-stretching fiber layer, the second non-stretching fiber layer disposed over the first non-stretching fiber layer and comprising a second epoxy layer;
- disposing a first volume of a rigid and flexible polyurethane mixture into the mold, the rigid and flexible polyurethane mixture comprising a greater volume of rigid polyurethane than flexible polyurethane, the rigid polyurethane comprising a glass;
- closing the mold to form a closed mold;
- laying in at least one special structure in contact with the first working structure;
- adding a second volume of the rigid and flexible polyurethane mixture into the closed mold through the at least one fluid conduit to form a second working structure from the first working structure;
- stabilizing the second working structure;
- and
- opening the closed mold;
- wherein:
- the second working structure is a composite structure, the composite structure having a residual compressive stress on an exterior surface;
- and
- the special structure is at least one of a fluid line and an electrical wire.
A method of manufacturing a composite structure comprising:
- providing a mold comprising at least one fluid conduit and a set of mold datums;
- lining a mold interior surface with a first epoxy layer;
- forming a first carbon fiber layer over the first epoxy layer;
- providing a shaped aluminum foam insert, the shaped aluminum foam comprising a set of anchor mechanisms;
- positioning the set of anchor mechanisms to align with at least one mold datum of the set of mold datums;
- connecting the at least one fluid conduit to the shaped aluminum foam insert;
- closing the mold to form a closed mold;
- injecting an expanding foam by way of the at least one fluid conduit into the shaped aluminum foam insert to eject excess epoxy from the shaped aluminum foam to form a second working structure;
- stabilizing the second working structure;
- and
- opening the closed mold;
- wherein:
- the second working structure is a composite structure.
Dependencies are inferred from the claim text.