Method for forming a composite structure
AssigneeAeroTrans
InventorsLarry J. Ashton, Todd H. Ashton
Life of this patent
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Abstract
A method of forming a three-dimensional composite structure. Uncured portions of the composite structure are first assembled between a initially rigid heat-softening inner layer of ABS plastic and a hard outer mold surface. Prior to curing of the composite structure, pressure and heat is applied to the ABS layer to soften the layer. Thereafter, pressure is applied to the side of the ABS layer opposite from the composite structure, thereby to compact the uncured portions of the composite structure against the hard outer mold. Stiffening beams may be incorporated into the composite structure, so as to yield a lightweight, strong composite structure that can be used as a pressure vessel in an aerospace vehicle.
Claims17
A method of forming a composite structure, said method comprising the steps of:
- forming a master plug tool having a finished surface,
- forming an exterior mold means about said master plug tool, said exterior mold means having a reference surface formed common with said finished surface,
- forming an interior mold means formed from a heat softenable material having a first temperature of deformation, said interior mold means having a mold surface shaped to form a portion of the interior surface of said composite structure, and a back surface,
- forming compaction means having an inner surface and an outer surface, the outer surface of said compaction means shaped to operatively engage a portion of the back surface of said interior mold means,
- assembling said compaction means adjacent the back surface of the interior mold means,
- assembling uncured portions of said composite structure adjacent the mold surface of the interior mold means,
- positioning the reference surface of said exterior mold means adjacent the outer surface of said portions of said composite structure,
- applying and maintaining pressure to the back surface of said interior mold means,
- softening the interior mold means by heating said interior mold means to said first temperature of deformation, the softened interior mold means and the composite structure being compacted towards the reference surface by the pressure applied to the back surface of the softened interior mold means by the compaction means,
- heating said composite structure to a second temperature of cure,
- maintaining said composite structure at said second temperature of cure until said structure dimensionally stabilizes,
- relieving the pressure on the back surface of said interior mold means, and
- removing said composite structure from between said interior mold means and said exterior mold means.
A method of forming a composite structure, said method comprising the steps of:
- forming an uncured composite structure between a first mold means and a heat-softenable second mold means,
- applying and maintaining pressure to the heat-softenable second mold means,
- softening the second mold means, the softened second mold means and the composite structure being compacted by said pressure towards said first mold means, and
- allowing the composite structure to cure.
A method of forming a composite structure, said method comprising the steps of:
- forming an uncured composite structure between a heat-softenable interior mold means having a shaped mold surface and an exterior mold means having a facing reference surface,
- applying and maintaining pressure to the back surface of the interior mold means,
- softening the interior mold means by applying heat thereto, the softened interior mold means and the composite structure being compacted towards the reference surface by the pressure applied to the back surface of the softened interior mold means, and
- curing the composite structure by applying heat thereto.
Dependencies are inferred from the claim text.