Tooling and process for variability reduction of composite structures

Abstract

Variability between composite structures can be reduced by utilizing forming and curing tooling that includes a cure tool and a preform tool. The cure tool has a curing surface. The curing surface defines the shape of a cured composite structure. The preform tool has a preform surface that is divided into at least first and second surface area portions. The first surface area portion is of the same surface shape to the corresponding surface area of the curing surface on the cure tool. The second surface portion is of a surface shape that is different from the surface shape of the corresponding surface area of the curing surface on the cure tool. The differences between the second surface area portion of the preform surface and its complementary surface on the curing surface is such that there is an increase in the surface area of the second surface area portion of the preform surface compared to a corresponding area on the curing surface of the cure tool. Because of these differences, when a preform structure is formed on the preform tool, additional uncured preform material is located at the area defined by the second surface area of the preform tool. Upon curing of the preform structure in the cure tool, this additional material is transferred to adjacent radii resulting in reduction of porosity, bridging, excess resin richness and delamination at the radii.

Dependencies are inferred from the claim text.