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US 9,039,858 B2Granted
Composite strip
AssigneeThe Boeing Company
InventorsKenneth M. Dull, William H. Ingram
Life of this patent
Estimating the term…
Abstract
A composite strip and a method of manufacturing a pre-cured composite strip. A pre-cured composite strip having a thermoset resin may be placed on a surface of a portion of a composite component where a caul plate seam may be expected. Caul plates may be placed on the composite component after placing the pre-cured composite strip to form the caul plate seam. The composite component may be cured after placing the caul plates on the composite component.
Claims18
A method of manufacturing a pre-cured composite strip for use with a composite part, the method comprising:
- laying up a composite strip comprising a set of fibers and a thermoset resin on a base plate, the composite strip characterized by a longitudinal axis, the set of fibers oriented substantially perpendicular to the longitudinal axis;
- curing the composite strip on the base plate to form the pre-cured composite strip, the thermoset resin configured not to melt or soften after curing;
- applying the pre-cured composite strip to a surface comprising a fiber reinforced composite material of the composite part, wherein the pre-cured composite strip has a width and a length and wherein the pre-cured composite strip has a thickness that tapers towards opposing edges of the width of the pre-cured composite strip;
- and
- placing a first caul plate and a second caul plate over the composite material and the composite strip, the first caul plate and the second caul plate defining a seam that overlies the composite strip.
2 more elements
A method of applying a pre-cured composite strip for use with a composite part, the method comprising:
- placing a first peel ply layer on a base plate;
- placing a first composite fabric layer on the first peel ply layer, the first composite fabric layer comprising a fiber material and a thermoset resin;
- placing a tape layer on the first composite fabric layer, the tape layer comprising a plurality of unidirectional fibers and the thermoset resin, the tape layer characterized by a longitudinal axis, the plurality of unidirectional fibers oriented substantially perpendicular with respect to the longitudinal axis;
- placing a second composite fabric layer on the tape layer, the second composite fabric layer comprising a fiber material and the thermoset resin;
- and
- curing the first composite fabric layer, the tape layer, and the second composite fabric layer to form the pre-cured composite strip, the thermoset resin in the first composite fabric layer, the tape layer, and the second composite fabric layer configured not to melt or soften after curing;
- placing the pre-cured composite strip on a surface comprising a fiber reinforced composite material of the composite part;
- bonding the pre-cured composite strip onto the surface of the composite part with an adhesive;
- placing a first caul plate and a second caul plate over the surface of the composite part such that a seam between the first caul plate and the second caul plate overlies the pre-cured composite strip;
- and
- curing the composite part.
8 more elements
A method of manufacturing a pre-cured composite strip for a composite part, the pre-cured composite strip oriented with respect to a longitudinal axis of a composite part, the method comprising:
- placing a first peel ply layer on a base plate;
- placing a first composite fabric layer on the first peel ply layer, the first composite fabric layer comprising a fiber material and a thermoset resin;
- placing a tape layer on the first composite fabric layer, the tape layer comprising a plurality of unidirectional fibers and the thermoset resin;
- placing a second composite fabric layer on the tape layer, the second composite fabric layer comprising a fiber material and the thermoset resin;
- curing the first composite fabric layer, the tape layer, and the second composite fabric layer to form the pre-cured composite strip, the thermoset resin in the first composite fabric layer, the tape layer, and the second composite fabric layer configured not to melt or soften after curing;
- removing the first peel ply layer so as to expose a surface of the first composite fabric layer;
- placing an adhesive on the surface of the first composite fabric layer;
- bonding the surface of the first composite fabric layer with the adhesive to a surface comprising a fiber reinforced composite material of the composite part, the composite part characterized by a longitudinal axis, the composite strip positioned such that the plurality of unidirectional fibers in the tape layer are oriented substantially perpendicular with respect to the longitudinal axis of the composite part, the composite part comprising a fiber reinforced with resin composite material;
- and
- placing a first caul plate and a second caul plate over the composite material and the composite strip, the first caul plate and the second caul plate defining a seam that overlies the composite strip.
7 more elements
Dependencies are inferred from the claim text.