Patent Application
20230311431
The present disclosure is generally related to manufacturing composite structures and, more particularly, to methods for configurating a shape of a tool and associated systems and methods for manufacturing composite structures.
Manufacturing composite structures typically includes draping composite material over a tool or mandrel prior to curing to a shape. Existing materials used for morphable tools and mandrels are limited in that they do not have the ability of being both rigid and completely vacuum tight. Existing tools that can morph contours are typically made from soft and flexible materials. Further, existing morphable molds that are rigid typically have slits or cuts on their surface to allow for flexibility of the part along the length, and thus are not vacuum tight.
Accordingly, those skilled in the art continue with research and development efforts in the field of improving methods and systems for manufacturing composite structures.
The following is a non-exhaustive list of examples, which may or may not be claimed, of the subject matter according to the present disclosure.
Disclosed are methods for configuring a shape of a tool from an initial shape to a reconfigured shape.
In an example, the method includes localized heating a portion of the tool to yield a heated portion of the tool and mechanically manipulating the heated portion of the tool to achieve the reconfigured shape.
Also disclosed are methods for manufacturing a composite structure.
In an example, the method includes localized heating a portion of a tool to yield a heated portion of the tool, mechanically manipulating the heated portion of the tool to change a shape of the tool from an initial shape to a reconfigured shape, and positioning composite material on an outside surface of the tool to yield a composite layup.
Other examples of the disclosed systems, apparatuses, and methods will become apparent from the following detailed description, the accompanying drawings, and the appended claims
The following detailed description refers to the accompanying drawings, which illustrate specific examples described by the present disclosure. Other examples having different structures and operations do not depart from the scope of the present disclosure. Like reference numerals may refer to the same feature, element, or component in the different drawings.
Illustrative, non-exhaustive examples, which may be, but are not necessarily, claimed, of the subject matter according to the present disclosure are provided below. Reference herein to “example” means that one or more feature, structure, element, component, characteristic, and/or operational step described in connection with the example is included in at least one aspect, embodiment, and/or implementation of the subject matter according to the present disclosure. Thus, the phrases “an example,” “another example,” “one or more examples,” and similar language throughout the present disclosure may, but do not necessarily, refer to the same example. Further, the subject matter characterizing any one example may, but does not necessarily, include the subject matter characterizing any other example. Moreover, the subject matter characterizing any one example may be, but is not necessarily, combined with the subject matter characterizing any other example.
Referring to
The tool 200 may include any material having requisite material properties for maintaining desired vacuum draw against the tool 200, as well as ability to reconfigure to a desired shape. In one example, the tool 200 includes a thermoset material. In another example, the tool 200 includes a composite material. In another example, the tool 200 comprises a material that is rigid at temperatures below about 150° F. and is flexible at temperatures at and above about 150° F. In yet another example, the tool 200 is impermeable to air. For example, the tool 200 may be a single, monolithic structure such that the entire surface area of the tool 200 is planar and does not include any discontinuities, thus it is impermeable to air.
The tool 200 may have any shape or configuration for the desired composite structure. In one example, the tool 200 is in the shape of an aerospace component. In another example, the tool 200 is in the shape of a stringer.
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The localized heating 120 may include heating less than 100 percent of a total volume of the tool 200. In one example, the localized heating 120 includes heating less than 50 percent of a total volume of the tool 200. In another example, the localized heating 120 includes heating less than 25 percent of a total volume of the tool 200. In another example, the localized heating 120 includes heating less than 15 percent of a total volume of the tool 200.
The localized heating 120 may include heating with a shaping machine 210, see
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The mechanically manipulating 130 may be automated and may be achieved via any suitable means of reconfiguring the shape of the tool 200. In one example, the mechanically manipulating 130 includes gripping the heated portion 220 of the tool. In another example, the mechanically manipulating 130 includes expanding the heated portion 220 of the tool. In yet another example, the mechanically manipulating 130 includes suctioning the heated portion 220 of the tool. The method 100 may further include coupling 140 a composite ply 252, i.e. uncured composite material, with the tool 200 or a previously laid ply on the tool 200 to yield a composite layup 250.
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The composite layup 250 includes at least one ply of composite material (e.g., a composite ply 252) placed on (e.g., over) the tool 200 or on a previously laid ply on the tool 200. The composite layup 250 can include any number (e.g., one or more) of composite plies. The composite material includes a reinforcement material embedded in a polymeric matrix material. In one or more examples, the composite material is pre-impregnated (“pre-preg”) thermoset composite material.
The tool 200 may include any material having requisite material properties. In one example, the tool 200 includes a thermoset material. In another example, the tool 200 includes a composite material. In another example, the tool 200 comprises a material that is rigid at temperatures below about 150° F. and is flexible at temperatures at and above about 150° F. In yet another example, the tool 200 is impermeable to air. For example, the tool 200 may be a single, monolithic structure such that the entire surface area of the tool 200 is planar and does not include any discontinuities, thus it is impermeable to air.
The tool 200 may have any shape or configuration for the desired composite structure. In one example, the tool 200 is in the shape of an aerospace component. In another example, the tool 200 is in the shape of a stringer.
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Each automated shaping member 212′ of the plurality of automated shaping members 212 includes a shaping feature 216′. Each shaping feature 216′ of a plurality of shaping features 216 may be movable about more or more of the longitudinal axis 230, the vertical axis 232, and the traverse axis 234. Further, each shaping feature 216′ of the plurality of shaping features 216 may be rotatable about one or more of the longitudinal axis 230, the vertical axis 232, and the traverse axis 234.
Referring to
Examples of the present disclosure may be described in the context of aircraft manufacturing and service method 1100 as shown in
Each of the processes of service method 1100 may be performed or carried out by a system integrator, a third party, and/or an operator (e.g., a customer). For the purposes of this description, a system integrator may include, without limitation, any number of aircraft manufacturers and major-system subcontractors; a third party may include, without limitation, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, and so on.
As shown in
System(s) and method(s) shown or described herein may be employed during any one or more of the stages of the manufacturing and service method 1100. For example, components or subassemblies corresponding to component and subassembly manufacturing (block 1108) may be fabricated or manufactured in a manner similar to components or subassemblies produced while aircraft 1102 is in service (Block 1114). Also, one or more examples of the system(s) and method(s), or combination thereof may be utilized during production stages component and subassembly manufacturing (Block 1108) and system integration (Block 1110), for example, by substantially expediting assembly of or reducing the cost of aircraft 1102. Similarly, one or more examples of the system or method realizations, or a combination thereof, may be utilized, for example and without limitation, while aircraft 1102 is in service (Block 1114) and/or during maintenance and service (Block 1116).
Different examples of the system(s) and method(s) disclosed herein include a variety of components, features, and functionalities. It should be understood that the various examples of the system(s) and method(s) disclosed herein may include any of the components, features, and functionalities of any of the other examples of the system(s) and method(s) disclosed herein in any combination, and all of such possibilities are intended to be within the scope of the present disclosure.
Many modifications of examples set forth herein will come to mind to one skilled in the art to which the present disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings.
Therefore, it is to be understood that the present disclosure is not to be limited to the specific examples illustrated and that modifications and other examples are intended to be included within the scope of the appended claims. Moreover, although the foregoing description and the associated drawings describe examples of the present disclosure in the context of certain illustrative combinations of elements and/or functions, it should be appreciated that different combinations of elements and/or functions may be provided by alternative implementations without departing from the scope of the appended claims. Accordingly, parenthetical reference numerals in the appended claims are presented for illustrative purposes only and are not intended to limit the scope of the claimed subject matter to the specific examples provided in the present disclosure.
