Formation of complex composite structures using laminate templates
First Claim
Patent Images
1. A method to fabricate a composite structure, comprising:
- providing a laminate template including a first template surface having a bend;
providing a first prepreg layup including a first side and a second side opposing the first side;
securing at least a portion of the first side of the first prepreg layup to the first template surface including the bend to form a laminate template-prepreg, wherein the portion of the first prepreg layup secured to the laminate template substantially adopts the shape of the first template surface;
providing a tool having a second template surface;
providing a second prepreg layup including a first side and a second side opposing the first side;
placing at least a portion of the first side of the second prepreg layup in contact with the second template surface of the tool such that the second prepreg layup substantially adopts the shape of the second template surface of the tool;
positioning the laminate template-prepreg with respect to the second prepreg layup such that at least a portion of the second side of the first prepreg layup contacts the second side of the second prepreg layup, wherein the portion of the first prepreg layup including the bend is offset from the second prepreg layup to define a cavity between the first prepreg layup and the second prepreg layup; and
co-curing the laminate template-prepreg and the second prepreg layup together after said positioning of the laminate template-prepreg to form a composite structure.
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Abstract
Embodiments of a method to fabricate complex structures include making a pre-cured laminate template. The laminate template is first cured to the required shape, then surface prepared for joining to additional composite lamina. The laminate templates are used to position composite lamina in contact with one another. The composite lamina are then co-cured together to form one monolithic composite structure lacking bond lines or bonded joints. The laminate template supports additional composite lamina for formation of complex structures and replaces template tools from conventional methods.
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Citations
10 Claims
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1. A method to fabricate a composite structure, comprising:
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providing a laminate template including a first template surface having a bend; providing a first prepreg layup including a first side and a second side opposing the first side; securing at least a portion of the first side of the first prepreg layup to the first template surface including the bend to form a laminate template-prepreg, wherein the portion of the first prepreg layup secured to the laminate template substantially adopts the shape of the first template surface; providing a tool having a second template surface; providing a second prepreg layup including a first side and a second side opposing the first side; placing at least a portion of the first side of the second prepreg layup in contact with the second template surface of the tool such that the second prepreg layup substantially adopts the shape of the second template surface of the tool; positioning the laminate template-prepreg with respect to the second prepreg layup such that at least a portion of the second side of the first prepreg layup contacts the second side of the second prepreg layup, wherein the portion of the first prepreg layup including the bend is offset from the second prepreg layup to define a cavity between the first prepreg layup and the second prepreg layup; and co-curing the laminate template-prepreg and the second prepreg layup together after said positioning of the laminate template-prepreg to form a composite structure. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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Specification