Flexible compactor with reinforcing spine

• US 10,195,811 B2
• Filed: 02/06/2018
• Issued: 02/05/2019
• Est. Priority Date: 08/08/2011
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Stewart, Samuel Ray
• Primary Examiner(s): Nguyen, Jimmy T
• Application Number:
  US15/890,195
• Publication Number:
  US 20180169991A1
• Time in Patent Office: 364 Days
• Field of Search: 100 35, 100211, 156 60, 156268, 156580, 29428
• CPC Class Codes: B29C 70/342 using isostatic pressure
• CPC Class Codes: B29C 70/38 Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns application heads for tyres B29D30/28
• CPC Class Codes: B29C 70/44 using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
• CPC Class Codes: B29C 70/549 Details of caul plates, e.g. materials or shape
• CPC Class Codes: B29D 99/001 Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings articles with hollow walls B29D24/00
• CPC Class Codes: B30B 11/001 using a flexible element, e.g. diaphragm, urged by fluid pressure; Isostatic presses
• CPC Class Codes: B30B 13/00 Methods of pressing not special to the use of presses of any one of the preceding main groups
• CPC Class Codes: B30B 15/024 using elastic mould parts
• CPC Class Codes: B32B 1/00 Layered products having a non-planar shape
• CPC Class Codes: Y10T 156/17 Surface bonding means and/or assemblymeans with work feeding or handling means

Abstract

A device for compacting a contoured elongate composite layup includes flexible first and second fiber reinforced resin flexible sections flexible along their lengths. The first section is flexible within a first plane and the second section is flexible within the first plane as well as within a second plane. The second section includes flexible joints reinforced by a spine.

Claims

1. A method of making a compactor flexible in orthogonal planes for compacting a contoured composite stiffener layup, comprising:

laying up at least a first portion of the compactor by placing a plurality of composite reinforcement strips in generally parallel, spaced apart relationship to each other;

forming flexible joints between the reinforcement strips by laminating at least one ply of flexible rubber with the reinforcement strips; and

reinforcing the flexible joints by laminating a reinforcing spine with the ply of flexible rubber, wherein the reinforcing spine extends longitudinally along the first portion and through the flexible joint.

2. The method of claim 1, wherein laying up the first portion of the compactor includes:

providing at least one flat ply of fiber reinforced resin;

castellating opposite edges of the flat ply to form flange strips on the flat ply; and

laying up the reinforcement strips over the flange strips.

3. The method of claim 1, wherein:

forming the flexible joints between the reinforcement strips includes laminating two plies of flexible rubber; and

reinforcing the flexible joints includes laying up tows of unidirectional fiber reinforced resin and laminating the tows between the two plies of flexible rubber.

4. The method of claim 3, wherein laying up the tows of unidirectional fiber reinforced resin includes locating the tows generally parallel to and near a neutral axis of the compactor.

5. The method of claim 1, wherein:

the compactor includes a hat portion and a cap portion.

6. The method of claim 5, wherein:

the flexible joint is located within the cap portion and allows the cap portion to flex along at least a first plane.

7. The method of claim 6, wherein:

the cap portion has a thickness; and

the flexible joint extends substantially throughout the entire thickness of the cap portion.

8. The method of claim 6, wherein the reinforcing spine is aligned with and located near a neutral axis of the combination of the cap portion and the hat portion.

9. The method of claim 5, wherein:

the cap portion includes strips of substantially rigid reinforcement extending transversely across a width of the cap portion.

10. The method of claim 5, wherein:

the reinforcement strips are spaced apart from each other along the length of the cap portion and define transverse slots.

11. The method of claim 9, wherein:

the transverse slots are substantially filled with a rubber.

12. The method of claim 5, wherein:

the flexible joint includes a flexible material; and

the reinforcing spine includes at least one ply of unidirectional fiber reinforced resin passing through the flexible joint.

13. The method of claim 12, wherein the ply of unidirectional fiber reinforced resin has a width less than a width of the reinforcement strips.

14. The method of claim 13, wherein the ply of unidirectional fiber reinforced resin has a fiber orientation substantially aligned with a length of the cap portion.

15. The method of claim 1, wherein:

the flexible joint includes a flexible rubber; and

the reinforcing spine extends through the flexible rubber.

16. The method of claim 3, wherein:

the unidirectional fiber reinforced resin includes a plurality of plies of carbon fiber reinforced tows.

17. The method of claim 1, wherein:

the compactor is elongate and includes a neutral axis; and

the reinforcing spine is located near and extends along the neutral axis.

18. The method of claim 1, wherein:

the flexible joint includes at least one ply of a flexible material having a width; and

the reinforcing spine includes at least one ply of reinforcement having a width that is less than the width of the flexible material.

19. The method of claim 2, wherein castellating opposite edges of the flat ply comprises:

die cutting the opposite edges to remove material from the flat ply of fiber reinforced resin.

20. The method of claim 2, wherein castellating the opposite edges results in a series of reinforcement flange strips which are spaced apart along a length of the first portion of the compactor and are separated by slots.