Device for transporting, placing and compacting composite stiffeners

• US 10,569,484 B2
• Filed: 03/26/2015
• Issued: 02/25/2020
• Est. Priority Date: 08/08/2011
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Stewart, Samuel Ray, Ballow, Paul James
• Primary Examiner(s): Nguyen, Jimmy T
• Application Number:
  US14/669,506
• Publication Number:
  US 20150197065A1
• Time in Patent Office: 1,797 Days
• Field of Search: 100211
• 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: B29D 99/0003 Producing profiled members, e.g. beams
• CPC Class Codes: B29L 2009/00 Layered products
• CPC Class Codes: B29L 2031/3076 Aircrafts blades, propellers B29L2031/08
• CPC Class Codes: B30B 11/001 using a flexible element, e.g. diaphragm, urged by fluid pressure; Isostatic presses
• CPC Class Codes: B30B 15/024 using elastic mould parts
• CPC Class Codes: B30B 5/02 wherein the pressing means is in the form of a flexible element, e.g. diaphragm, urged by fluid pressure
• CPC Class Codes: Y02T 50/40 Weight reduction
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 156/1082 Partial cutting bonded sandwich [e.g., grooving or incising]
• CPC Class Codes: Y10T 29/49826 Assembling or joining

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.

Claims

1. A compactor for use in fabricating a contoured elongate composite structure, comprising:

a hat portion; and

a cap portion coupled to the hat portion, the cap portion comprising;

at least a first longitudinal section flexible along its length within a first plane; and

at least a second longitudinal section coupled with the first longitudinal section and flexible along its length within the first plane and within a second plane, wherein the first and second planes are generally orthogonal to each other.

2. The compactor of claim 1, wherein the second longitudinal section of the cap portion is generally planar and the hat portion is adapted to be received within a cavity in the composite structure.

3. The compactor of claim 2, wherein the second longitudinal section includes:

a plurality of reinforcement strips extending transversely across the width of the second longitudinal section and spaced apart along the length of the second longitudinal section,

slots between the reinforcement strips, and

a flexible material in the slots.

4. The compactor of claim 3, wherein:

the hat portion includes a plurality of transversely extending slits therein, and

the slits are substantially aligned with the slots in the second longitudinal section.

5. The compactor of claim 1, wherein the second longitudinal section includes a plurality of flexible rubber joints along its length allowing the second section to flex within the second plane.

6. The compactor of claim 1, wherein the second longitudinal section includes alternating strips of reinforcement and rubber along its length.

7. The compactor of claim 1, further comprising a splice joint between the first longitudinal section and the second longitudinal section.

8. The compactor of claim 3, wherein:

the reinforcement strips include unidirectional fiber reinforced resin.

9. The compactor of claim 3, wherein:

the flexible material includes a synthetic rubber.

10. The compactor of claim 3, wherein:

the hat portion includes a plurality of slits therein along its length.

11. The compactor of claim 10, wherein:

the slits extend substantially perpendicular to the plane of the cap portion.

12. The compactor of claim 11, wherein:

the slits are substantially aligned with the slots between the reinforcement strips.

13. The compactor of claim 12, wherein:

the hat portion has a generally open interior.

14. The compactor of claim 13, further comprising:

a vacuum source, coupled to the hat portion, for drawing a vacuum within the open interior.

15. The compactor of claim 14, wherein:

the plurality of slits are adapted to be coupled with the vacuum source to draw a composite layup against the hat portion.

16. The compactor of claim 1, wherein the hat portion further comprises:

inclined side walls; and

a bottom wall.

17. The compactor of claim 1, wherein the first longitudinal section and the second longitudinal section are coupled together by a joint.

18. The compactor of claim 17, wherein the joint is selected from a splice joint, a scarf joint, and a butt joint.

19. The compactor of claim 1, wherein at least one of the hat portion and the cap portion comprises laminated plies of fiber reinforced resin.

20. The compactor of claim 19, wherein the fiber reinforced resin is carbon fiber epoxy.