Methods and systems for manufacturing composite components

• US 20060272143A1
• Filed: 06/03/2005
• Published: 12/07/2006
• Est. Priority Date: 06/03/2005
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Kismarton, Max U.
• Granted Patent: US 7,748,119 B2
• Time in Patent Office: Days
• US Class Current: 29/458
• CPC Class Codes: B29C 37/00 Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
• CPC Class Codes: B29C 70/202 arranged in parallel planes or structures of fibres crossing at substantial angles, e.g. cross-moulding compound [XMC] B29C70/207 takes precedence
• CPC Class Codes: B29C 70/34 and shaping or impregnating by compression , i.e. combined with compressing after the lay-up operation
• CPC Class Codes: B29C 70/865 completely encapsulated
• CPC Class Codes: Y10T 29/49622 Vehicular structural member making
• CPC Class Codes: Y10T 29/49801 Shaping fiber or fibered material
• CPC Class Codes: Y10T 29/49885 with coating before or during assembling
• CPC Class Codes: Y10T 29/49895 Associating parts by use of aligning means [e.g., use of a drift pin or a "fixture"]
• CPC Class Codes: Y10T 29/49966 with supplemental joining
• CPC Class Codes: Y10T 29/4998 Combined manufacture including applying or shaping of fluent material
• CPC Class Codes: Y10T 409/30868 Work support
• CPC Class Codes: Y10T 428/12493 Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]

Abstract

Methods and systems for manufacturing composite components, including asymmetric composite components, are disclosed. In one embodiment, a method of forming a composite component includes providing a forming tool having a base portion and at least one retaining portion; forming an uncured composite component on the forming tool; curing the composite component; performing a manufacturing operation on the cured composite component engaged with the forming tool; and after performing the manufacturing operation on the cured composite component, removing the cured composite component from the forming tool. In further embodiments, the forming tool may have a plurality of reference apertures disposed therethrough for performing drilling operations on the cured composite component.

Claims

1. A method of forming a composite component, comprising:

providing a forming tool having a base portion and at least one retaining portion;

forming an uncured composite component on the forming tool;

curing the composite component;

performing a manufacturing operation on the cured composite component engaged with the forming tool; and

after performing the manufacturing operation on the cured composite component, removing the cured composite component from the forming tool.

2. The method of claim 1, wherein forming an uncured composite component on the forming tool includes forming an asymmetric composite component on the forming tool.

3. The method of claim 1, wherein forming an uncured composite component on the forming tool includes forming an asymmetric composite component having at least one 45 degree layer and at least one minus 45 degree layer.

4. The method of claim 1, wherein forming an uncured composite component on the forming tool includes forming an asymmetric composite component having a first zero degree layer, a second 45 degree layer, a third minus 45 degree layer, and a fourth 90 degree layer.

5. The method of claim 1, wherein performing a manufacturing operation on the cured composite component includes performing at least one of a drilling operation, a riveting operation, a sanding operation, a welding operation, an attaching operation, a milling operation, a deburring operation, an etching operation, and a coating operation.

6. The method of claim 1, wherein providing a forming tool having a base portion and at least one retaining portion includes providing a forming tool having a reference aperture disposed therethrough, and wherein performing a manufacturing operation on the cured composite component includes performing at least one drilling operation through the reference aperture to form an attachment aperture in the cured composite component.

7. The method of claim 1, wherein

providing a forming tool having a base portion and at least one retaining portion includes providing a forming tool having a plurality of reference apertures disposed through the base and retaining portions;

forming an uncured composite component on the forming tool includes forming an asymmetric composite component on the forming tool; and

performing a manufacturing operation on the cured composite component includes performing a plurality of drilling operations through the plurality of reference apertures to form a plurality of attachment apertures in the cured asymmetric composite component.

8. The method of claim 1, wherein forming an uncured composite component on the forming tool includes forming a bead of resinous material along an interface between the base portion and the retaining portion.

9. The method of claim 8, wherein removing the cured composite component from the forming tool includes disengaging the cured composite component from the bead of resinous material.

10. The method of claim 1, wherein curing the composite component includes applying at least one of an elevated temperature and an elevated pressure to the composite component.

11. The method of claim 1, wherein forming an uncured composite component on the forming tool includes forming an uncured composite component that includes a metallic layer on the forming tool.

12. A method of manufacturing an aircraft, comprising:

forming a composite aircraft component, including;

providing a forming tool having a base portion and at least one retaining portion;

forming an uncured composite component on the forming tool;

curing the composite component;

performing a manufacturing operation on the cured composite component engaged with the forming tool; and

after performing the manufacturing operation on the cured composite component, removing the cured composite component from the forming tool; and

coupling the composite aircraft component to at least one of a frame assembly and a second component.

13. The method of claim 12, wherein forming an uncured composite component on the forming tool includes forming an asymmetric composite component on the forming tool.

14. The method of claim 12, wherein performing a manufacturing operation on the cured composite component includes performing at least one of a drilling operation, a riveting operation, a sanding operation, a welding operation, an attaching operation, a milling operation, a deburring operation, an etching operation, and a coating operation.

15. The method of claim 12, wherein providing a forming tool having a base portion and at least one retaining portion includes providing a forming tool having a reference aperture disposed therethrough, and wherein performing a manufacturing operation on the cured composite component includes performing at least one drilling operation through the reference aperture to form an attachment aperture in the cured composite component.

16. The method of claim 15, wherein forming an uncured composite component on the forming tool includes forming an asymmetric composite component on the forming tool.

17. The method of claim 12, wherein forming an uncured composite component on the forming tool includes forming an uncured composite component that includes a metallic layer on the forming tool.

18. An assembly for manufacturing composite components, comprising:

a base portion; and

a retaining portion removeably coupled to the base portion, the base portion and the retaining portion being adapted to securely engage at least a portion of a composite component and to endure a curing environment applied to the composite component, the base portion and the retaining portion being further adapted to provide for a manufacturing operation on the composite component subsequent to an application of the curing environment, and to maintain a desired shape of the composite component during the performance of the manufacturing operation.

19. The assembly of claim 18, wherein at least one of the base portion and the retaining portion includes a plurality of reference apertures disposed therethrough and adapted to provide for a drilling operation on the composite component.

20. The assembly of claim 18, wherein the base portion includes a substantially flat member, and wherein the retaining portion includes a plurality of arcuate retaining members distributed over the flat member and forming an enclosed retaining ring assembly on the flat member.

21. The assembly of claim 20, wherein at least one of the flat member and the enclosed retaining ring assembly includes a plurality of reference apertures disposed therethrough and adapted to provide for a drilling operation on the composite component.