MOULDING TOOL AND METHOD OF MANUFACTURING A PART

• US 20100000667A1
• Filed: 07/25/2007
• Published: 01/07/2010
• Est. Priority Date: 08/14/2006
• Status: Abandoned Application

• Current Assignee: Airbus Operations Limited (Airbus SE)
• Original Assignee: Airbus Operations Limited (Airbus SE)
• Inventors: Funnell, Marc Edwin
• Application Number:
  US12/310,138
• Publication Number:
  US 20100000667A1
• Time in Patent Office: Days
• US Class Current: 156/189
• CPC Class Codes: B29C 33/306 Exchangeable mould parts, e.g. cassette moulds, mould inserts moulds with exchangeable mould parts for injection moulding B29C45/2673; mounting of exchangeable mould inserts for injection moulding B29C45/2675
• CPC Class Codes: B29C 33/48 with means for collapsing or disassembling
• CPC Class Codes: B29C 33/485 cores or mandrels collapsible mandrels for shaping tube ends B29C57/02; collapsible mandrels for winding and joining B29C53/824
• CPC Class Codes: B29C 43/021 characterised by the shape of the surface
• CPC Class Codes: B29C 70/32 on a rotating mould, former or core
• CPC Class Codes: B29C 70/342 using isostatic pressure
• 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 70/446 Moulding structures having an axis of symmetry or at least one channel, e.g. tubular structures, frames
• CPC Class Codes: B29D 99/0014 provided with ridges or ribs, e.g. joined ribs
• CPC Class Codes: B29D 99/0028 hollow blades
• CPC Class Codes: B29K 2105/0809 Fabrics
• CPC Class Codes: B29K 2105/0872 Prepregs
• CPC Class Codes: B29L 2031/3085 Wings
• CPC Class Codes: B64C 3/182 Stringers, longerons
• CPC Class Codes: B64C 3/187 Ribs
• CPC Class Codes: B64C 3/24 Moulded or cast structures
• CPC Class Codes: Y02T 50/40 Weight reduction

Abstract

A tool set comprising: a moulding tool comprising a moulding surface and a mandrel recess in the moulding surface; a first mandrel configured to fit into the mandrel recess and form a first component; and a second mandrel configured to fit into the mandrel recess and form a second component which has a different shape or size to the first component. A method of manufacturing a part, the method comprising: arranging a set of components on one or more inner mould line tools; forming a layer around the inner mould line tool(s); fitting a pair of outer mould line tools on opposite sides of the inner mould line tool(s); moulding the part by compressing the layer and the components between the inner and outer mould line tools; and removing the inner mould line tool(s) from the part.

Claims

1-31. -31. (canceled)

32. A method of manufacturing a part, the method comprising:

forming a component on a mandrel;

fitting the mandrel into a mandrel recess of a moulding tool;

arranging a panel with a first portion of the panel engaging a moulding surface of the moulding tool and a second portion of the panel engaging the component on the mandrel;

bonding the first portion of the panel to the component by compressing them against the mandrel; and

moulding the second portion of the panel by compressing it against the moulding surface of the moulding tool.

34. A moulding tool comprising a moulding surface, and a mandrel recess in the moulding surface, wherein the mandrel recess has a mandrel locator configured to engage with a mandrel so as to locate the mandrel at a desired position in the mandrel recess.

35. The tool of claim 34 wherein the mandrel locator is configured to engage with the mandrel by means of a male/female connection.

36. The tool of claim 35 wherein the mandrel locator comprises a hole in the mandrel recess.

37. The tool of claim 34 comprising a plurality of mandrel recesses formed in the moulding surface.

38. The tool of claim 37 wherein the mandrel recesses are formed in a contiguous piece of material.

39. The tool of claim 37 comprising:

two or more stringer mandrel recesses in the moulding surface, each configured to receive a respective stringer mandrel; and

one or more additional mandrel recesses in the moulding surface, each configured to receive a mandrel for an additional component.

40. A method of manufacturing the moulding tool of claim 34, the method comprising forming each mandrel recess by removing material from the moulding tool.

51. A tool set comprising:

the moulding tool of claim 34; and

a mandrel configured to fit into the mandrel recess and form a component.

41. A tool set comprising:

a moulding tool comprising a moulding surface, and a mandrel recess in the moulding surface, and

a mandrel configured to fit into the mandrel recess and form a component.

43. A method of manufacturing a part, the method comprising:

arranging a set of components on a moulding tool; and

simultaneously compressing the set of components on the moulding tool against a panel so as to bond the components to the panel,

wherein the set of components includes a plurality of stringers, and one or more additional components.

44. The method of claim 43 further comprising:

arranging a second set of components on the moulding tool; and

compressing the second set of components on the moulding tool against a second panel so as to bond the second set of components to the second panel,

wherein the second set of components are compressed against the second panel at the same time that the first set of components are compressed against the first panel.

45. A tool set comprising:

at least two inner mould line tools;

at least two outer mould line tools; and

one or more spacers, each adapted to be removably fitted between the inner mould line tools so as to maintain a desired spacing between the inner mould line tools.

46. A method of manufacturing a part, the method comprising:

arranging a first set of components on an outer face of a first inner mould line tool;

arranging a second set of components on an outer face of a second inner mould line tool;

fitting one or more spacers between the inner mould line tools, with the spacer(s) engaging inner faces of the inner mould line tools so as to maintain a desired spacing between the inner mould line tools;

forming a layer around the inner mould line tools;

fitting outer mould line tools on opposite sides of the inner mould line tools;

moulding the part by compressing the layer and the components between the inner and outer mould line tools;

removing the spacer(s);

disengaging the inner mould line tools from the part after the spacer(s) have been removed; and

removing the inner mould line tools from the part.

48. The method of claim 46 wherein the layer is formed by wrapping around the or each inner mould line tool.

49. The method of claim 48 wherein the or each inner mould line tool is rotated as the layer is wrapped around the inner mould line tool(s).

47. A method of manufacturing a part, the method comprising:

arranging a set of components on one or more inner mould line tools;

forming a layer around the inner mould line tool(s);

fitting a pair of outer mould line tools on opposite sides of the inner mould line tool(s);

moulding the part by compressing the layer and the components between the inner and outer mould line tools; and

removing the inner mould line tool(s) from the part.

50. The method of claim 47 wherein the layer is formed by wrapping around the or each inner mould line tool.