Composite Manufacturing Method

• US 20100239865A1
• Filed: 06/04/2007
• Published: 09/23/2010
• Est. Priority Date: 07/14/2006
• Status: Active Grant

• Current Assignee: Airbus Operations Limited (Airbus SE)
• Original Assignee: Airbus Operations Limited (Airbus SE)
• Inventors: Kallinen, Risto
• Granted Patent: US 8,057,623 B2
• Time in Patent Office: Days
• US Class Current: 428/411.100
• 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 70/46 using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
• CPC Class Codes: B29C 70/543 Fixing the position or configuration of fibrous reinforcements before or during moulding for non-woven fabrics D04H3/08
• CPC Class Codes: B29C 70/545 Perforating, cutting or machining during or after moulding
• CPC Class Codes: B29D 99/0014 provided with ridges or ribs, e.g. joined ribs
• CPC Class Codes: B29L 2031/3076 Aircrafts blades, propellers B29L2031/08
• 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 156/1002 with permanent bending or reshaping or surface deformation of self sustaining lamina
• CPC Class Codes: Y10T 156/1043 Subsequent to assembly
• CPC Class Codes: Y10T 428/24331 including nonapertured component
• CPC Class Codes: Y10T 428/31504 Composite [nonstructural laminate]

Abstract

A method of manufacturing a panel, the panel comprising a composite skin and at least one composite stiffener, the method comprising: positioning first and second mandrels on opposite sides of the stiffener; positioning first and second compaction tools on opposite sides of the skin; and compacting the skin between the first and second compaction tools by moving one or both of the compaction tools, wherein the movement of the compaction tool(s) causes the first and second mandrels to move towards the stiffener along inclined paths so as to compact the stiffener between the mandrels.

Claims

1. A method of manufacturing a panel, the panel comprising a composite skin and at least one composite stiffener, the method comprising:

positioning first and second mandrels on opposite sides of the stiffener;

positioning first and second compaction tools on opposite sides of the skin; and

compacting the skin between the first and second compaction tools by moving one or both of the compaction tools,

wherein the movement of the compaction tool(s) causes the first and second mandrels to move towards the stiffener along inclined paths so as to compact the stiffener between the mandrels.

2. The method of claim 1 wherein the mandrels slide against inclined surfaces of one of the compaction tools as they move towards the stiffener.

3. The method of claim 2 wherein the one of the compaction tools has a channel with a base, and first and second walls which are both inclined outwardly from the base;

and wherein the mandrels slide against the first and second walls as they move towards the stiffener.

18. The method of claim 1 wherein the panel is an aircraft part.

19. A composite panel manufacture by the method of claim 1.

4. Apparatus for manufacturing a composite panel, the apparatus comprising:

first and second mandrels, each mandrel having a pair of inclined surfaces;

a first compaction tool; and

a second compaction tool having a first inclined surface engaging the first mandrel and a second inclined surface engaging the second mandrel.

5. A method of manufacturing a panel, the panel comprising a composite skin and at least one composite stiffener, the method comprising:

forming the stiffener on a mandrel;

transporting the stiffener and mandrel to a joining station, the mandrel supporting the weight of the stiffener during the transporting step; and

joining the stiffener to the skin at the joining station.

6. The method of claim 5 further comprising laying the skin onto the stiffener on the mandrel at the joining station, the mandrel supporting the weight of the stiffener during the laying step.

7. A method of manufacturing a composite panel, the method comprising:

fitting a control member through the panel;

fitting a plug through a compaction tool;

engaging the control member with the plug;

engaging the plug with a datum surface of the compaction tool;

compacting the panel with the compaction tool; and

disengaging the plug from the control member after the panel has been compacted.

8. The method of claim 7 wherein the compaction tool comprises a tool body and a guiding insert fitted into a hole in the tool body, and wherein the guiding insert provides the datum surface.

9. The method of claim 7 further comprising engaging male and female parts of the plug and control member.

10. The method of claim 9 wherein the control member has a male part which engages a female part of the plug, and wherein the male part of the control member protrudes beyond an outer surface of the panel.

11. Apparatus for manufacturing a composite panel, the apparatus comprising:

a control member;

a compaction tool for compacting the panel; and

a plug which is dimensioned to pass through the compaction tool and engage the control member, and which can be disengaged after the panel has been compacted,

wherein the compaction tool has a datum surface which engages the plug when the plug passes through the compaction tool.

12. The apparatus of claim 11 wherein the control member is a cylindrical pin.

13. The apparatus of claim 11 wherein the control member is formed of carbon.

14. The apparatus of claim 11, wherein the compaction tool comprises a tool body and a guiding insert fitted into a hole in the tool body, and wherein the guiding insert provides the datum surface.

15. The apparatus of claim 14 wherein the guiding insert has a flange which engages an outer surface of the tool body, and the plug has a flange which engages the flange of the guiding insert when the plug engages the control member.

16. The apparatus of claim 11 wherein the plug and control member have male and female parts which engage with each other when the plug passes through the compaction tool.

17. The apparatus of claim 16 wherein the male part tapers inwardly and the female part flares outwardly.

20. A method of manufacturing a composite laminate, the method comprising:

placing the composite laminate on an upwardly directed male tool whereby the composite laminate is locally compressed at a seed zone where it engages the male tool and droops under the action of gravity on two opposite sides of the seed zone; and

deforming the laminate to cause the laminate to be molded against the male tool on the two opposite sides of the seed zone.

21. The method of claim 20 wherein the male tool is locally curved where it engages the composite laminate.

22. The method of claim 20 wherein the male tool has inclined faces on the two opposite sides of the seed zone.

23. The method of claim 20, wherein the composite laminate is an aircraft part.

24. A composite laminate manufactured by the method of claim 20.