SYSTEM AND METHOD FOR MINIMIZING WRINKLES IN COMPOSITES

• US 20140127473A1
• Filed: 11/02/2012
• Published: 05/08/2014
• Est. Priority Date: 11/02/2012
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Kline, William T.
• Granted Patent: US 9,731,457 B2
• Time in Patent Office: Days
• US Class Current: 428/174
• CPC Class Codes: B29C 33/42 characterised by the shape of the moulding surface, e.g. ribs or grooves
• 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 70/56 Tensioning reinforcements before or during shaping
• CPC Class Codes: B29C 70/683 Pretreatment of the preformed part, e.g. insert
• CPC Class Codes: Y10T 156/1002 with permanent bending or reshaping or surface deformation of self sustaining lamina
• CPC Class Codes: Y10T 428/24628 Nonplanar uniform thickness material

Abstract

A wrinkle mitigation system may include at least one tooling rod disposed against a tool surface at a location on the tool where a composite ply is configured to overlap the tooling rod. The tooling rod may have an elongated shape and may be generally oriented along a direction of wrinkle formation in the composite ply. The tooling rod may have a rod width that results in the composite ply assuming a corrugated shape when compaction pressure is applied to the composite ply.

Claims

1. A system for controlling wrinkle formation in a composite ply, comprising:

a tooling rod disposed against a tool surface at a location on a tool where a composite ply is configured to overlap the tooling rod;

the tooling rod having an elongated shape and being generally oriented along a direction of wrinkle formation in the composite ply; and

the tooling rod having a rod width that results in the composite ply assuming a corrugated shape when compaction pressure is applied to the composite ply against the tooling rod.

2. The system of claim 1, wherein:

the tooling rod has a rod length such that a portion of the tooling rod extends outwardly beyond a ply edge of the composite ply.

3. The system of claim 1, further comprising:

a protective film at least partially covering the tooling rod such that the protective film is positioned between the composite ply and the tooling rod.

4. The system of claim 1, further comprising:

an attachment device mounting the tooling rod to the tool surface.

5. The system of claim 1, wherein:

the tooling rod is positioned on the tool surface at a location where excess ply material gathers.

6. The system of claim 1, wherein:

the tooling rod is positioned adjacent to a complex curvature in the tool surface.

7. The system of claim 1, wherein:

the tooling rod has a rod width in a range of from approximately 0.050 to 0.25 inch.

8. The system of claim 1, wherein:

the tooling rod having a rod length to rod width aspect ratio of at least 10.

9. The system of claim 1, wherein:

the tooling rod comprises a plurality of tooling rods oriented generally parallel to one another and forming a tooling rod assembly.

10. The system of claim 9, wherein:

the tooling rods are oriented generally parallel to one another at a rod spacing of between approximately 0.50 and 3.0 inch.

11. The system of claim 9, comprising:

a pair of tooling rod assemblies for sandwiching the composite ply therebetween.

15. The system of claim 1, further comprising:

removably attaching the tooling rod to the tool surface using at least one attachment device.

12. A system for controlling wrinkle formation in a composite laminate, comprising:

a tooling rod assembly disposed against a tool surface at a location on a tool where a composite laminate is configured to overlap the tooling rod assembly;

the tooling rod assembly including a plurality of tooling rods each having an elongated shape and being oriented along a general direction of wrinkle formation in the composite laminate; and

the tooling rods may have a rod width that results in the composite ply assuming a corrugated shape when compaction pressure is applied to the composite laminate against the tooling rods.

13. A method of controlling wrinkle formation in a composite ply, comprising the steps of:

providing at least one tooling rod with a tool surface;

applying a composite ply over the tooling rod and the tool surface;

applying a compaction pressure to the composite ply; and

forming the composite ply into a corrugated shape over the tooling rod.

14. The method of claim 13, wherein:

removing the tooling rod from the tool surface; and

curing the composite ply.

16. The method of claim 13, further comprising the step of:

sizing the tooling rod in a rod width that substantially eliminates uncontrolled wrinkle formation in the composite ply when the compaction pressure is applied to the composite ply.

17. The method of claim 13, further comprising the step of:

applying a protective film over the tooling rod prior to applying the composite ply.

18. The method of claim 13, wherein the step of applying the tooling rod onto the tool surface comprises:

applying a plurality of tooling rods adjacent to a complex curvature in the tool surface.

19. The method of claim 18, further comprising the step of:

spacing the tooling rods at a rod spacing of between approximately 0.50 and 3.0 inch.

20. A composite article formed by the method of claim 13.