METHODS FOR COMBINING COMPONENTS OF VARYING STAGES OF CURE
First Claim
1. A method of fabricating a composite structure from components of varying stages of cure, comprising the steps of:
- providing a stiffener component;
providing a dry fabric component;
combining the stiffener component and the dry fabric component to form an assembly, wherein the stiffener component provides structural support to the assembly;
infusing the assembly with resin to yield an infused assembly; and
curing the infused assembly to yield a cured assembly.
1 Assignment
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Accused Products
Abstract
The present invention provides a method of fabricating a composite structure from components of varying stages of cure while reducing the steps associated with the fabrication process of infusing, curing, and bonding composite materials to form a hybrid unitized structure. The method provides a pre-cured stiffener and a pi-preform having a clevis and a base portion. The pre-cured stiffener may be inserted into the clevis of the pi-preform to form a composite structure assembly. The composite structure assembly may be infused with a resin system at the time of cure and bonded to a second composite structure to form a hybrid unitized structure.
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Citations
21 Claims
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1. A method of fabricating a composite structure from components of varying stages of cure, comprising the steps of:
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providing a stiffener component; providing a dry fabric component; combining the stiffener component and the dry fabric component to form an assembly, wherein the stiffener component provides structural support to the assembly; infusing the assembly with resin to yield an infused assembly; and curing the infused assembly to yield a cured assembly. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A method of fabricating a composite structure from components of varying stages of cure, comprising the steps of:
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providing a pre-cured composite stiffener; providing a dry fabric component having a base portion and a clevis configured to receive the pre-cured composite stiffener, wherein the clevis is substantially perpendicular to the base portion; wrapping a first film adhesive around a first edge of said pre-cured stiffener; wrapping a first resin film around the first edge of said pre-cured stiffener; inserting the first edge of said pre-cured composite stiffener into the clevis of the dry fabric component to form a composite structure assembly; applying a second film adhesive to a surface of the dry fabric component; applying a second resin film to the base portion of the dry fabric component; securing the pre-cured stiffener substantially perpendicular to the base portion of the dry fabric component, wherein the pre-cured stiffener provides structural support to the composite structure assembly; applying a film adhesive to the exterior base portion of the dry fabric component securing the pre-cured stiffener with dry fabric component to another substrate to which it will bond; infusing the composite structure assembly by heating the assembly to a first temperature for a first period of time; and curing the composite structure assembly by increasing the heat to a second temperature, wherein the second temperature is greater than the first temperature.
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14. A method of fabricating a composite structure from components of varying stages of cure, comprising the steps of:
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providing a pre-cured composite stiffener; providing a dry fabric component having a base portion and a clevis configured to receive the pre-cured composite stiffener, wherein the clevis is substantially perpendicular to the base portion; wrapping a first resin film around a first edge of said pre-cured stiffener; inserting the first edge of said pre-cured composite stiffener into the clevis of the dry fabric component to form a composite structure assembly; applying a second resin film to a surface of the dry fabric component; securing the pre-cured stiffener substantially perpendicular to the base portion of the dry fabric component, wherein the pre-cured stiffener provides structural support to the composite structure assembly; infusing the composite structure assembly; and curing the composite structure assembly. - View Dependent Claims (15, 16, 17, 18, 19)
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20. A method of fabricating a composite structure from components of varying stages of cure, comprising the steps of:
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providing a pre-cured composite stiffener; providing a dry fabric component having a base portion and a clevis configured to receive the pre-cured composite stiffener, wherein the clevis is substantially perpendicular to the base portion; wrapping a first resin film around a first edge of said pre-cured stiffener; inserting the first edge of said pre-cured composite stiffener into the clevis of the dry fabric component to form a composite structure assembly; applying a second resin film to a surface of the dry fabric component; securing the pre-cured stiffener substantially perpendicular to the base portion of the dry fabric component, wherein the pre-cured stiffener provides structural support to the composite structure assembly; infusing the composite structure assembly by heating the assembly to a first temperature for a first period of time; and curing the composite structure assembly by increasing the heat to a second temperature, wherein the second temperature is greater than the first temperature. - View Dependent Claims (21)
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Specification