Method and apparatus for making composite parts
First Claim
1. A method for making a composite part, the method comprising:
- forming a first structure, the first structure including a fiber-reinforced material having an interface defined by a relatively sharp discontinuity between a resin-infused portion and a non-resin-infused portion;
forming a second structure, the second structure including a fiber-reinforced material having an interface defined by a relatively sharp discontinuity between a resin-infused portion and a non-resin-infused portion;
coupling the non-resin-infused portions of the first and second structures to create a coupled non-resin-infused portion;
infusing the coupled non-resin-infused portion with a resin; and
curing the resin to couple the first and second structures.
2 Assignments
0 Petitions
Accused Products
Abstract
A method of making a composite part includes the steps of placing a first section of a fibrous pre-form in a mold and infusing the first section of the fibrous pre-form with a resin so as to produce a resin-infused portion and a non-resin-infused portion. Next, the method includes coupling the non-resin-infused portion to a second section of the fibrous pre-form to create a coupled non-resin-infused portion. Then, the coupled non-resin-infused portion is infused with resin to create a second resin-infused portion and a second non-resin-infused portion. These steps are repeated to separately infuse different sections of the part until the part is complete. The corresponding apparatus preferably employs a rigid mold having a shape defining only a portion of the composite part to be made. And, the method is particularly adapted to making both cored and non-cored structures that are large or unconventionally shaped.
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Citations
22 Claims
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1. A method for making a composite part, the method comprising:
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forming a first structure, the first structure including a fiber-reinforced material having an interface defined by a relatively sharp discontinuity between a resin-infused portion and a non-resin-infused portion;
forming a second structure, the second structure including a fiber-reinforced material having an interface defined by a relatively sharp discontinuity between a resin-infused portion and a non-resin-infused portion;
coupling the non-resin-infused portions of the first and second structures to create a coupled non-resin-infused portion;
infusing the coupled non-resin-infused portion with a resin; and
curing the resin to couple the first and second structures. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
infusing the stacked non-resin-infused portion with resin; and
curing the resin.
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10. The method of claim 7, wherein a core is positioned between at least some of the layers of fiber-reinforced material.
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11. The method of claim 1, wherein the composite part is a closed-form composite part.
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12. The method of claim 1, wherein the fiber-reinforced material is stitch-bonded fabric.
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13. The method of claim 1, wherein the resin-infused portion is contiguous with the non-resin-infused portion, and the interface between the resin-infused portion and the non-resin-infused portion is generally planar.
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14. A method for making a composite part, the method comprising:
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placing a first section of a fibrous pre-form in a mold;
infusing the first section with a resin so as to produce an interface defined by a relatively sharp discontinuity between a first resin-infused portion and a first non-resin-infused portion;
coupling the first non-resin-infused portion to a second section of the fibrous pre-form to create a coupled non-resin-infused portion;
infusing the coupled non-resin-infused portion with resin to create a second resin-infused portion and a second non-resin-infused portion; and
allowing the resin to cure to couple the first and second sections. - View Dependent Claims (15, 16, 17, 18, 19, 20, 21, 22)
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Specification