High pressure co-cure of lightweight core composite article utilizing a core having a plurality of protruding pins

• US 6,739,861 B2
• Filed: 11/26/2001
• Issued: 05/25/2004
• Est. Priority Date: 11/26/2001
• Status: Active Grant

• Current Assignee: Sikorsky Aircraft Corporation (Martin Marietta Corporation)
• Original Assignee: Sikorsky Aircraft Corporation (Martin Marietta Corporation)
• Inventors: Rogg, Christian A., Cournoyer, David M., Carstensen, Thomas A., Osiecki, Michael G., Cawthra, Neil W.
• Primary Examiner(s): Davis, Robert
• Assistant Examiner(s): Del Sole, Joseph S.
• Application Number:
  US09/995,393
• Publication Number:
  US 20030098520A1
• Time in Patent Office: 911 Days
• Field of Search: 425/389, 425/504, 425/520, 249/135, 264/313, 264/316, 264/511
• US Class Current: 425/520
• CPC Class Codes: B29C 70/086 and with one or more layers of pure plastics material, e.g. foam layers applying a non-preformed coating, e.g. a gel-coat, B29C37/0025; with foam blocks B29C70/86
• CPC Class Codes: B29C 70/24 oriented in at least three directions forming a three dimensional structure
• 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 70/543 Fixing the position or configuration of fibrous reinforcements before or during moulding for non-woven fabrics D04H3/08
• CPC Class Codes: B29C 70/549 Details of caul plates, e.g. materials or shape
• CPC Class Codes: B29C 70/865 completely encapsulated
• CPC Class Codes: B29K 2715/003 Cellular or porous

Abstract

The composite molding apparatus includes a rigid base member and a complementary semi-rigid mold member or “black bag” caul plate having a sieve member formed therein. The sieve member layer of the semi-rigid mold member engages pins which extend from the sandwich core to limit penetration into the semi-rigid mold member to a predetermined depth. The semi-rigid mold member is supported relative to the rigid mold member by the pins to provide uniform pressure transfer to the composite article during a high pressure co-cure molding process without crushing the sandwich core.

Claims

1. A semi-rigid mold member, comprising:

a first ply, comprising an elastomeric sheet rubber and a release film;

a second ply adjacent said first ply; and

a sieve member adjacent said first ply and said second ply, said sieve member adjacent said elastomeric sheet rubber opposite said release film.

2. The semi-rigid mold member as recited in claim 1, wherein said sieve member is embedded in said first ply.

3. The semi-rigid mold member as recited in claim 1, wherein said first ply and said second ply include a fluoroelastomer material.

4. The semi-rigid mold member as recited in claim 1, wherein said sieve member includes a stainless steel screen.

5. The semi-rigid mold member as recited in claim 4, wherein said screen provides approximately 60 micron retention.

6. The semi-rigid mold member as recited in claim 1, wherein said release film comprises an FEP layer adjacent said first ply and opposite said second ply.

7. The semi-rigid mold member as recited in claim 6, further comprising a third ply adjacent said second ply, and a fourth ply adjacent said third ply.

8. The semi-rigid mold member as recited in claim 7, further comprising a rigid reinforcement insert between said third ply and said fourth ply.

9. The semi-rigid mold member as recited in claim 8, wherein said reinforcement insert includes a metallic sheet.

10. The semi-rigid mold member as recited in claim 7, wherein said third ply and said fourth ply include a fiber reinforced fluoroelastomer material.

20. The semi-rigid mold member as recited in claim 1, wherein said elastomeric sheet rubber material comprises an unreinforced Fluoroelastomeric sheet rubber.

21. The semi-rigid mold member as recited in claim 1, wherein said second ply comprises an unreinforced Fluoroelastomeric sheet rubber.

23. The semi-rigid mold member as recited in claim 1, wherein said first ply locates said sieve member a predetermined distance from said release film, said predetermined distance related to a plurality of protruding pins within a core located between a first composite prepreg and a second composite prepreg.

11. A composite molding apparatus, comprising:

a rigid mold member; and

a semi-rigid mold member matable with said rigid mold member, said semi rigid mold member comprising a first ply located directly opposite said rigid mold member, said first ply compromising a sieve member, an elastomeric sheet rubber, and a release film, said release film and said sieve member located a adjacent said elastomeric sheet rubber, said release film facing said rigid mold member.

12. The composite molding apparatus as recited in claim 11, wherein said semi-rigid mold member comprises a second ply, said sieve member adjacent said first ply and said second ply.

13. The composite molding apparatus as recited in claim 12, wherein said second ply comprises a fluoroelastomer material.

14. The composite molding apparatus as recited in claim 12, further comprising a third ply adjacent said second ply, and a fourth ply adjacent said third ply.

15. The composite molding apparatus as recited in claim 14, further comprising a rigid reinforcement insert between said third ply and said fourth ply.

16. The composite molding apparatus as recited in claim 15, wherein said rigid reinforcement insert includes a metallic plate.

17. The composite molding apparatus as recited in claim 14, wherein said third ply and said fourth ply include a fiber reinforced fluoroelastomer material.

19. The composite molding apparatus as recited in claim 11, wherein said sieve member is embedded in said first ply.

22. The composite molding apparatus as recited in claim 11, herein said elastomeric sheet rubber material comprises an unreinforced Fluoroelastomeric sheet rubber.

24. The composite molding apparatus as recited in claim 11, wherein said first ply locates said sieve member a predetermined distance from said release film, said predetermined distance related to a plurality of protruding pins within a core located between a first composite prepreg and a second composite prepreg formed within a cavity defined by said rigid mold member and said semi-rigid mold member.

25. The composite molding apparatus as recited in claim 11, wherein said sieve member provides approximately 60 micron retention.

18. A semi-rigid mold member, comprising:

a first ply;

a second ply adjacent said first ply; and

a sieve member adjacent said first ply and said second ply, said sieve member embedded in said first ply.