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Rotor blade spar manufacturing apparatus and method

  • US 9,144,944 B1
  • Filed: 10/27/2011
  • Issued: 09/29/2015
  • Est. Priority Date: 09/09/2010
  • Status: Active Grant
First Claim
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1. A method for manufacturing a rotor blade comprising:

  • placing an uncured composite blade spar having a non-uniform wall thickness between first and second molds, the first mold defining a first mold surface and the second mold comprising a rigid core and a heated layer secured thereto, the heated layer defining a second mold surface such that the uncured composite blade spar is positioned between the first and second mold surfaces, the second mold further comprising a plurality of heating elements embedded therein; and

    simultaneously activating the plurality of heating elements according to a plurality of different temperature progressions effective to cure portions of the uncured composite blade spar coextensive with each heating element of the plurality of heating elements, each temperature progression of the plurality of different temperature progressions being defined according to a thickness of a region of the composite blade spar over the heating element of the plurality of heating elements corresponding to the each temperature progression;

    wherein the heated layer includes a thermally expandable material having a non-uniform thickness corresponding to pressure requirements for curing the composite blade spar in accordance with the non-uniform wall thickness;

    wherein the plurality of different temperature progressions are effective to cause the thermally expandable material to apply non-uniform pressure to the uncured composite blade spar.

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