Method for producing a component comprising at least one hollow profile

• US 9,193,114 B2
• Filed: 04/23/2011
• Issued: 11/24/2015
• Est. Priority Date: 04/29/2010
• Status: Active Grant

• Current Assignee: Premium Aerotec GmbH (Airbus SE)
• Original Assignee: Premium Aerotec GmbH (Airbus SE)
• Inventors: Arnold, Ralph, Eisenbeiss, Fred
• Primary Examiner(s): Cozart, Jermie
• Assistant Examiner(s): Salone, Bayan
• Application Number:
  US13/695,133
• Publication Number:
  US 20130036595A1
• Time in Patent Office: 1,676 Days
• Field of Search: 294/47, 295/57, 244/119, 244/120, 244/129.1, 244/123.1, 244/133, 264/407, 264/406, 736/32, 736/35, 736/18, 73620-631
• US Class Current: 1/1
• CPC Class Codes: B29C 70/54 Component parts, details or accessories; Auxiliary operations , e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
• CPC Class Codes: B29C 70/545 Perforating, cutting or machining during or after moulding
• CPC Class Codes: B29C 70/742 Forming a hollow body around the preformed part
• CPC Class Codes: Y10T 29/49865 by temperature differential [e.g., shrink fit]
• CPC Class Codes: Y10T 29/49867 of skin on frame member

Abstract

A method for producing a component with at least one hollow profile from a fiber composite material includes producing a component blank from the fiber composite material. The component blank includes a hollow profile with open ends. The component blank is thermally treated. Each open end of the hollow profile is closed with a stopper that includes at least an outer circumference of a closed-pore foam. The thermally treated component blank is tested using ultrasound in accordance with a non-destructive material-testing method. The component blank is then mechanically treated so as to obtain a finished component and the stoppers are removed. Alternatively, the component blank is mechanically treated to obtain the finished product before the ultrasound testing.

Claims

1. A method for producing a component including at least one hollow profile from a fiber composite material, the method comprising:

a) producing a component blank from the fiber composite material, the component blank including a hollow profile with open ends;

b) thermally treating the component blank;

c) after removing a core from the component blank, closing each open end of the hollow profile with a stopper, each stopper including at least an outer circumference of a closed-pore foam;

d) testing the thermally treated component blank using ultrasound in accordance with a non-destructive material-testing method while each open end of the hollow profile is closed with the stopper;

e) mechanically processing the component blank so as to obtain a finished component; and

f) removing the stoppers.

2. The method recited in claim 1, wherein the foam of the stoppers is polyethylene.

3. The method recited in claim 1, wherein the foam of the stoppers is predominantly polyethylene.

4. The method recited in claim 1, wherein the foam of the stoppers has a density no greater than 30 kg/m³.

5. The method recited in claim 4, wherein the foam of the stoppers has a density in a range of 10 kg/m³ to 20 kg/m³.

6. The method recited in claim 1, wherein the foam of the stoppers has a size no greater than 2 mm.

7. The method recited in claim 6, wherein the foam of the stoppers has a size in a range of 0.6 mm to 1.2 mm.

8. The method recited in claim 1 wherein the fiber composite material is a carbon fiber reinforced plastics material.

9. The method recited in claim 1, wherein the mechanical processing includes machining.

10. The method recited in claim 9, wherein the machining includes at least one of sawing, milling, grinding, planing or cutting.

11. A method for producing a component including at least one hollow profile from a fiber composite material, the method comprising:

a) producing a component blank from the fibre composite material, the component blank including a hollow profile with open ends;

b) thermally treating the component blank;

c) after removing a core from the component blank, closing each open end of the hollow profile with a stopper, each stopper including at least an outer circumference of a closed-pore foam;

d) mechanically processing the component blank so as to obtain a finished component;

e) testing the finished component using ultrasound in accordance with a non-destructive material-testing method while each open end of the hollow profile is closed with the stopper; and

f) removing the stoppers.

12. The method recited in claim 11, wherein the foam of the stoppers is polyethylene.

13. The method recited in claim 11, wherein the foam of the stoppers is predominantly polyethylene.

14. The method recited in claim 11, wherein the foam of the stoppers has a density no greater than 30 kg/m³.

15. The method recited in claim 14, wherein the foam of the stoppers has a density in a range of 10 kg/m³ to 20 kg/m³.

16. The method recited in claim 11, wherein the foam of the stoppers has a size no greater than 2 mm.

17. The method recited in claim 16, wherein the foam of the stoppers has a size in a range of 0.6 mm to 1.2 mm.

18. The method recited in claim 11 wherein the fiber composite material is a carbon fiber reinforced plastics material.

19. The method recited in claim 11, wherein the mechanical processing includes machining.

20. The method recited in claim 19, wherein the machining includes at least one of sawing, milling, grinding, planing or cutting.