Compaction system for composite stringers

• US 9,272,495 B1
• Filed: 09/25/2012
• Issued: 03/01/2016
• Est. Priority Date: 09/25/2012
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Robins, Brian G., Willden, Kurtis S., Rotter, Daniel M., Coxon, Brad A.
• Primary Examiner(s): Orlando, Michael N
• Assistant Examiner(s): Hoover, Matthew
• Application Number:
  US13/626,452
• Time in Patent Office: 1,253 Days
• US Class Current: 1/1
• CPC Class Codes: B29C 65/00 Joining or sealing of preformed parts , e.g. welding of plastics materials; Apparatus therefor general aspects of processes or apparatus for joining preformed parts B29C66/00; using porous material formed by internal pressure generated therein for joining preformed parts B29C44/1228, B29C44/326
• CPC Class Codes: B29C 66/00145 Vacuum, e.g. partial vacuum
• 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: B29D 99/0003 Producing profiled members, e.g. beams
• CPC Class Codes: B32B 2605/18 Aircraft blades, propellers B32B2603/00
• CPC Class Codes: B32B 37/00 Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
• CPC Class Codes: B32B 37/0046 characterised by constructional aspects of the apparatus
• CPC Class Codes: B32B 37/10 characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
• CPC Class Codes: B32B 37/1018 using only vacuum
• CPC Class Codes: B64C 1/00 Fuselages; Constructional features common to fuselages, wings, stabilising surfaces or the like
• CPC Class Codes: B64C 1/06 Frames; Stringers; Longerons ; Fuselage sections
• CPC Class Codes: B64C 1/061 Frames
• CPC Class Codes: B64C 1/064 Stringers; Longerons
• CPC Class Codes: B64C 1/068 Fuselage sections
• CPC Class Codes: B64C 1/069 Joining arrangements therefor
• CPC Class Codes: B64C 2001/0072 from composite materials
• CPC Class Codes: B64C 3/18 Spars; Ribs; Stringers
• CPC Class Codes: B64C 3/182 Stringers, longerons
• CPC Class Codes: B64C 3/24 Moulded or cast structures
• CPC Class Codes: B64C 3/26 Construction, shape, or attachment of separate skins, e.g. panels
• CPC Class Codes: B64C 3/28 : Leading or trailing edges attached to primary structures, e.g. forming fixed slots
• CPC Class Codes: B64C 3/30 : comprising inflatable structural components
• CPC Class Codes: B64F 5/10 : Manufacturing or assembling aircraft, e.g. jigs therefor
• CPC Class Codes: Y02T 50/40 : Weight reduction

Abstract

A method and apparatus for compacting composite stringers. In one illustrative embodiment, an apparatus comprises a compacting structure, a compactor vacuum system, and a carrier vacuum system. The compacting structure has a shape configured to contact layers of uncured composite material for a composite stringer. The compactor vacuum system is associated with the compacting structure. The compactor vacuum system is configured to cause the compacting structure to apply a pressure to the layers of uncured composite material when a compactor vacuum is applied to the compactor vacuum system. The carrier vacuum system is associated with the compacting structure. The carrier vacuum system is configured to hold the layers of uncured composite material against the compacting structure when a carrier vacuum is applied to the carrier vacuum system.

Claims

1. An apparatus comprising:

a compacting structure having;

a first surface;

a second surface having a shape of one side of a composite stringer, wherein the first and second surface form an enclosure structure when the compacting structure is placed against a mold;

a first opening in the first surface; and

a number of second openings in the second surface;

a compactor vacuum system associated with the first opening of the compacting structure, wherein the compactor vacuum system is configured to cause a vacuum in the enclosure structure and apply a pressure to layers of uncured composite material when a compactor vacuum is applied to the compactor vacuum system; and

a carrier vacuum system associated with the number of second openings in the second surface, wherein the carrier vacuum system holds the layers of uncured composite material against the compacting structure while the compacting structure is positioned and placed against the mold when a carrier vacuum is applied to the carrier vacuum system.

2. The apparatus of claim 1, wherein the compactor vacuum system causes the compacting structure to apply the pressure to the layers of uncured composite material such that the layers of uncured composite material are compacted.

3. The apparatus of claim 2, wherein the compactor vacuum causes the compacting structure to apply the pressure to the layers of uncured composite material such that the layers of uncured composite material are compacted when the layers of uncured composite material are placed in the mold.

4. The apparatus of claim 1, wherein the shape of the second surface of the compacting structure corresponds to a channel in an interior of the composite stringer.

5. The apparatus of claim 1, wherein the compactor vacuum system comprises:

a port configured to be connected to a vacuum source;

wherein the enclosure structure is configured to cause the compacting structure to push the compacting structure towards a surface of the mold with the layers of uncured composite material located between the compacting structure and the mold such that the compacting structure applies the pressure to the layers of uncured composite material, wherein the enclosure structure is in communication with the port.

6. The apparatus of claim 5, wherein the enclosure structure is selected from one of a vacuum bag, and a flexible structure with a seal.

7. The apparatus of claim 1, wherein the carrier vacuum system is configured to hold the layers of uncured composite material against the compacting structure during movement of the compacting structure when the carrier vacuum is applied.

8. The apparatus of claim 1, wherein the carrier vacuum system comprises:

a port configured to be connected to a vacuum source; and

a channel extending through the compacting structure, wherein the port is in communication with the number of second openings in the compacting structure that connect the channel to an exterior of the compacting structure, wherein the number of openings is located on a portion of the compacting structure that contacts the layers of uncured composite material.

9. The apparatus of claim 1 further comprising:

a vacuum source configured to independently apply the compactor vacuum and the carrier vacuum.

10. The apparatus of claim 1, wherein the compacting structure, the compactor vacuum system, and the a carrier vacuum system are flexible such that a shape of the compacting structure, a shape of the compactor vacuum system, and a shape of the carrier vacuum system are configured to bend to correspond to a shape of the mold.

11. The apparatus of claim 1, wherein the compacting structure is comprised of a number of materials selected from at least one of a plastic, graphite, aluminum, a polycarbonate, wood, and a composite material.