Compaction system for composite stringers

• US 9,782,960 B1
• Filed: 02/29/2016
• Issued: 10/10/2017
• 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): Minskey, Jacob T
• Assistant Examiner(s): Hoover, Matthew
• Application Number:
  US15/057,031
• Time in Patent Office: 589 Days
• 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
• 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 1/064 Stringers; Longerons
• CPC Class Codes: B64C 1/068 Fuselage sections
• 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. A method for processing a composite stringer, the method comprising:

placing layers of uncured composite material for a composite stringer onto a tool; and

applying a compactor vacuum to a compactor vacuum system associated with a compacting structure such that the layers of uncured composite material of the composite stringer are compacted against the tool;

wherein the compacting structure further comprises;

a first surface having a shape of one side of the composite stringer; and

a second surface, wherein the first surface and the second surface form an enclosure structure when the compacting structure is placed against a mold;

wherein the first surface further comprises a first opening in the first surface; and

wherein the second surface further comprises a number of second openings in the second surface;

further comprising;

applying a compactor vacuum to the enclosure

structure by the compactor vacuum system associated with the first opening of the compacting structure;

applying a pressure to layers of uncured composite material when the compactor vacuum system applies the compactor vacuum to the enclosure structure;

applying a carrier vacuum to a carrier vacuum system associated with the number of second openings in the second surface; and

holding the layers of uncured composite material against the compacting structure by the carrier vacuum while the compacting structure is positioned and placed against the mold.

2. The method of claim 1 further comprising:

placing a number of additional layers of uncured composite material for a number of additional stringers on the tool; and

applying the vacuum to a number of additional vacuum systems associated with a number of additional compacting structures such that the number of additional layers of uncured composite material for a number of additional composite stringers is compacted against the tool.

3. The method of claim 2, wherein the step of applying the vacuum to the number of additional vacuum systems associated with the number of additional compacting structures such that the number of additional layers of uncured composite material for the number of additional composite stringers is compacted against the tool is performed as the number of additional layers of uncured composite material for the number of additional composite stringers is placed onto the tool.

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

5. The method of claim 1 further comprising:

applying a carrier vacuum to a carrier vacuum system associated with the compacting structure such that the layers of uncured composite material for the composite stringer are held against the compacting structure; and

placing the layers of uncured composite material for the composite stringer on the tool.

6. The method of claim 5, wherein the compactor vacuum system comprises a port configured to be connected to a vacuum source and an enclosure structure configured to cause the compacting structure to move the compacting structure towards a surface of the tool with the layers of uncured composite material located between the compacting structure and the tool such that the compacting structure applies a pressure to the layers of uncured composite material, wherein the enclosure structure is in communication with the port.

7. The method of claim 5, wherein the carrier vacuum system comprises a port configured to be connected to a vacuum source and a number of openings extending through the compacting structure, wherein the port is in communication with the number of openings.

8. The method of claim 1, further comprising:

applying pressure to the layers of uncured composite material by compacting structure when the compactor vacuum system is applied such that the layers of uncured composite material are compacted.

9. The method of claim 8, further comprising:

applying the pressure to the layers of uncured composite material compacting structure when the compactor vacuum system is applied such that the layers of uncured composite material are compacted when the layers of uncured composite material are placed in the mold.

10. The method 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.

11. The method of claim 1, wherein the compactor vacuum system comprises a port configured to be connected to a vacuum source, the method further comprising:

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

12. The method of claim 11, wherein the enclosure structure is selected from one of a vacuum bag, and a flexible structure with a seal.

13. The method of claim 1, further comprising:

holding the layers of uncured composite material against the compacting structure during movement of the compacting structure when a carrier vacuum is applied, wherein a carrier vacuum system is configured to hold the layers of uncured composite material.

14. The method 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 a number of second openings in the compacting structure that connect the channel to an exterior of the compacting structure, wherein the number of second openings is located on a portion of the compacting structure that contacts the layers of uncured composite material.

15. The method of claim 1 further comprising:

independently apply the compactor vacuum and a carrier vacuum by a vacuum source.

16. The method of claim 1, wherein the compacting structure, the compactor vacuum system, and the carrier vacuum system are flexible, the method further comprising:

bending at least one of a shape of the compacting structure, a shape of the compactor vacuum system, and a shape of the carrier vacuum system to correspond to a shape of a mold.

17. The method 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.