Methods and tools for forming contoured composite structures with shape memory alloy
First Claim
1. A tool for forming a contoured composite structure, the tool comprising:
- a structure of shape memory alloy configured to deform from a first conformation to a second conformation when heated to within an activated temperature range, wherein the second conformation corresponds to a desired contour of a sheet of composite material, and wherein the structure of shape memory alloy is configured to operatively receive the sheet of composite material;
a heat source configured to heat the structure of shape memory alloy to within the activated temperature range to actively deform the structure of shape memory alloy from the first conformation to the second conformation, thus resulting in conformation of the sheet of composite material to the desired contour at least partially corresponding to the second conformation of the shape memory alloy, wherein the sheet of composite material is maintained in the desired conformation when the structure of shape memory alloy returns to the first conformation; and
a retention structure configured to selectively retain the sheet of composite material relative to the structure of shape memory alloy when the heat source heats the structure of shape memory alloy to within the activated temperature range.
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Abstract
Methods and tools for forming contoured composite structures are disclosed. Methods include positioning a sheet of composite material relative to a structure of shape memory alloy, heating the structure of shape memory alloy to deform the structure of shape memory alloy to a deformed conformation and thereby conform the sheet of composite material to a desired contour corresponding to the deformed conformation of the structure of shape memory alloy. Tools include a structure of shape memory alloy and a heat source for heating the structure of shape memory alloy to conform a sheet of composite material to a desired contour corresponding to the deformed conformation of the structure of shape memory alloy.
20 Citations
20 Claims
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1. A tool for forming a contoured composite structure, the tool comprising:
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a structure of shape memory alloy configured to deform from a first conformation to a second conformation when heated to within an activated temperature range, wherein the second conformation corresponds to a desired contour of a sheet of composite material, and wherein the structure of shape memory alloy is configured to operatively receive the sheet of composite material; a heat source configured to heat the structure of shape memory alloy to within the activated temperature range to actively deform the structure of shape memory alloy from the first conformation to the second conformation, thus resulting in conformation of the sheet of composite material to the desired contour at least partially corresponding to the second conformation of the shape memory alloy, wherein the sheet of composite material is maintained in the desired conformation when the structure of shape memory alloy returns to the first conformation; and a retention structure configured to selectively retain the sheet of composite material relative to the structure of shape memory alloy when the heat source heats the structure of shape memory alloy to within the activated temperature range. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18)
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19. A tool for forming a contoured composite structure, the tool comprising:
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a structure of shape memory alloy configured to deform from a first conformation to a second conformation when heated to within an activated temperature range, wherein the second conformation corresponds to a desired contour of a sheet of composite material, and wherein the structure of shape memory alloy is configured to operatively receive the sheet of composite material; a heat source configured to heat the structure of shape memory alloy to within the activated temperature range to actively deform the structure of shape memory alloy from the first conformation to the second conformation, thus resulting in confirmation of the sheet of composite material to the desired contour at least partially corresponding to the second conformation of the shape memory alloy, wherein the sheet of composite material is maintained in the desired conformation when the structure of shape memory alloy returns to the first conformation; and a controller configured to operatively control the heat source to sequentially heat predetermined sub-regions of the structure of shape memory alloy in a predetermined sequence.
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20. A tool for forming a contoured composite structure, the tool comprising:
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a structure of shape memory alloy configured to deform from a first conformation to a second conformation when heated to within an activated temperature range, wherein the second conformation corresponds to a desired contour of a sheet of composite material, and wherein the structure of shape memory alloy is configured to operatively receive the sheet of composite material; and a heat source configured to heat the structure of shape memory alloy to within the activated temperature range to actively deform the structure of shape memory alloy from the first conformation to the second conformation, thus resulting in confirmation of the sheet of composite material to the desired contour at least partially corresponding to the second conformation of the shape memory alloy, wherein the sheet of composite material is maintained in the desired conformation when the structure of shape memory alloy returns to the first conformation;
wherein the structure of shape memory alloy includes a plurality of sub-regions, and wherein the heat source is configured to operatively heat fewer than all of the plurality of sub-regions.
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Specification