Method for forming inner mold line tooling without a part model
First Claim
1. A method of forming a caul plate for aligning against the inner mold line of a composite part, comprising:
- laying-up a first uncured composite material on a lay-up mandrel, the first uncured composite material having a first primary curing temperature;
extending a nonporous film over an inner mold line of the first uncured composite material;
arranging a second composite material over the nonporous film so as to form an assembly, the second composite material having a second primary curing temperature that is lower than the first primary curing temperature; and
curing the assembly at a curing temperature that is at least as high as the second primary curing temperature but is less than the first primary curing temperature such that the second composite material is made substantially rigid, whereby the cured, second composite material can be used as a caul plate for the inner mold line of the first uncured composite material.
1 Assignment
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Accused Products
Abstract
A method of forming a caul plate (14) for use in producing a composite honeycomb core sandwich panel (27). The uncured honeycomb core sandwich panel (27) is laid-up on a lay-up mandrel (20). An inner bagging film (28) is then extended over the uncured honeycomb core sandwich panel (27). Tooling prepreg sheets (34) are extended over the inner bagging film (28), and a outer bagging film (40) is extended over the tooling prepreg sheets (34). Reduced vacuum is applied to the inner bagging film (28), and full vacuum is applied to the outer bagging film (40). The tooling prepreg sheets (34) are then partially cured so that they harden into the shape of the inner mold line of the honeycomb core sandwich panel (27). The partially cured tooling prepreg sheets (34) are then final cured to form the caul plate (14). The caul plate (14) can then be used for inner mold line tooling for the honeycomb core sandwich panel (27) or parts having the same inner mold line shape.
27 Citations
20 Claims
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1. A method of forming a caul plate for aligning against the inner mold line of a composite part, comprising:
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laying-up a first uncured composite material on a lay-up mandrel, the first uncured composite material having a first primary curing temperature; extending a nonporous film over an inner mold line of the first uncured composite material; arranging a second composite material over the nonporous film so as to form an assembly, the second composite material having a second primary curing temperature that is lower than the first primary curing temperature; and curing the assembly at a curing temperature that is at least as high as the second primary curing temperature but is less than the first primary curing temperature such that the second composite material is made substantially rigid, whereby the cured, second composite material can be used as a caul plate for the inner mold line of the first uncured composite material. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A method of forming a caul plate for aligning against the inner mold line of a composite honeycomb core sandwich panel, comprising:
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laying-up an uncured composite honeycomb core sandwich panel having a honeycomb core on a lay-up mandrel, the uncured composite honeycomb core sandwich panel having a first primary curing temperature; extending a nonporous film over an inner mold line of the uncured composite honeycomb core sandwich panel; arranging a second composite material over the nonporous film so as to form an assembly, the second composite material having a second primary curing temperature that is lower than the first primary curing temperature; and curing the assembly at a curing temperature that is at least as high as the second primary curing temperature but is less than the first primary curing temperature such that the second composite material is made substantially rigid, whereby the cured, second composite material can be used as a caul plate for the inner mold line of the uncured composite honeycomb core sandwich panel. - View Dependent Claims (13, 14, 15, 16, 17, 18, 19, 20)
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Specification