초록 ▼

A method of manufacturing a laid-up, bonded and, cured composite part, includes filling a groove on a facing surface of a tool with a foaming, self-skinning sacrificial material and covering the facing surface of the tool with a caul sheet. The tool is heated to cure the foaming material, filling th

A method of manufacturing a laid-up, bonded and, cured composite part, includes filling a groove on a facing surface of a tool with a foaming, self-skinning sacrificial material and covering the facing surface of the tool with a caul sheet. The tool is heated to cure the foaming material, filling the groove and forming a hard, smooth surface skin on the foam, flush with the facing surface of the tool. A series of plies are laid-up on the facing surface of the tool to form a tool-side skin, and other components of the part are laid-up on top of the tool-side skin plies. An adhesive/resin matrix is coated on or pre-impregnated into the skin plies and the components for bonding/curing to create a rigid integral assembly of the skin and components. A vacuum bag is applied over the laid-up skin and components and is sealed to peripheral regions of the facing surface of the tool around the laid-up skin and components. Air is evacuated from under the vacuum bag to cause air pressure outside the vacuum bag to press the vacuum bag against the components. The adhesive/resin matrix is bonded/cured to transform the skin and components into the rigid integral assembly. The vacuum bag is removed from the facing surface of the tool, uncovering the rigid integral assembly. The tool is fixed in a known position on a CNC machine tool bed to position the facing surface of the tool at a known position for edge routing of the rigid integral assembly by a machine tool. A cutter of the machine tool is guided on a predetermined path around the facing surface of the tool, with the cutter extending into the groove below the facing surface of the tool and cutting a peripheral edge around the rigid integral assembly. After edge routing, the rigid integral assembly is a finished part and is removed from the from the facing surface of the tool.

대표청구항 ▼

[ Obviously, numerous modifications and variations of this preferred embodiment will occur to those skilled in the art in light of this disclosure. Accordingly, it is expressly to be understood that these modifications and variation, and the equivalents thereof, shall be considered to be within the

[ Obviously, numerous modifications and variations of this preferred embodiment will occur to those skilled in the art in light of this disclosure. Accordingly, it is expressly to be understood that these modifications and variation, and the equivalents thereof, shall be considered to be within the spirit and scope of the invention as defined in the following claims, wherein I claim:] [1.] A dual purpose tool serving both as a form on which constituent materials are applied for bonding or curing on said tool into a part in a desired configuration, and for holding said materials in the originally applied position during subsequent machining of a peripheral edge of said part after said constituent materials have bonded or cured on said tool, comprising:a tool body having a facing surface configured to a desired shape of one surface of a part to be made on said tool;a supporting structure for supporting said tool body to maintain said facing surface in said desired shape;a substantially continuous groove in said tool body opening in said facing surface into which a cutting tool extends while edge trimming said peripheral edge of said part;a sacrificial material filling said groove and having a top surface substantially flush with said tool body facing surface for supporting said constituent materials substantially flush with said tool body facing surface during bonding or curing;whereby said constituent materials for said part are applied on said tool body, bonded or cured, and then edge trimmed thereon with said cutting tool which extends into said groove, cutting into said sacrificial material and engaging the full thickness of said part, all while said materials for said part remain on said tool body in said originally applied position.