IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
US-0751931
(2007-05-22)
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등록번호 |
US-8568551
(2013-10-29)
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발명자
/ 주소 |
- Brennan, Joseph D.
- Hempstead, George D.
- Jones, Darrell D.
- Lum, Matthew K.
- McCowin, Peter D.
- Rowe, Terrence J.
- Schlosstein, Hugh R.
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출원인 / 주소 |
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대리인 / 주소 |
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인용정보 |
피인용 횟수 :
10 인용 특허 :
122 |
초록
▼
A pre-patterned layup kit with layup patterned to accommodate an airframe topological feature, trimmed to fit a preselected target region of a layup structure, and conformed to the target region contour. The kit can be fabricated in advance of airframe manufacture and stored until use. The kit inclu
A pre-patterned layup kit with layup patterned to accommodate an airframe topological feature, trimmed to fit a preselected target region of a layup structure, and conformed to the target region contour. The kit can be fabricated in advance of airframe manufacture and stored until use. The kit includes a flexible carrier upon which the layup is laid, and a release layer between the layup and the carrier. The layup has multiple laminae oriented to an carrier indexing element, and indexed to the target region thereby. A kit manufacturing method includes preparing the laminae constituent of the layup, preparing the carrier, and laying down the laminae on the carrier to make the kit. The kit can be compacted, inspected, and prepared for storage. The layup can be fabricated of a pre-patterned lamina or multiple laminae that are shaped and trimmed to accommodate an airframe topological feature.
대표청구항
▼
1. A method for manufacturing a kit for a part for an airframe, comprising: applying a layup release layer to an obverse surface of a flexible carrier;compacting the layup release layer and the flexible carrier in a vacuum bag;laying down a first pre-patterned lamina in a first lamina orientation on
1. A method for manufacturing a kit for a part for an airframe, comprising: applying a layup release layer to an obverse surface of a flexible carrier;compacting the layup release layer and the flexible carrier in a vacuum bag;laying down a first pre-patterned lamina in a first lamina orientation on the compacted release layer of the flexible carrier and iteratively laying down each of a plurality of subsequent laminae in a respective subsequent lamina orientation on the first pre-patterned lamina so as to fabricate a pre-patterned layup having a preselected pattern shaped to accommodate an airframe topological feature;wherein the pre-patterned layup is laid down in a predetermined orientation indexed to the flexible carrier so as to define a spatial relationship between the pre-patterned layup and the flexible carrier relative to a known fiducial location; andperforming a second compacting of the pre-patterned layup, the release layer, and the flexible carrier in a vacuum bag wherein the flexible carrier and the pre-patterned layup comprise a kit for an airframe part. 2. The method of claim 1, wherein fabricating the pre-patterned layup further comprises: cutting the preselected pattern into at least one prepreg lamina to fabricate the first pre-patterned lamina. 3. The method of claim 1, further comprising, after the second compacting, iteratively laying down additional pre-patterned laminae on the pre-patterned layup in a respective lamina orientation indexed to the flexible carrier; andcompacting all pre-patterned laminae, the release layer, and the flexible carrier in a vacuum bag for at least 5 minutes. 4. The method of claim 2, wherein fabricating the pre-patterned layup further comprises: pre-trimming the first pre-patterned lamina to fit to a preselected target region; andconforming the first pre-patterned lamina to an airframe contour corresponding to the preselected target region. 5. The method of claim 1, wherein the compacting includes vacuum-compacting for at least about 5 minutes. 6. The method of claim 5, further comprising: inspecting selected ones of the pre-patterned laminae for a ply characteristic, a ply edge overlap, a bonding characteristic, an interlaminar characteristic, or a combination thereof. 7. The method of claim 1 wherein the flexible carrier comprises an indexing element. 8. The method of claim 7 wherein the pre-patterned layup comprises multiple prepreg laminae, wherein at least one of the multiple laminae includes the pre-selected pattern, and wherein selected ones of the multiple laminae are laid down on the flexible carrier in respective lamina orientations relative to the indexing element. 9. The method of claim 1 wherein the airframe topological feature further comprises an airframe feature selected from the group consisting of a fuselage, a wing, a canard, a cone, a door, a radome, a fin, a nose, an empennage, a nacelle, a strake, a spar, a fairing, a hatch, and a port. 10. A method for manufacturing a layup part for an airframe, wherein the manufacturing method is part of an aircraft assembly process having a production phase, the method comprising the steps of: applying a layup release layer to an obverse surface of a flexible carrier;compacting the layup release layer and the flexible carrier in a vacuum bag;laying down a first pre-patterned lamina in a first lamina orientation on the compacted layup release layer of the flexible carrier and iteratively laying down each of a plurality of subsequent laminae in a respective subsequent lamina orientation so as to fabricate a pre-patterned layup, in the production phase, into an airframe topological feature,wherein the airframe topological feature further comprises an airframe feature selected from the group consisting of a fuselage, a wing, a canard, a cone, a door, a radome, a fin, a nose, an empennage, a nacelle, a strake, a spar, a fairing, a hatch, and a port; andwherein the pre-patterned layup is laid down in a predetermined layup orientation indexed to the flexible carrier, in the production phase, wherein the flexible carrier further comprises a sheet of metal material;supporting the pre-patterned layup on the flexible carrier; andcompacting the pre-patterned layup and the flexible carrier in a vacuum bag. 11. The method of claim 10, wherein the pre-patterned layup includes at least one ply. 12. The method of claim 10, wherein fabricating the pre-patterned layup further comprises: cutting the preselected pattern into at least one prepreg lamina to fabricate the first pre-patterned lamina. 13. The method of claim 12, wherein fabricating the pre-patterned layup further comprises: pre-trimming the first pre-patterned lamina to fit to a preselected target region; andconforming the first pre-patterned lamina to an airframe contour corresponding to the preselected target region. 14. A method for manufacturing a layup assembly for an airframe, wherein the method for manufacturing is part of an aircraft assembly process having a pre-production phase, a production phase, and a post-production phase, the method comprising: applying a layup release layer to an obverse surface of a flexible carrier;compacting the layup release layer and the flexible carrier in a vacuum bag;laying down a first pre-patterned lamina in a first lamina orientation on the compacted release layer of the flexible carrier and iteratively laying down each of a plurality of subsequent laminae in a respective subsequent lamina orientation on the flexible carrier so as to fabricate a pre-patterned layup into an airframe topological feature, in the production phase, the pre-patterned layup having a preselected pattern shaped to accommodate an airframe topological feature,wherein the airframe topological feature further comprises an airframe feature selected from the group consisting of a fuselage, a wing, a canard, a cone, a door, a radome, a fin, a nose, an empennage, a nacelle, a strake, a spar, a fairing, a hatch, and a port;wherein the pre-patterned layup is laid down in a predetermined layup orientation indexed to the flexible carrier wherein the flexible carrier further comprises a sheet of metal material, in the production phase;supporting the pre-patterned layup on the flexible carrier; andcompacting the pre-patterned layup and the flexible carrier in a vacuum bag. 15. The method of claim 14 further comprising the steps of: selecting a component fabricated by a third party in the pre-production phase; andusing the component in an aircraft assembly. 16. The method of claim 15 wherein the step of using further comprises using the component in an aircraft sub-assembly. 17. The method of claim 14 further comprising the step of: designing the pre-patterned layup for the layup placement in the pre-production phase. 18. The method of claim 14 further comprising the step of: replacing a defective lamina using the pre-patterned layup for a layup structure in the post-production phase.
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