Method for producing contoured composite structures and structures produced thereby
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B29C-070/44
B32B-037/10
B29C-070/34
B29C-070/30
B29C-070/38
B29L-031/30
출원번호
US-0104529
(2008-04-17)
등록번호
US-9090028
(2015-07-28)
발명자
/ 주소
McCarville, Douglas A.
Stickler, Patrick B.
Guzman, Juan C.
Noel, Jennifer S.
Sweetin, Joseph L.
출원인 / 주소
The Boeing Company
대리인 / 주소
Yee & Associates, P.C.
인용정보
피인용 횟수 :
2인용 특허 :
47
초록▼
A method is provided for forming a composite part contoured along its length and having at least one leg. The method includes forming a stack of fiber reinforced, pre-preg plies by laying down individual segments of unidirectional fibers in each ply. Each of the segments is placed in a preselected o
A method is provided for forming a composite part contoured along its length and having at least one leg. The method includes forming a stack of fiber reinforced, pre-preg plies by laying down individual segments of unidirectional fibers in each ply. Each of the segments is placed in a preselected orientation related to the contour of the part. The leg is formed by bending a portion of the stack over a tool.
대표청구항▼
1. A method of forming a composite part contoured along its length and having at least one leg, comprising: forming a ply stack of fiber reinforced pre-preg plies, the forming comprising: laying down a first set of individual tow segments of unidirectional fibers in a first ply layer, the segments e
1. A method of forming a composite part contoured along its length and having at least one leg, comprising: forming a ply stack of fiber reinforced pre-preg plies, the forming comprising: laying down a first set of individual tow segments of unidirectional fibers in a first ply layer, the segments extending a length of the part, including placing each of the segments in a preselected orientation related to a contour of the part, such that the segments are generally aligned to a radial coordinate defining the contour of the part, the contour defining at least a curvature; andlaying down a second set of individual segments of unidirectional fibers in a second ply layer, the second ply layer positioned over the first ply layer, and the second set of individual segments forming a number of tapered wedges;placing the ply stack on a forming mandrel and a layup shelf such that a portion of the ply stack generally corresponding to the at least one leg contacts the layup shelf;moving the layup shelf from contact with the portion of the ply stack generally corresponding to the at least one leg;forming a first bend so as to create the at least one leg by bending a portion of the ply stack over the mandrel;placing the ply stack on the forming mandrel and a layup shelf such that a portion of the ply stack generally corresponding to the at least one leg corresponding to a first leg contacts a first portion of the layup shelf, and a second portion of the ply stack generally corresponding to a second leg contacts the forming mandrel, the forming mandrel configured in the shape of the second leg; andforming a second bend so as to create the second leg of the frame section by bending a portion of the ply stack along a second edge of the stack and to form a web between the first leg and the second leg, and the first leg, the web, and the second leg configured in a Z shape. 2. The method of claim 1, wherein laying down the individual segments is performed by an automatic fiber placement machine. 3. The method of claim 1, wherein forming the stack further includes laying down a third set of individual segments of unidirectional fibers along the length of the part, a fiber orientation of the third set of individual segments of individual fibers at approximately 45 degrees to the first set of individual segments. 4. The method of claim 1, further comprising compacting and curing the formed stack. 5. The method of claim 1, wherein the composite part comprises a frame section for an aircraft. 6. A method of forming a contoured composite frame section, comprising: forming a flat stack of fiber reinforced, pre-preg plies to form a ply stack, the forming comprising: laying down individual fiber tow segments in a first ply layer, the fiber tow segments being unidirectional and continuous, in a preselected polar orientation, said polar orientation comprising a longitudinal axis of each of the segments generally aligned to a radial coordinate defining the contour of the frame section, the contour defining at least a curvature, and the segments extending the length of the part;laying down a second set of continuous individual segments of unidirectional continuous fibers in a second ply layer, the second ply layer positioned over the first ply layer, the second set of individual segments extending generally perpendicular to an orientation of the first set of individual tow segments, and the second set of individual segments forming a number of tapered wedge segments; andlaying down a third set of individual continuous segments of unidirectional fibers along the length of the part, a fiber orientation of the third set of individual segments of individual fibers at approximately 45 degrees to the first set of individual segments;cutting a number of cutouts along an outer edge of the ply stack;placing the ply stack on a forming mandrel and a layup shelf such that a first portion of the ply stack generally corresponding to a first leg of the contoured composite frame section contacts the layup shelf and a second portion of the ply stack generally corresponding to a second leg of the contoured composite frame section contacts the mandrel, the mandrel configured to form the second leg;moving the layup shelf from contact with the leg;forming a first leg of the frame section by placing and bending a portion of the stack over a tool following forming of said stack, wherein forming the first leg of the frame section is performed by bending the stack along a first edge of the stack, and further comprising forming a second leg of the frame section by bending the stack along a second edge of the stack, the second leg bent in an opposition direction than the first leg; and,compacting and curing the formed stack. 7. The method of claim 6, wherein individually placing the fiber segments includes tapering a pattern of the fibers in the segments of the second layer. 8. The method of claim 7, wherein individually placing the fiber segments is performed using an automatic fiber placement machine. 9. The method of claim 6, wherein individually placing the fiber segments is performed by placing fiber tape wedges in side-by-side relationship to each other in the second layer. 10. The method of claim 6, wherein the contoured composite frame section comprises a vehicle. 11. A method of fabricating a contoured composite structure with stringers, the structure characterized by a radial orientation, the method comprising the steps of: laying down a plurality of pre-preg plies so as to form a ply stack, the laying down comprising: laying down continuous unidirectional fiber tow segments in a first ply layer, the fiber segments generally aligned to a radial coordinate defining a curvature of the composite structure, the segments extending the length of the part;laying down continuous unidirectional fiber tow segments in a second ply layer, the second ply layer positioned over the first ply layer, the fiber segments of the second ply layer extending generally perpendicular to an orientation of the tow segments of the first ply layer, and the individual segments of the second ply layer forming a number of tapered wedge segments; andlaying down continuous unidirectional fiber tow segments in a third ply layer, an orientation of the fiber segments of the third ply layer at approximately 45 degrees to the individual segments of the first ply layer;cutting a number of cutouts along a first outer edge of the ply stack, the cutouts adapted to receive the stringers;placing the ply stack on a forming mandrel and a layup shelf, the layup shelf positioned proximate to the forming mandrel such that a supported portion of the ply stack is supported by the layup shelf, the supported portion including the first outer edge of the ply stack having the number of cutouts, and the forming mandrel including a bend, a second outer edge of the ply stack positioned proximate the bend in the forming mandrel;moving the layup shelf from the forming mandrel such that the layup shelf does not support the supported portion of the ply stack; andvacuum bagging and bending the ply stack so as to form a first leg and a second leg, the first leg located at the first outer edge of the ply stack, the second leg located at the second outer edge of the ply stack, the first leg and the second leg bending in opposite directions. 12. The method of claim 11, wherein laying down a plurality of pre-preg plies further comprises tapering a pattern of fibers in at least a segment of at least the second ply. 13. The method of claim 11, wherein laying down a plurality of pre-preg plies is performed using an automatic fiber placement machine. 14. The method of claim 11, wherein laying down a plurality of pre-preg plies further comprises placing a set of fiber tape wedges in a side-by-side relationship with each other in the second layer. 15. The method of claim 1 further comprising cutting a number of cutouts along an outer edge of the ply stack. 16. The method of claim 1 further comprising forming the second leg such that the first leg, the second leg, and a web portion of the ply stack form a z configuration. 17. The method of claim 1, wherein the second set of individual segments have an orientation different than the first set of individual tow segments. 18. The method of claim 1, wherein the second set of individual segments extend generally perpendicular to an orientation of the first set of individual tow segments.
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