초록

A mandrel tool for layup of composite material comprises a composite face sheet for providing a layup surface for the composite material, and a cellular header board structure for supporting the face sheet.

대표청구항 ▼

1. A method comprising fabricating a masterless layup mandrel tool for laying up and curing a fiber-reinforced composite part, wherein fabricating the layup mandrel tool includes: creating a cellular structure from header boards;filling the cellular structure with a foam-like material;forming a fibe

1. A method comprising fabricating a masterless layup mandrel tool for laying up and curing a fiber-reinforced composite part, wherein fabricating the layup mandrel tool includes: creating a cellular structure from header boards;filling the cellular structure with a foam-like material;forming a fiber-reinforced composite face sheet on the filled cellular structure, including machining to alter the shape of the foam-like material and the cellular structure of the filled cellular structure to obtain a desired surface for layup, laying up fabric having reinforcing fibers and resin on the desired surface, and curing the fabric and resin; andmachining an exposed surface of the face sheet to form a layup surface. 2. The method of claim 1, further comprising cleaning, sealing and release coating the machined face sheet surface. 3. The method of claim 1, wherein the cellular structure is an egg crate cellular structure. 4. The method of claim 1, wherein the header boards are made of an epoxy resin. 5. The method of claim 1, wherein the header boards are made of Bismaleimide. 6. The method of claim 1, wherein the face sheet has a complex contour surface. 7. The method of claim 1, wherein the cellular structure includes a grid of empty cells. 8. The method of claim 1, wherein the header boards are configured to release the foam-like material as blocks. 9. The method of claim 1, wherein the foam-like material is removed from the cellular structure as blocks. 10. The method of claim 1, wherein filling the cellular structure includes using previously-used blocks of foam-like material. 11. The method of claim 1, wherein the face sheet is bonded to the cellular structure. 12. The method of claim 1, further comprising: forming a resin-impregnated carbon fiber layup of the part on the tool;bagging the layup; andcuring the layup on the tool. 13. The method of claim 1, wherein the foam-like material includes autoclave aerated concrete. 14. The method of claim 1, wherein the foam-like material includes ceramic. 15. The method of claim 1, wherein the foam-like material includes carbon foam. 16. The method of claim 1, wherein the foam-like material includes polyisocyanurate. 17. The method of claim 1, wherein the foam-like material includes polyurethane. 18. A method comprising fabricating a layup mandrel tool for laying up and curing a fiber-reinforced composite part, wherein fabricating the layup mandrel tool includes creating an egg crate cellular structure from header boards;filling the cellular structure with a material of one of polyurethane, polyisocyanurate, carbon foam, ceramic, and autoclave aerated concrete;forming a fiber-reinforced composite face sheet on the filled cellular structure, including machining to alter the shape of the material filling and the cellular structure to obtain a desired surface for layup, laying up and curing fabric having reinforcing fibers on the desired surface; andmachining an exposed surface of the face sheet to form a layup surface. 19. The method of claim 18, further comprising: forming a resin-impregnated carbon fiber layup of the part on the tool;bagging the layup; andcuring the layup on the tool.