Formation of composite laminates having one or more divergent flanges

Patent metadata

Field	Value
Publication number	US-10105940-B2
Application number	US-201615132073-A
Country	US
Kind code	B2
Filing date	Apr 18, 2016
Priority date	Apr 18, 2016
Publication date	Oct 23, 2018
Grant date	Oct 23, 2018

Abstract

Systems and methods are provided for divergent laminates. A method comprises providing a layup tool having a first upper face and a second upper face that rise to intersect each other at a ridge line, the layup tool further having a protrusion on top of a portion of the ridge line, and laying up a laminate onto the upper faces and the protrusion. The method also comprises placing a cure tool on top of the layup tool, the cure tool having a lower face that is dimensioned to mate with the upper faces along a portion of the ridge line that is not covered by the protrusion, thereby leaving a divergent flange of the laminate on top of the protrusion exposed, and sweeping the divergent flange of the laminate upward from the layup tool onto a vertical side the cure tool.

First claim

The invention claimed is:

1. A method comprising:
providing a layup tool having a first upper face and a second upper face that rise to intersect each other at a ridge line, the layup tool further having a protrusion on top of a portion of the ridge line;
laying up a laminate onto the upper faces and the protrusion;
mating a cure tool to a top of the layup tool; and
sweeping the divergent flange of the laminate upward from the layup tool onto a vertical side the cure tool.

2. The method of claim 1 wherein:
the cure tool has lower faces that are dimensioned to mate with the upper faces along a portion of the ridge line that is not covered by the protrusion, thereby leaving a divergent flange of the laminate on top of the protrusion exposed.

3. The method of claim 1 further comprising:
laying up a convergent flange of the laminate onto a vertical side of the layup tool.

4. The method of claim 1 wherein:
the laminate is laid-up symmetrically onto the layup tool with respect to the ridge line.

5. The method of claim 1 wherein:
sweeping the divergent flange of the laminate upward causes divergence in the divergent flange.

6. The method of claim 1 further comprising:
applying constant pressure to the divergent flange while sweeping the divergent flange.

7. The method of claim 1 further comprising:
curing the laminate into a composite part.

8. A system comprising:
a laminate that will be cured into a composite part;
a layup tool for shaping the laminate, the layup tool comprising:
a first upper face and a second upper face that rise to intersect each other at a ridge line and support a web of the laminate; and
a protrusion on top of a portion of the ridge line that supports a divergent flange of the laminate; and

a cure tool on top of the layup tool, the cure tool comprising:
a lower section that is mated with the upper faces and leaves the divergent flange of the laminate exposed; and
a vertical side to which the divergent flange of the laminate is folded upward onto.

9. The system of claim 8 wherein:
a size of the protrusion increases based on distance along the ridge line.

10. The system of claim 8 wherein:
a size of the protrusion corresponds with an amount of divergence that will occur when the divergent flange is folded upward onto the vertical side.

11. The system of claim 8 wherein:
the lower section is mated with the upper faces along a portion of the ridge line that is not covered by the protrusion.

12. A system comprising:
a layup tool for shaping a laminate that will be cured into a composite part, the layup tool comprising:
a first upper face and a second upper face that rise to intersect each other at a ridge line and receive a web of the laminate; and
a protrusion on top of a portion of the ridge line that receives a divergent flange of the laminate; and

a cure tool on top of the layup tool, the cure tool comprising:
a lower section that mates with the upper faces and leaves the divergent flange of the laminate exposed; and
a vertical side that receives the divergent flange of the laminate when the divergent flange of the laminate is folded upward.

13. The system of claim 12 wherein:
a size of the protrusion increases based on distance along the ridge line.

14. The system of claim 12 wherein:
a size of the protrusion corresponds with an amount of divergence that will occur when the divergent flange is folded upward onto the vertical side.

15. The system of claim 12 wherein:
the protrusion is symmetrical with respect to the ridge line.

16. The system of claim 12 wherein:
the upper faces rise symmetrically towards the ridge line.

17. The system of claim 12 wherein:
the upper faces slope upward to the ridge line at an angle of less than ten degrees.

18. The system of claim 12 wherein:
the protrusion size corresponds with an amount of divergence that will occur in the divergent flange when the second portion is folded upward onto the side.

19. The system of claim 12 wherein:
the ridge line is straight.

20. The system of claim 12 wherein:
the lower section comprises two lower faces that intersect each other at a line.

21. The system of claim 12 wherein:
the layup tool further comprises a vertical side dimensioned to receive a convergent flange of the laminate.

Assignees

• Boeing Co

Inventors

• Chapman Michael Robert
• Carlson Lisa Christina

Classifications

• B32B2305/72

  Cured, e.g. vulcanised, cross-linked · CPC title

• B29C33/00

  Moulds or cores; Details thereof or accessories therefor · CPC title

• B29C70/345 Primary

  using matched moulds · CPC title

• B32B37/10

  characterised by the pressing technique, e.g. using action of vacuum or fluid pressure · CPC title

• B29C33/42

  characterised by the shape of the moulding surface, e.g. ribs or grooves · CPC title