Flexible Caul and Method of Making the Same

Patent metadata

Field	Value
Publication number	US-2021107239-A1
Application number	US-201916600925-A
Country	US
Kind code	A1
Filing date	Oct 14, 2019
Priority date	Oct 14, 2019
Publication date	Apr 15, 2021
Grant date	—

Abstract

A flexible caul for applying pressure to a part comprises a caul member having a plurality of spaced apart gaps therein to provide the caul member with flexibility, and a flexible covering that limits flexing of the caul member.

First claim

What is claimed is:

1 . A flexible caul for applying pressure to a part, comprising:
a caul member configured to be placed against the part and having a plurality of spaced apart gaps therein to provide the caul member with flexibility; and a flexible covering on the caul member and configured to limit flexing of the caul member.

2 . The flexible caul of claim 1 , wherein the caul member is formed of a rigid material, and has a length and a plurality of hinged segments along its length.

3 . The flexible caul of claim 1 , wherein:
each of the spaced apart gaps is a slit having an end, and the caul member includes a flexible zone at the end of each slits.

4 . The flexible caul of claim 3 , wherein the caul member has a width and each slit extends at least partially across the width of the caul member.

5 . The flexible caul of claim 1 , wherein the caul member is a composite laminate.

6 . The flexible caul of claim 1 , wherein the flexible covering fills the plurality of spaced apart gaps such that the caul member comprises a substantially smooth surface to be placed against the part.

7 . The flexible caul of claim 1 , wherein:
the caul member has a length, and the plurality of spaced apart gaps are spaced along the length of the caul member.

8 . The flexible caul of claim 1 , wherein:
the caul member includes a width, a length, a first side, and a second side opposite the first side, the plurality of spaced apart gaps comprise slits extending at least partially across the width of the caul member, and the slits are arranged in an alternating relationship to each other along the length.

9 . A configurable tool for forming a part, comprising:
a tool member formed of a rigid material and having surfaces configured to engage the part, the tool member having a length and including a plurality of spaced apart gaps therein along its length, the plurality of spaced apart gaps forming flexible zones to allow the tool member to flex to a desired shape; and a flexible material to fill the plurality of spaced apart gaps such that flexing of the tool member is limited.

10 . The configurable tool of claim 9 , wherein each of the spaced apart gaps is a slit extending at least partially across a width of the tool member to allow the tool member to flex.

11 . The configurable tool of claim 10 , wherein each slit has an end, and the tool member includes a flexible zone forming a hinge at the end of each of the slits.

12 . The configurable tool of claim 9 , wherein the tool member is a composite laminate.

13 . The configurable tool of claim 9 , wherein flexible material is an elastomer and covers the tool member.

14 . The configurable tool of claim 9 , wherein each of the flexible zones is located at an end of each spaced apart gap of the plurality of spaced apart gaps.

15 . The configurable tool of claim 9 , wherein the tool member has opposite sides and the plurality of spaced apart gaps extend inwardly from the opposite sides of the tool member.

16 . A method of making a flexible tool, comprising:
producing a tool member formed of a rigid material and having a length; forming a plurality of gaps in the tool member at spaced apart locations such that the gaps allow the tool member to flex; and covering the tool member with a flexible material that limits flexing of the tool member.

17 . The method of claim 16 , wherein producing the tool member includes laying up, compacting and forming plies of a composite material.

18 . The method of claim 16 , wherein forming the plurality of gaps includes forming slits in the tool member at opposite sides of the tool member partially across a width of the tool member.

19 . The method of claim 16 , wherein forming the plurality of gaps includes forming slits in the tool member by at least one of cutting and sawing.

20 . The method of claim 16 , wherein covering the tool member is performed by at least one of—
spraying the tool member with the flexible material,
dipping the tool member in the flexible material, and
insert-molding the tool member in the flexible material.

Assignees

• Boeing Co

Inventors

• Saini Gagandeep
• Carlson Lisa Christina
• Santiago Jonathan
• Willden Kurtis Shuldberg

Classifications

• B29C70/54 Primary

  Component parts, details or accessories; Auxiliary operations {, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing} · CPC title

• B29C70/549 Primary

  Details of caul plates, e.g. materials or shape · CPC title

• B29C70/30

  Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core · CPC title

• B29C2043/3655

  Pressure transmitters, e.g. caul plates; pressure pads · CPC title

• B29C33/56

  Coatings {, e.g. enameled or galvanised}; Releasing, lubricating or separating agents {(in-mould coating B29C37/0028; using or applying separating agents B29C37/0067)} · CPC title