Method of manufacturing folded structure with additive features

Patent metadata

Field	Value
Publication number	US-2022016834-A1
Application number	US-202016929195-A
Country	US
Kind code	A1
Filing date	Jul 15, 2020
Priority date	Jul 15, 2020
Publication date	Jan 20, 2022
Grant date	—

Abstract

A method of manufacturing a multi-sided or otherwise relatively three-dimensional formed structure for, e.g., an aerospace vehicle. A relatively planar base structure is constructed using a first construction technique. Features (e.g., ribs) are incorporated into the base structure using a second construction technique (e.g., additive or subtractive manufacturing) to create an intermediate structure. The intermediate structure is folded along fold-lines or otherwise physically formed to create the formed structure, such that some of the features are located within an internal space defined by the formed structure. Joints between the sides of the formed structure are welded, fastened, or otherwise secured. Separately constructed additional elements (e.g., bulkheads) may be incorporated into the structure. A closeout element may be added to the formed structure to further define and close the internal space. Throughout the process, the structures, features, and elements may be refined to desired tolerances.

First claim

Having thus described one or more embodiments of the invention, what is claimed as new and desired to be protected by Letters Patent includes the following:

1 . A method of manufacturing a three-dimensional formed structure, the method comprising:
constructing a base structure; incorporating one or more features into the base structure to create an intermediate structure; physically forming the intermediate structure to create the three-dimensional formed structure, wherein at least one of the one or more features is located within an internal space defined by the three-dimensional formed structure; and securing one or more joints between two or more sides of the three-dimensional formed structure.

2 . The method of claim 1 , wherein the base structure is constructed from wrought plate metal and comprises one or more thicker areas associated with one or more attachment points of the three-dimensional formed structure.

3 . The method of claim 1 , wherein at least one of the one or more features are incorporated into the base structure using an additive manufacturing technique.

4 . The method of claim 1 , wherein the one or more features include one or more stiffening ribs configured to physically stiffen the three-dimensional formed structure.

5 . The method of claim 1 , further including, prior to forming, refining to a tolerance an area of the intermediate structure which will be located within the internal space after forming.

6 . The method of claim 1 , wherein forming the intermediate structure to create the three-dimensional formed structure includes folding the intermediate structure.

7 . The method of claim 6 , wherein the intermediate structure includes one or more fold lines which facilitate forming the three-dimensional formed structure by folding the intermediate structure along the one or more fold lines.

8 . The method of claim 1 , wherein at least one of the one or more joints are secured by welding.

9 . The method of claim 1 , wherein at least one of the one or more joints are secured by fastening.

10 . The method of claim 1 , further including incorporating one or more separately constructed additional elements into the intermediate structure prior to forming or into the three-dimensional formed structure after forming.

11 . The method of claim 10 , wherein the one or more separately constructed additional elements include a bulkhead extending across the internal space.

12 . The method of claim 1 , further including incorporating a closeout element into the three-dimensional formed structure, wherein the closeout element further defines and closes the internal space.

13 . A method of manufacturing a multi-sided formed structure, the method comprising:
constructing a base structure using a first construction technique; incorporating one or more features into the base structure using a second construction technique to create an intermediate structure, wherein the intermediate structure includes one or more fold lines; refining to a tolerance an area of the intermediate structure which will be located within an internal space defined by the multi-sided formed structure; folding the intermediate structure along the one or more fold lines to create the multi-sided formed structure having two or more sides, wherein at least one of the one or more additional features is located within the internal space defined by the multi-sided formed structure; and securing one or more joints between the two or more sides of the multi-sided formed structure.

14 . The method of claim 13 , wherein the base structure is constructed from wrought plate metal and comprises one or more thicker areas associated with one or more attachment points of the multi-sided formed structure.

15 . The method of claim 13 , wherein the second construction technique is an additive manufacturing technique.

16 . The method of claim 13 , wherein the one or more features include one or more stiffening ribs configured to physically stiffen the multi-sided formed structure.

17 . The method of claim 13 , wherein at least one of the one or more joints are secured by welding.

18 . The method of claim 13 , further including incorporating one or more separately constructed additional elements into the intermediate structure prior to forming or into the multi-sided formed structure after forming.

19 . The method of claim 13 , further including incorporating a closeout element into the multi-sided formed structure, wherein the closeout element further defines and closes the internal space.

20 . A method of manufacturing a multi-sided formed structure which is a component of an aerospace vehicle, the method comprising:
constructing a base structure using a first construction technique; incorporating one or more features into the base structure using an additive manufacturing technique to create an intermediate structure, wherein the one or more features include one or more stiffening ribs configured to physically stiffen the multi-sided formed structure, and wherein the intermediate structure includes one or more fold lines; refining to a tolerance an area of the intermediate structure which will be located within an internal space defined by the multi-sided formed structure; folding the intermediate structure along the one or more fold lines to create the multi-sided formed structure having two or more sides, wherein at least one of the one or more additional features is located within the internal space defined by the multi-sided formed structure; and welding one or more joints between the two or more sides of the multi-sided formed structure. incorporating a closeout element into the multi-sided formed structure, wherein the closeout element further defines and closes the internal space.

Assignees

• Spirit Aerosys Inc

Inventors

• West Randall Ray

Classifications

• B64D27/402

  comprising box like supporting frames, e.g. pylons or arrangements for embracing the power plant · CPC title

• Y02T50/60

  Efficient propulsion technologies, e.g. for aircraft · CPC title

• Y02P10/25

  Process efficiency · CPC title

• B64F5/10

  Manufacturing or assembling aircraft, e.g. jigs therefor · CPC title

• B22F10/25

  Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS] · CPC title