Method for making contoured composite stiffeners

Patent metadata

Field	Value
Publication number	US-9604417-B2
Application number	US-201113079945-A
Country	US
Kind code	B2
Filing date	Apr 5, 2011
Priority date	Apr 5, 2011
Publication date	Mar 28, 2017
Grant date	Mar 28, 2017

Abstract

A contoured composite part is made by assembling a preform charge, including aligning a plurality of plies along a preselected contour. The assembled aligned preform charge is then placed in a forming tool, where the charge is formed and cured.

First claim

What is claimed:

1. A method of making a compound contoured composite blade stringer for aircraft, comprising:
placing a resin distribution media on an assembly tool;
placing a preform on the assembly tool covering the resin distribution media to form a preform charge;
aligning the resin distribution media and the preform charge relative to each other and along an alignment guide having a first contour;
placing a blade height spacer over the preform charge;
clamping a flange portion of the charge to maintain the alignment of the charge, including using the blade height spacer to control placement of clamps on the charge, to form a clamped charge;
installing an inner vacuum bag over a forming tool;
applying a first vacuum to a forming tool side of the inner vacuum bag
transferring the clamped charge to the forming tool;
clamping a web portion of the charge in the forming tool, including inflating a bladder and using the inflation of the bladder to move a pair of mandrels into clamping engagement with the charge;
removing the clamps from the flange portion of the charge while the web portion of the charge is clamped between the mandrels;
forming a formed charge including a pair of stringer flanges by folding the flange portion of the charge down onto the mandrels;
folding the inner vacuum bag back over the formed charge;
placing an outer vacuum bag over the inner vacuum bag covering the formed charge;
sealing the inner and outer bags;
applying second and third vacuums respectively to the inner vacuum bag and the outer vacuum bag;
infusing the preform with resin by introducing resin into the inner vacuum bag to form a resin infused fiber preform;
curing the resin infused fiber preform on the forming tool to form a cured stringer; and
removing the cured stringer from the forming tool following curing.

Assignees

• Modin Andrew E
• Boeing Co

Inventors

• Modin Andrew E

Classifications

• B29C70/342

  using isostatic pressure · CPC title

• Y10T156/1044

  of parallel stacked sheets only · CPC title

• Y10T428/24

  Structurally defined web or sheet [e.g., overall dimension, etc.] · CPC title

• B29C70/543 Primary

  Fixing the position or configuration of fibrous reinforcements before or during moulding (for non-woven fabrics D04H3/08) · CPC title

• B29C70/443

  and impregnating by vacuum or injection · CPC title