Fuselage mandrel insert and method

Patent metadata

Field	Value
Publication number	US-9862152-B2
Application number	US-201615078364-A
Country	US
Kind code	B2
Filing date	Mar 23, 2016
Priority date	Jun 19, 2013
Publication date	Jan 9, 2018
Grant date	Jan 9, 2018

Abstract

An apparatus for use in formation of a composite structure about a mandrel. A generally flexible pneumatic tool and a generally rigid insert are inserted end to end in a cavity of the mandrel. A first end of the insert is positioned in the cavity, adjacent the pneumatic tool, and defines an interface therebetween. The retainer is connected to the insert proximate the first end of the insert. The retainer has an end that extends outwardly from the first end of the insert across the interface and over a portion of the end of the pneumatic tool. The uppermost surfaces of the insert, retainer, and pneumatic tool are generally flush with one another and facilitate a smooth surface being formed over such uppermost surfaces as the composite material is wound about the mandrel in the formation of the composite structure.

First claim

What is claimed is:

1. An apparatus for use with an elongated pneumatic tool in a cavity of a mandrel used in the formation of an elongated composite structure, the elongated pneumatic tool defining a generally vertical end and having a generally tapered top surface portion that terminates in a generally horizontal uppermost top surface, the mandrel defining an end and an uppermost surface on which composite material is applied, and the apparatus comprising:
a generally rigid insert having a first end defining a generally vertical surface portion and a second end generally opposite the first end;
the generally vertical surface portion of the first end of the insert being configured to be positioned in the cavity in a close or abutting relationship with the generally vertical end of the elongated pneumatic tool to define an interface between the first end of the insert and the end of the elongated pneumatic tool;
an elongated retainer having a first end connected with a fastener to the insert proximate the first end of the insert; and
the retainer having a second end generally opposite the first end of the retainer that extends longitudinally outwardly from the first end of the insert across the interface and over a portion of the end of the elongated pneumatic tool.

2. The apparatus of claim 1 , wherein:
the retainer defines an uppermost surface and a second surface generally opposite the uppermost surface;
the second end of the retainer having an extreme end; and
the second surface of the retainer is upwardly sloped towards the extreme end of the second end of the retainer.

3. The apparatus of claim 1 , wherein the retainer is constructed of Invar.

4. The apparatus of claim 1 , wherein the insert is constructed of substantially the same material as is the mandrel.

5. The apparatus of claim 1 , wherein the insert is constructed of composite material.

6. The apparatus of claim 1 , wherein the second end of the insert is substantially adjacent the end of the mandrel.

7. The apparatus of claim 1 , wherein the first end of the insert is substantially distal from the end of the mandrel.

8. The apparatus of claim 1 , wherein:
the insert defines an uppermost surface and a lower surface; and
the uppermost surface of the insert defines a recess that receives the retainer.

9. The apparatus of claim 1 , wherein the uppermost surface of the insert adjacent the recess is substantially flush with the uppermost surface of the retainer.

10. The apparatus of claim 1 , wherein the retainer is removably attached to the insert.

11. An apparatus for forming an elongated composite structure, comprising: an elongated mandrel defining at least one cavity;
at least one generally flexible elongated pneumatic tool that is inserted in the cavity, the flexible elongated pneumatic tool having a generally vertical end;
at least one generally rigid elongated insert that is inserted in the cavity;
the insert having a generally vertical first end and a second end generally opposite the first end and being configured to be positioned in the cavity in a close or abutting relationship with the generally vertical end of the flexible elongated pneumatic tool to define an interface therebetween;
an elongated retainer having a first end connected with a fastener to the insert proximate the first end of the insert; and
the retainer having a second end generally opposite the first end of the retainer that extends longitudinally outwardly from the first end of the insert across the interface and over a portion of the end of the flexible elongated pneumatic tool.

12. The apparatus of claim 11 , wherein:
the end of the flexible elongated pneumatic tool defines a sloped upper surface portion and an uppermost portion generally adjacent the sloped upper surface portion;
the retainer defines an uppermost surface and a second surface generally opposite the uppermost surface;
the second end of the retainer is an extreme end;
the second surface of the retainer is upwardly sloped towards the extreme end of the second end of the retainer; and
the second surface of the retainer extends adjacent the sloped uppermost surface portion of the flexible elongated pneumatic tool.

13. The apparatus of claim 11 wherein:
the insert defines an uppermost surface and a lower surface; and
the uppermost surface of the insert defines a recess that receives the retainer.

14. The apparatus of claim 11 , wherein:
the uppermost surface of the insert adjacent the recess is substantially flush with the uppermost surface of the retainer; and
the uppermost surface of the retainer is substantially flush with the uppermost surface of the flexible elongated pneumatic tool.

15. The apparatus of claim 11 , wherein:
the end of the flexible elongated pneumatic tool defines a sloped upper surface portion and an uppermost portion generally adjacent the sloped upper surface portion;
the retainer defines an uppermost surface and a second surface generally opposite the uppermost surface;
the second end of the retainer has an extreme end;
the second surface of the retainer is upwardly sloped towards the extreme end of the second end of the retainer;
the second surface of the retainer extends adjacent the sloped uppermost surface portion of the flexible elongated pneumatic tool;
the insert defines an uppermost surface;
the uppermost surface of the insert defines a recess that receives the retainer;
the uppermost surface of the insert adjacent the recess is substantially flush with the uppermost surface of the retainer; and
the uppermost surface of the retainer is substantially flush with the uppermost surface of the flexible elongated pneumatic tool.

16. The apparatus of claim 11 , wherein the retainer is constructed of Invar.

17. The apparatus of claim 11 , wherein the insert is constructed of substantially the same material as is the mandrel.

18. The apparatus of claim 11 , wherein the insert is constructed of composite material.

19. The apparatus of claim 11 , wherein the second end of the insert is substantially adjacent the end of the mandrel.

20. The apparatus of claim 11 , wherein the first end of the insert is substantially distal from the end of the mandrel.

Assignees

• Boeing Co

Inventors

• Nguyen Loi K
• Havens Jesse M
• Morassutti Jean-Marc

Classifications

• B29C33/405

  Elastomers, e.g. rubber (B29C33/50 takes precedence) · CPC title

• Y02T50/433

  Cross-Sectional Technologies · mapped topic

• B29L2031/3082

  Fuselages · CPC title

• B29C70/446 Primary

  Moulding structures having an axis of symmetry or at least one channel, e.g. tubular structures, frames · CPC title

• B29C70/021 Primary

  Combinations of fibrous reinforcement and non-fibrous material · CPC title