US20160129647A1 - Method and device for the production of tubular structural components - Google Patents
Method and device for the production of tubular structural components Download PDFInfo
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- US20160129647A1 US20160129647A1 US14/928,389 US201514928389A US2016129647A1 US 20160129647 A1 US20160129647 A1 US 20160129647A1 US 201514928389 A US201514928389 A US 201514928389A US 2016129647 A1 US2016129647 A1 US 2016129647A1
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- support
- moulding tool
- fibre fabric
- tubular
- pressure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/44—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
- B29C33/48—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles with means for collapsing or disassembling
- B29C33/50—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles with means for collapsing or disassembling elastic or flexible
- B29C33/505—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles with means for collapsing or disassembling elastic or flexible cores or mandrels, e.g. inflatable
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
- B29C70/48—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- 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
- B29C70/34—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 and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
- B29C70/345—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 and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using matched moulds
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- 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
- B29C70/36—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 and impregnating by casting, e.g. vacuum casting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
- B29C70/443—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding and impregnating by vacuum or injection
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
- B29C70/446—Moulding structures having an axis of symmetry or at least one channel, e.g. tubular structures, frames
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
- B29C70/541—Positioning reinforcements in a mould, e.g. using clamping means for the reinforcement
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D23/00—Producing tubular articles
- B29D23/001—Pipes; Pipe joints
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B30—PRESSES
- B30B—PRESSES IN GENERAL
- B30B5/00—Presses characterised by the use of pressing means other than those mentioned in the preceding groups
- B30B5/02—Presses characterised by the use of pressing means other than those mentioned in the preceding groups wherein the pressing means is in the form of a flexible element, e.g. diaphragm, urged by fluid pressure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
- B29K2105/0872—Prepregs
- B29K2105/089—Prepregs fabric
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2307/00—Use of elements other than metals as reinforcement
- B29K2307/04—Carbon
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2023/00—Tubular articles
- B29L2023/22—Tubes or pipes, i.e. rigid
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3076—Aircrafts
- B29L2031/3082—Fuselages
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T50/00—Aeronautics or air transport
- Y02T50/40—Weight reduction
Definitions
- the present invention relates to a method and a device for the production of a tubular structural component, in particular a fuselage barrel section of an aircraft or spacecraft.
- the winding body Since it is possible for slight differences in diameter of adjacent fuselage barrel sections to impede the final assembly, the winding body has to have a high dimensional accuracy and must not expand any further after the fibre placement procedure, for example during a heat treatment. At the same time, it is necessary to configure the winding body such that it can be split or collapsed, so that after the curing procedure, it can be contracted inwards by splitting or collapsing and can be removed from the fuselage barrel section. The provision of a winding body which combines these characteristics is associated with high costs.
- pressure sheets are also applied for the curing procedure.
- tear-off or ventilation fabric between the pressure sheet and prepreg layers as this would result in a rough surface of the fuselage barrel section.
- an inadequate removal of resin or air results in porous and thus low-quality components.
- the thickness of the prepreg layers is reduced during the curing procedure by the so-called setting path, which is to be considered during shaping and when the pressure sheets are pressed on.
- the setting path of the prepreg material can vary as a function of the material charge and thus, for example when there is a charge with a relatively long setting path, this can give rise to porosity. Since the internal diameter of the fuselage barrel section is predetermined in a fixed manner by the external diameter of the winding body, the external diameter of the fuselage barrel section is reduced during the gradual setting of the prepreg interlaid scrim. Consequently, the prepreg layers are pushed together in the peripheral direction of the section, which readily results in an undesirable waviness of the fibres.
- the support is then arranged in the moulding tool such that the support surface covered by the tubular non-crimp fibre fabric is opposite the inner surface of the moulding tool, the expansion spacing which is reduced by the thickness of the non-crimp fibre fabric remaining between the non-crimp fibre fabric and the inner surface.
- the support is then expanded, as a result of which this remaining spacing is shrunk to zero and the non-crimp fibre fabric is pressed against the inner surface of the moulding tool by the support surface of the expanded support.
- the non-crimp fibre fabric held between the support surface and the inner surface of the moulding tool is infiltrated by a curable matrix.
- the expansion spacing is between 1 and 10 cm, for example approximately 5 cm. With such a spacing, sufficient clearance remains between the support surface and the inner surface of the moulding tool in order to move the support into and out of the moulding tool in a particularly fast and contact-free manner, while on the other hand the tubular non-crimp fibre fabric is prevented from being overstretched during the expanding procedure.
- the reinforcing element is arranged in a correspondingly configured recess in the support surface. This facilitates the charging of the support with the reinforcing element.
- FIG. 3A-D are cross-sectional views of details of a device according to a third embodiment during the production of a tubular structural component.
- FIG. 1A to 1C are three schematic perspective views of a device for the production of a fuselage barrel section of an aircraft, each of the three figures showing different steps of a production method.
- the fuselage barrel section to be produced is approximately in the shape of a cylinder barrel, the cross section typically differing from the ideal circular shape and changing over the length of the section.
- the non-crimp fibre fabric 114 comprises a plurality of fibre layers of different orientations in which the fibres 116 run diagonally, as shown by way of example, i.e. spirally around the periphery of the support 110 . In further fibre layers (not shown), fibres run at other inclination angles diagonally or parallel to the longitudinal direction of the support 110 .
- a reinforcing element 208 with a T-shaped profile as used for example in aircraft construction as a so-called T-stringer, has been inserted into the recess 120 .
- the horizontal bar 209 of the T-shaped profile rests inside the flattened area 211 against the support frame 111 covered by the pressure membrane 200 .
- FIG. 2F shows the support 110 arranged in the moulding tool 102 after the interior 202 between the support frame 111 and the pressure membrane 200 has been connected to a compressor 205 and has been subjected to excess pressure through the fine holes 203 .
- the excess pressure has inflated the pressure membrane 200 such that it has expanded in a radial direction 212 as far as the surface 106 of the moulding tool 102 .
- Both the pressure membrane and the non-crimp fibre fabric have been stretched by the expansion.
- the reinforcing element 208 and the non-crimp fibre fabric 114 have been guided by the expanding pressure membrane 200 to the mould surface 106 and, in the illustrated state, are pressed against the mould surface 106 with uniform contact pressure provided by the excess pressure.
- the reinforcing element 208 has been guided through the recess 120 in a radial direction 112 and, in the illustrated state, is also still held in the recess 120 , as in a guide slot, and is thus positioned precisely.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Physics & Mathematics (AREA)
- Fluid Mechanics (AREA)
- Moulding By Coating Moulds (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Abstract
A method for producing a tubular structural component and device for production thereof are disclosed. A tubular moulding tool has an inner mould surface shaped corresponding to an outer surface of the structural component. A support surface of an expandable support, formed corresponding to the moulding tool shape such that in an unexpanded state the support fills the moulding tool while the support surface and the mould surface run parallel leaving an expansion spacing of the support surface to the mould surface, is covered with a tubular non-crimp fibre fabric, such that fibres of a fibre layer of the non-crimp fibre fabric run diagonally around the support. After the support has been arranged in the moulding tool, the non-crimp fibre fabric is pressed against the mould surface by expanding the support with radial expansion of the non-crimp fibre fabric. The non-crimp fibre fabric is infiltrated by a curable matrix.
Description
- This application is a divisional patent application of and claims priority to U.S. patent application Ser. No. 14/285,704, filed May 23, 2014, which is a continuation of U.S. patent application Ser. No. 12/794,487 filed Jun. 10, 2010, which is a continuation of PCT/EP2008/065355 which claims the benefit of U.S. Provisional Application No. 61/007,492, filed Dec. 13, 2007 and German Patent Application No. 10 2007 060 029.3, filed Dec. 13, 2007, the entire disclosures of which are herein incorporated by reference.
- The present invention relates to a method and a device for the production of a tubular structural component, in particular a fuselage barrel section of an aircraft or spacecraft.
- Although the present invention and the problem on which it is based can be applied to any tubular structural components with any cross-sectional shapes, they will be described in detail in respect of the production of fuselage barrel sections of aircraft.
- In the construction of aircraft fuselage, particularly for commercial aircraft, it is usual to prefabricate tubular or barrel-shaped fuselage sections individually and to assemble them into the finished fuselage in a subsequent final assembly. Materials which are used to an increasing extent are fibre composite materials, for example carbon fibre reinforced plastics materials (CFRP) which make it possible to achieve a high stability of the sections with a relatively low weight.
- A fuselage barrel section based on fibre composite materials is produced according to a conventional method using a winding body as a positive mould, onto which layers of a fibre material pre-impregnated with a resin matrix (prepreg) are wound and subsequently cured, for example by a heat treatment. The fibre placement or winding procedure is very time-intensive due to the size of the component and to different fibre directions of the prepreg layers.
- Since it is possible for slight differences in diameter of adjacent fuselage barrel sections to impede the final assembly, the winding body has to have a high dimensional accuracy and must not expand any further after the fibre placement procedure, for example during a heat treatment. At the same time, it is necessary to configure the winding body such that it can be split or collapsed, so that after the curing procedure, it can be contracted inwards by splitting or collapsing and can be removed from the fuselage barrel section. The provision of a winding body which combines these characteristics is associated with high costs.
- In order to obtain a fuselage barrel section which has a smooth outer surface and correspondingly advantageous aerodynamic characteristics, pressure sheets are also applied for the curing procedure. In this case, there must not be any auxiliary material, for example tear-off or ventilation fabric between the pressure sheet and prepreg layers as this would result in a rough surface of the fuselage barrel section. In general, it is not possible to remove excess resin or air from the space between the winding body and the pressure sheets. However, an inadequate removal of resin or air results in porous and thus low-quality components.
- Further problems are caused in that the thickness of the prepreg layers is reduced during the curing procedure by the so-called setting path, which is to be considered during shaping and when the pressure sheets are pressed on. However, the setting path of the prepreg material can vary as a function of the material charge and thus, for example when there is a charge with a relatively long setting path, this can give rise to porosity. Since the internal diameter of the fuselage barrel section is predetermined in a fixed manner by the external diameter of the winding body, the external diameter of the fuselage barrel section is reduced during the gradual setting of the prepreg interlaid scrim. Consequently, the prepreg layers are pushed together in the peripheral direction of the section, which readily results in an undesirable waviness of the fibres.
- It is therefore the object of the present invention to achieve a high quality at a low cost when tubular structural components and in particular fuselage barrel sections are produced.
- The idea on which the present invention is based is to use for the production of the structural component a moulding tool which is also tubular and is configured as a negative mould, i.e. it has an inner mould surface which is a negative of the outer surface to be formed of the structural component. The term “tubular” as used herein is not restricted to tubes with a circular cross section, but explicitly includes tubes with elliptical, rectangular or other randomly shaped cross sections, in which case the cross section does not need to be constant over the length of the tubes, but can be narrowed, widened or shaped in another way.
- In order to arrange non-crimp fibre fabrics on the inner surface of the moulding tool, a support is also provided which can be expanded, in other words can be selectively brought at least into an expanded and an unexpanded state. In the unexpanded state, the shape of the support is smaller than the space described by the inner surface of the moulding tool such that the support can be arranged in this state inside the moulding tool. In so doing, there remains between the inner surface of the moulding tool and an outer surface of the support a minimum spacing which is termed here the expansion spacing.
- The outer surface of the support which opposes the inner surface of the moulding tool when the support is arranged in the moulding tool serves as a support surface which supports the non-crimp fibre fabric to be processed during the production process. The non-crimp fibre fabric is provided in tubular form and arranged on the support surface such that the support surface is covered by the tubular non-crimp fibre fabric. For example, the tubular non-crimp fibre fabric is pulled over the support while the support, in the unexpanded state, is freely accessible outside the moulding tool.
- The support is then arranged in the moulding tool such that the support surface covered by the tubular non-crimp fibre fabric is opposite the inner surface of the moulding tool, the expansion spacing which is reduced by the thickness of the non-crimp fibre fabric remaining between the non-crimp fibre fabric and the inner surface. The support is then expanded, as a result of which this remaining spacing is shrunk to zero and the non-crimp fibre fabric is pressed against the inner surface of the moulding tool by the support surface of the expanded support. In a final step, the non-crimp fibre fabric held between the support surface and the inner surface of the moulding tool is infiltrated by a curable matrix.
- The use of a negative mould which reproduces the outer contour of the fuselage barrel section makes it possible to observe the desired external dimensions with a high degree of accuracy. The moulding tool can be configured without a considerable constructive expense in one piece or in a simple manner such that it can be opened outwards or can be disassembled. The setup of the non-crimp fibre fabric on the support, regardless of the moulding tool and curing tool, makes it possible to provide a plurality of supports suitable for a given moulding tool and to alternately charge one of the supports with non-crimp fibre fabric outside the moulding tool, while another support is located in the moulding tool for curing. In this manner, it is possible to use the moulding tool and, if appropriate, a curing station in a continuous manner, which reduces the production costs and shortens dead time.
- The use of non-crimp fibre fabric which is infiltrated by a separately provided matrix affords further advantages in terms of time and greater freedom in the construction of the structural components which have been produced compared to the conventional use of prepregs. Fibre undulations are prevented due to the fact that the non-crimp fibre fabric is stretched by the expansion of the support in the peripheral direction.
- According to a preferred development, the expansion spacing is between 1 and 10 cm, for example approximately 5 cm. With such a spacing, sufficient clearance remains between the support surface and the inner surface of the moulding tool in order to move the support into and out of the moulding tool in a particularly fast and contact-free manner, while on the other hand the tubular non-crimp fibre fabric is prevented from being overstretched during the expanding procedure.
- According to a preferred development, the support surface is covered such that fibres of a fibre layer of the non-crimp fibre fabric run diagonally around the support. This advantageously allows the tubular non-crimp fibre fabric to expand radially, the angle of inclination of the fibres changing without the fibres being overstretched in their longitudinal direction. After the support has been covered, the tubular non-crimp fibre fabric is preferably longer than the structural component, such that when the support is expanded radially, the non-crimp fibre fabric is able to contract in its longitudinal direction, while still completely covering the support surface.
- According to a preferred development, the support comprises a pressure membrane, the support being expanded by the production of a pressure differential between an inner region of the support and an intermediate region between the pressure membrane and the moulding tool. The pressure membrane exerts on the tubular non-crimp fibre fabric a uniform contact pressure which can be precisely adjusted by the pressure differential, over the entire inner surface of the tubular moulding tool, which allows a particularly uniform shaping of the wall of the structural component.
- To produce the pressure differential, the pressure in the inner region of the support is preferably increased above atmospheric pressure. Suitable compression devices can be accommodated inside the support, so that when the support is arranged in the moulding tool, the support can be expanded without sealing off the intermediate region, for example. Alternatively or in addition, to produce the pressure differential, the pressure in the intermediate region between the pressure membrane and the moulding tool is decreased below atmospheric pressure. This allows the inner region to be made accessible, for example for inspection purposes. The pressure membrane does not need to be configured for high absolute pressures.
- According to a preferred development, a step is furthermore provided for arranging a reinforcing element between the support surface and the non-crimp fibre fabric. This makes it possible to connect the reinforcing element, for example a stringer, to be connected to the structural component in a single operation with the production of the structural component. The reinforcing element is preferably guided in at least one guide slot which runs in a radial direction of the tubular moulding tool, while the support is being expanded. The reinforcing element is thus guided precisely into the desired connecting position without tilting.
- According to a preferred development, the reinforcing element is arranged between the support surface and the non-crimp fibre fabric as a pre-impregnated or non-impregnated semi-finished fibre product. The reinforcing element is connected by jointly infiltrating the reinforcing element and the wall of the tubular structural component and by a joint curing process.
- According to another preferred development, the reinforcing element is arranged between the support surface and the non-crimp fibre fabric as a pre-cured semi-finished fibre product. This allows the co-bonding of the reinforcing element with the wall of the tubular structural component, in which case for example the curable matrix with which the tubular non-crimp fibre fabric is infiltrated, acts as an adhesive.
- According to a preferred development, the reinforcing element is arranged in a correspondingly configured recess in the support surface. This facilitates the charging of the support with the reinforcing element.
- According to a preferred development, a placeholder is arranged in a cavity between the reinforcing element and the tubular non-crimp fibre fabric. During the curing procedure when the reinforcing element is subjected to the mutual pressure of the support surface and the inner surface of the moulding tool, this placeholder keeps the desired cavity of the reinforcing element free. The placeholder preferably has a membrane sheath, in which case a step is furthermore provided for expanding the placeholder by increasing a pressure in the membrane sheath. A placeholder which can be expanded in this manner can be contracted again after the curing procedure and can therefore be easily removed.
- According to a preferred development of the device according to the invention, at least one guide cover is provided for positioning on at least one end of the moulding tool ad/or of the support. The guide cover has a guide slot which runs in a radial direction of the tubular moulding tool and is to guide the reinforcing element. During the expansion of the support, the guiding slot guides the reinforcing element precisely in a radial direction into the desired position on the inside of the structural component, irrespective of the shape of the reinforcing element and the shape of the support surface.
- In the following, the invention is described in detail on the basis of embodiments with reference to the accompanying figures of the drawings.
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FIG. 1A-C are schematic perspective views of a device for the production of a fuselage barrel section of an aircraft according to a first embodiment of the invention; -
FIG. 2A-G are cross-sectional views of details of a device according to a second embodiment during the production of a tubular structural component; and -
FIG. 3A-D are cross-sectional views of details of a device according to a third embodiment during the production of a tubular structural component. - In the figures, the same reference numerals denote the same or functionally identical components, unless indicated otherwise.
-
FIG. 1A to 1C are three schematic perspective views of a device for the production of a fuselage barrel section of an aircraft, each of the three figures showing different steps of a production method. The fuselage barrel section to be produced is approximately in the shape of a cylinder barrel, the cross section typically differing from the ideal circular shape and changing over the length of the section. -
FIG. 1A shows atubular moulding tool 102 with aninner surface 106 which is shaped corresponding to the desired shape of the outer surface of the fuselage barrel section to be produced. Themoulding tool 102 is a so-called negative mould, because itsinner surface 106 forms a negative shape for the outer surface of the fuselage barrel section. Next to themoulding tool 102 is asupport 110 for supporting a tubularnon-crimp fibre fabric 114. - The
support 110 is of an approximately cylindrical shape, having approximately the same length as themoulding tool 102 and an external diameter which is slightly smaller than the internal diameter of the moulding tool. Consequently, it can be arranged both inside and outside themoulding tool 102. Thesupport 110 comprises an inner frame which defines the illustrated shape and itslateral surface 108 is covered by a resilient pressure membrane which separates an inner region of the support from the outside in a pressure-tight manner. For the simple, contact-free insertion of the support inside the moulding tool, the support and/or the moulding tool can be provided with rollers for example (not shown). - The surface of the pressure membrane arranged around the
lateral surface 108 of the approximatelycylindrical support 110 forms asupport surface 108 which supports the tubularnon-crimp fibre fabric 114 during the production of the fuselage barrel section. At the start of the production method, thesupport 110 is arranged outside themoulding tool 102. The tubularnon-crimp fibre fabric 114 is cut to size and drawn over thesupport 110 until it completely covers thesupport surface 108. Thenon-crimp fibre fabric 114 used is for example a non-woven fabric such as for example a so-called NCF (non-crimped fabric) consisting of carbon fibres or other suitable fibres, which may be reinforced locally according to constructive details of the fuselage section to be produced. Thenon-crimp fibre fabric 114 comprises a plurality of fibre layers of different orientations in which thefibres 116 run diagonally, as shown by way of example, i.e. spirally around the periphery of thesupport 110. In further fibre layers (not shown), fibres run at other inclination angles diagonally or parallel to the longitudinal direction of thesupport 110. - The
length 118 of the cut tubularnon-crimp fibre fabric 114 is greater than the length of thesupport 110 and of themoulding tool 102, such that thenon-crimp fibre fabric 114 not only covers thesupport surface 108 of thesupport 110, but projects beyond thesupport 110 at both ends thereof. -
FIG. 1B shows a subsequent step of the production method in which thesupport 110 covered by thenon-crimp fibre fabric 114 has been moved into themoulding tool 102. Since the diameter of thesupport 110 is smaller than the internal diameter of themoulding tool 102, thesupport 110 fits into themoulding tool 102 without thesupport surface 108 contacting theinner surface 106 of the moulding tool. Instead, thesupport surface 108 and theinner surface 106 of themoulding tool 102 run approximately parallel, aminimum spacing 112 of, for example 5-10 cm remaining at any point between them. Thenon-crimp fibre fabric 114 covering thesupport surface 108 projects at both ends out of themoulding tool 102 due to itslength 118. -
FIG. 1C shows a further step of the production method in which acompressor 205 has produced an excess pressure in the inner region of thesupport 110. The pressure membrane, forming the support surface, of the support is inflated by the excess pressure, such that thesupport 110 is expanded radially beyond the dimensions of its inner frame. The radial expansion of thesupport 110 stretches the tubularnon-crimp fibre fabric 114 in the direction of the periphery of thesupport 110. At the same time, due to thefibres 116 which run diagonally around the support, the tubularnon-crimp fibre fabric 114 has contracted in its longitudinal direction up to a shortenedlength 119. In this respect, the tubularnon-crimp fibre fabric 114 had initially been cut generously such that it still completely covered the support surface even with its shortened length. - In the illustrated expanded state of the
support 110, the pressure membrane presses thenon-crimp fibre fabric 114 against theinner surface 108 of the moulding tool due to the excess pressure in the inner region of thesupport 110. In a further step, the non-crimp fibre fabric, fixed in this manner, is infiltrated by a liquid,curable resin matrix 115, for example in that the resin matrix is introduced from one end of themoulding tool 102, as indicated by arrows, into the gap between the pressure membrane and themoulding tool 102. - The resin matrix is then cured, for example by a heat treatment. The excess pressure is discharged from the inner region of the
support 110, so that thesupport 110 returns into its original, unexpanded state and can easily be removed from themoulding tool 102. The finished fuselage barrel section is removed from themoulding tool 102. Sections which are moulded such that they taper towards one end are removed from themoulding tool 102, for example in the direction of the other end. Alternatively, themoulding tool 102 can be configured in two or more parts, such that it can be opened for the finished section to be removed. - A further embodiment of the production method will now be described in more detail with reference to
FIG. 2A-G .FIG. 2A-G are each cross-sectional views of a detail of the periphery of thesupport 110 for different steps of the method. -
FIG. 2A shows the mentioned detail of thesupport 110 in a starting state in which a non-crimp fibre fabric has not yet been arranged on thesupport surface 108 and thesupport 110 is outside themoulding tool 102. Thesupport 110 comprises arigid support frame 111 with a substantially circular cross section. Thesupport frame 111 is formed from aluminium, for example and has on its surface a large number of small holes for charging with vacuum and/or excess pressure, which have not been shown here to improve clarity. A slot-like recess 210 is configured in one location of its periphery to later receive a reinforcing element. The periphery of thesupport frame 111 is flattened in anedge region 211 on both sides of therecess 210. - The surface of the
support frame 111 is covered by apressure membrane 200 which extends over the entire lateral surface of the overall approximatelycylindrical support frame 111 and is connected to the surface of thesupport frame 111 in a pressure-tight manner at the edges of the lateral surface. Aninner region 202 between thepressure membrane 200 and thesupport frame 111 is therefore sealed off in a pressure-tight manner from the exterior. Thepressure membrane 200 is configured as a plastics material film, for example. -
FIG. 2B shows a state of thesupport 110 ofFIG. 2A after avacuum pump 204 has been connected to the interior 202 and has evacuated it via the fine holes 213 in the surface of thesupport frame 111, of which only one hole 213 is shown here by way of example. The vacuum in the interior 202 tightly suctioned the pressure membrane against thesupport frame 111. In particular, the pressure membrane follows the contour of thesupport frame 111 as far as into the recess 120. - In
FIG. 2C , a reinforcingelement 208 with a T-shaped profile, as used for example in aircraft construction as a so-called T-stringer, has been inserted into the recess 120. Thehorizontal bar 209 of the T-shaped profile rests inside the flattenedarea 211 against thesupport frame 111 covered by thepressure membrane 200. - In
FIG. 2D , thepressure membrane 200 has been covered by a tubularnon-crimp fibre fabric 114 consisting of carbon fibres. Theouter surface 108 of thepressure membrane 200 acts as thesupport surface 108, supporting thenon-crimp fibre fabric 114, of thesupport 110. The reinforcingelement 208 is included between thesupport surface 108 and thenon-crimp fibre fabric 114 and is held in therecess 210. Since thehorizontal bar 209 of the T-shaped profile is also in a concealed position inside the flattenedarea 111, thenon-crimp fibre fabric 114 does not have a bulge above the reinforcingelement 208, but follows a gentle curve. -
FIG. 2E shows thesupport 110 which has been prepared in this manner and has been charged with the reinforcingelement 208 and thenon-crimp fibre fabric 114, after it has been pushed into atubular moulding tool 102. Thesupport 110 is smaller than the interior of themoulding tool 102 and is configured corresponding to the shape of said moulding tool to the extent that aspacing 112 always remains between itssupport surface 108 and thesurface 106 of the moulding tool. In other words, thesupport surface 108 and themould surface 106 run parallel to one another in thespacing 112 in the illustrated state. On the other hand, thenon-crimp fibre fabric 114 and thepressure membrane 200 as well as the pressure membrane and thesupport frame 111 contact one another and are shown at a distance from one another inFIG. 2B-E merely for the sake of clarity. -
FIG. 2F shows thesupport 110 arranged in themoulding tool 102 after the interior 202 between thesupport frame 111 and thepressure membrane 200 has been connected to acompressor 205 and has been subjected to excess pressure through the fine holes 203. The excess pressure has inflated thepressure membrane 200 such that it has expanded in aradial direction 212 as far as thesurface 106 of themoulding tool 102. Both the pressure membrane and the non-crimp fibre fabric have been stretched by the expansion. The reinforcingelement 208 and thenon-crimp fibre fabric 114 have been guided by the expandingpressure membrane 200 to themould surface 106 and, in the illustrated state, are pressed against themould surface 106 with uniform contact pressure provided by the excess pressure. During the expansion procedure, the reinforcingelement 208 has been guided through the recess 120 in aradial direction 112 and, in the illustrated state, is also still held in the recess 120, as in a guide slot, and is thus positioned precisely. -
FIG. 2G shows the state after the space between thepressure membrane 200 and themoulding tool 102 has been filled with acurable matrix system 115. Thematrix 115 has infiltrated both thenon-crimp fibre fabric 114 and the fibre material of the reinforcingelement 208, as indicated by the hatching. The excess pressure in theinner region 202 of thesupport 110 is maintained during the subsequent curing procedure by a heat treatment. The excess pressure is then discharged and the finishedfuselage barrel section 100 is removed from themoulding tool 102. -
FIG. 3A-D show another embodiment of the production method. The figures are again each cross-sectional views of details of the periphery of thesupport 110 for different steps of the method. -
FIG. 3A shows a state corresponding toFIG. 2B in which apressure membrane 200 has been arranged tightly along the surface of asupport frame 111, for example likewise by evacuating the interlying inner region of the support. As in the above embodiment, a recess 120 for a reinforcing element is configured in thesupport frame 111, said recess having here, however, the shape of a wide, trapezoidal trough. - In the state shown in
FIG. 3B , a reinforcingelement 208 which is formed from prepreg and has an Ω-shaped profile, a so-called Ω stringer has been arranged in therecess 210. Acavity 304 to be configured in the finished fuselage barrel section under the Ω-shaped profile of thestringer 208 is filled here by aplaceholder 300 which is formed in this case by way of example from amembrane sheath 301 filled with compressed air. A tubularnon-crimp fibre fabric 114 covers thesupport surface 108 formed by thepressure membrane 200, thefoot portion 306 of the Ω stringer and the outwardly facing side of theplaceholder 300. - In the state shown in
FIG. 3C , thesupport 110 prepared thus has been arranged in atubular moulding tool 102. Anexpansion spacing 112 remains between thesupport surface 106 and the mould surface, as in the embodiment described above. In order to expand thesupport 110, itsinner region 202 is subjected to excess pressure and/or theintermediate region 206 located between thepressure membrane 200 and themoulding tool 102 is subjected to vacuum. In order to be able to guide the C)stringer 208 precisely in aradial direction 212 during the expansion procedure, aguide pin 502 is anchored in theplaceholder 300 at both ends of the C)stringer 208. Said guide pin slides in a radially 212 runningguide slot 302 which is recessed in aguide cover 500 respectively fitted to the ends of themoulding tool 102. -
FIG. 3D shows a state in which the pressure membrane presses the tubularnon-crimp fibre fabric 114 together with theΩ stringer 208 and the includedplaceholder 300 against theinner surface 106 of themoulding tool 102 by the applied pressure differential betweeninner region 202 andintermediate region 206. In subsequent steps, thenon-crimp fibre fabric 114 and theΩ stringer 208 are jointly infiltrated by a resin matrix and cured. In so doing, the introduced matrix and the resin material contained in the prepreg of theΩ stringer 208 are combined. After a curing heat treatment, the excess pressure in theinner region 202 and the vacuum in theintermediate region 206 are discharged and the cured fuselage barrel section is removed from themoulding tool 102. After the excess pressure in the interior of theplaceholder 300 has also been released, said placeholder is removed below theΩ stringer 208 in order to free itscavity 304. - Although the present invention has been presently described using preferred embodiments, it is not restricted thereto, but can be modified in many different ways.
- For example, reinforcing elements of various other profiles can be used. It is possible to produce fuselage barrel sections and other tubular structural components with complex, tapering cross sections, door and window openings.
-
- 100 structural component
- 102 moulding tool
- 104 outer surface
- 106 mould surface
- 108 support surface
- 110 support
- 111 frame
- 112 expansion spacing
- 114 non-crimp fibre fabric
- 115 matrix
- 116 fibres
- 118 length of the non-crimp fibre fabric before expansion
- 119 length of the non-crimp fibre fabric after expansion
- 200 pressure membrane
- 202 inner region
- 203 hole
- 204 vacuum pump
- 205 compressor
- 206 intermediate region
- 208 reinforcing element
- 209 horizontal portion
- 210 recess
- 211 flattened area
- 212 radial direction
- 301 membrane sheath
- 302 guide slot
- 304 cavity
- 306 foot portion
- 500 guide cover
- 502 guide pin
Claims (7)
1. A device for producing a tubular structural component, the device comprising:
a tubular moulding tool which has an inner mould surface shaped corresponding to an outer surface of the structural component;
an expandable support which is formed such that, in an unexpanded state, it fills the moulding tool while leaving an expansion spacing between a support surface of the support and the mould surface, the expansion spacing amounting to 1 to 10 cm; and
an expansion device configured to expand the support such that when the support surface is covered with a tubular non-crimp fibre fabric and when the support is arranged in the moulding tool, the support surface radially expands the non-crimp fibre fabric and presses it against the mould surface;
wherein the non-crimp fibre fabric is configured to be infiltrated with a curable matrix.
2. The device according to claim 1 , wherein the support comprises a pressure membrane, the expansion device being configured to produce a pressure differential between an inner region of the support and an intermediate region between the pressure membrane and the moulding tool.
3. The device according to claim 2 , wherein the expansion device comprises a compressor for increasing a pressure in the inner region of the support above atmospheric pressure.
4. The device according to claim 2 , wherein the expansion device comprises a vacuum pump for reducing a pressure in the intermediate region below atmospheric pressure.
5. The device according to claim 1 , wherein the support comprises a recess for inserting a reinforcing element.
6. The device according to claim 5 , further comprising a guide for guiding the reinforcing element, during the expanding of the support, in a radial direction of the moulding tools.
7. The device according to claim 6 , wherein the guide comprises at least one guide cover for fitting to at least one end of the moulding tool and/or of the support, the guide cover having a guide slot running in a radial direction of the tubular moulding tool for guiding the reinforcing element.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US14/928,389 US20160129647A1 (en) | 2007-12-13 | 2015-10-30 | Method and device for the production of tubular structural components |
Applications Claiming Priority (7)
Application Number | Priority Date | Filing Date | Title |
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US749207P | 2007-12-13 | 2007-12-13 | |
DE102007060029.3 | 2007-12-13 | ||
DE102007060029A DE102007060029A1 (en) | 2007-12-13 | 2007-12-13 | Method and device for producing tubular structural components |
PCT/EP2008/065355 WO2009074419A1 (en) | 2007-12-13 | 2008-11-12 | Method and device for producing tube-shaped structural components |
US12/794,487 US20100276069A1 (en) | 2007-12-13 | 2010-06-04 | Method and device for the production of tubular structural components |
US14/285,704 US9180628B2 (en) | 2007-12-13 | 2014-05-23 | Method and device for the production of tubular structural components |
US14/928,389 US20160129647A1 (en) | 2007-12-13 | 2015-10-30 | Method and device for the production of tubular structural components |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US14/285,704 Division US9180628B2 (en) | 2007-12-13 | 2014-05-23 | Method and device for the production of tubular structural components |
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US20160129647A1 true US20160129647A1 (en) | 2016-05-12 |
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US12/794,487 Abandoned US20100276069A1 (en) | 2007-12-13 | 2010-06-04 | Method and device for the production of tubular structural components |
US14/285,704 Expired - Fee Related US9180628B2 (en) | 2007-12-13 | 2014-05-23 | Method and device for the production of tubular structural components |
US14/928,389 Abandoned US20160129647A1 (en) | 2007-12-13 | 2015-10-30 | Method and device for the production of tubular structural components |
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US12/794,487 Abandoned US20100276069A1 (en) | 2007-12-13 | 2010-06-04 | Method and device for the production of tubular structural components |
US14/285,704 Expired - Fee Related US9180628B2 (en) | 2007-12-13 | 2014-05-23 | Method and device for the production of tubular structural components |
Country Status (9)
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US (3) | US20100276069A1 (en) |
EP (1) | EP2229273B1 (en) |
JP (1) | JP2011506136A (en) |
CN (1) | CN101896329B (en) |
BR (1) | BRPI0821246A2 (en) |
CA (1) | CA2707802A1 (en) |
DE (1) | DE102007060029A1 (en) |
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-
2007
- 2007-12-13 DE DE102007060029A patent/DE102007060029A1/en not_active Ceased
-
2008
- 2008-11-12 CA CA2707802A patent/CA2707802A1/en not_active Abandoned
- 2008-11-12 CN CN200880120453.0A patent/CN101896329B/en not_active Expired - Fee Related
- 2008-11-12 RU RU2010122662/05A patent/RU2488488C2/en not_active IP Right Cessation
- 2008-11-12 EP EP08860048.1A patent/EP2229273B1/en not_active Not-in-force
- 2008-11-12 BR BRPI0821246-5A patent/BRPI0821246A2/en not_active IP Right Cessation
- 2008-11-12 WO PCT/EP2008/065355 patent/WO2009074419A1/en active Application Filing
- 2008-11-12 JP JP2010537352A patent/JP2011506136A/en active Pending
-
2010
- 2010-06-04 US US12/794,487 patent/US20100276069A1/en not_active Abandoned
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2014
- 2014-05-23 US US14/285,704 patent/US9180628B2/en not_active Expired - Fee Related
-
2015
- 2015-10-30 US US14/928,389 patent/US20160129647A1/en not_active Abandoned
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US11634206B2 (en) * | 2016-08-02 | 2023-04-25 | The Boeing Company | Tubular structure and a method of manufacturing thereof |
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US20100276069A1 (en) | 2010-11-04 |
US9180628B2 (en) | 2015-11-10 |
EP2229273B1 (en) | 2016-01-27 |
BRPI0821246A2 (en) | 2015-06-16 |
US20140346715A1 (en) | 2014-11-27 |
WO2009074419A1 (en) | 2009-06-18 |
JP2011506136A (en) | 2011-03-03 |
RU2488488C2 (en) | 2013-07-27 |
CN101896329B (en) | 2014-04-09 |
RU2010122662A (en) | 2012-01-20 |
CA2707802A1 (en) | 2009-06-18 |
DE102007060029A1 (en) | 2009-06-18 |
EP2229273A1 (en) | 2010-09-22 |
CN101896329A (en) | 2010-11-24 |
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