US20200254702A1 - Apparatus and method to tailor fiber distortion in composite parts - Google Patents

Apparatus and method to tailor fiber distortion in composite parts Download PDF

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Publication number
US20200254702A1
US20200254702A1 US16/269,614 US201916269614A US2020254702A1 US 20200254702 A1 US20200254702 A1 US 20200254702A1 US 201916269614 A US201916269614 A US 201916269614A US 2020254702 A1 US2020254702 A1 US 2020254702A1
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US
United States
Prior art keywords
caul plate
slit
extends
composite material
uncured composite
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
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US16/269,614
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English (en)
Inventor
Gagandeep Saini
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Boeing Co
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Boeing Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Boeing Co filed Critical Boeing Co
Priority to US16/269,614 priority Critical patent/US20200254702A1/en
Priority to CA3064841A priority patent/CA3064841A1/en
Priority to JP2019224633A priority patent/JP7469034B2/ja
Priority to EP19217732.7A priority patent/EP3693155B1/en
Priority to AU2020200004A priority patent/AU2020200004A1/en
Priority to BR102020000707-6A priority patent/BR102020000707A2/pt
Priority to CN202010080661.5A priority patent/CN111531924B/zh
Publication of US20200254702A1 publication Critical patent/US20200254702A1/en
Priority to US17/872,282 priority patent/US11993033B2/en
Abandoned legal-status Critical Current

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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
    • 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
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/681—Component parts, details or accessories; Auxiliary operations
    • B29C70/682—Preformed parts characterised by their structure, e.g. form
    • 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
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
    • 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
    • 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
    • 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
    • B29C70/549—Details of caul plates, e.g. materials or shape
    • 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
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/78—Moulding material on one side only of the preformed part
    • 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
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/0003—Producing profiled members, e.g. beams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64C—AEROPLANES; HELICOPTERS
    • B64C3/00—Wings
    • B64C3/18—Spars; Ribs; Stringers
    • B64C3/182—Stringers, longerons
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64C—AEROPLANES; HELICOPTERS
    • B64C3/00—Wings
    • B64C3/26—Construction, shape, or attachment of separate skins, e.g. panels
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
    • B29C43/3642—Bags, bleeder sheets or cauls for isostatic pressing
    • B29C2043/3655—Pressure transmitters, e.g. caul plates; pressure pads
    • 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
    • B29L2031/3085—Wings
    • 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

  • This disclosure relates to fabrication of composite parts, and more particularly to controlling wrinkling in a finished composite part which incurred fiber distortion prior to curing.
  • An alteration or distortion of fiber straightness can occur in a number of different ways with respect to a composite part prior to curing.
  • Examples of distortion of fibers prior to curing can occur with the composite part experiencing a change in geometry such as the uncured composite part being positioned to extend about a radius of curvature or with the uncured composite part having a ply drop.
  • the change of direction of the composite part can impart tension to fibers in a portion of the composite part and can impart compression to another portion of the composite part prior to curing.
  • the fibers positioned in compression within the uncured composite part the fibers can be distorted from a straight line alignment and experience bunching of the fibers. With the fibers in a distorted condition, curing of the composite part can result in uncontrolled wrinkling to occur in the cured composite part.
  • Wrinkles which appear in a cured composite part can identify locations within the composite part where the fibers have been distorted and where the composite part has diminished strength.
  • the fabricator can add additional composite material to the composite part to reinforce the composite part at those wrinkled locations so as to provide additional strength to the composite part.
  • This procedure of adding composite material adds time, labor and material cost in fabricating the composite part.
  • this procedure of adding composite material adds weight to the finished composite part. Adding weight to the finished composite part, that is used for example in fabricating an aircraft, contributes to additional cost of operation of the aircraft.
  • the control of wrinkling of the finished composite part can avoid the need to add composite material to reinforce the strength of the composite part, which can add weight to a structure being fabricated with the composite part such as an aircraft, resulting in additional operational cost and/or can avoid uncontrolled wrinkling in the composite part exceeding engineering specifications and/or regulatory guidelines and being discarded.
  • An example includes a caul plate for application onto an uncured composite material which includes a first slit defined by and which extends through and along the caul plate.
  • An example includes a method for fabricating a part constructed from an uncured composite material having a geometric change within the uncured composite material, including a step of positioning a caul plate in overlying relationship to the uncured composite material having a geometric change in the uncured composite material, wherein the caul plate includes a first slit defined by and which extends through and along the caul plate.
  • FIG. 1 is perspective view of an aircraft
  • FIG. 2 is a schematic cross section view of a wing constructed of a composite skin and composite blade stringers as seen along line 2 - 2 of FIG. 1 ;
  • FIG. 3 is a perspective view of an uncured composite blade stringer extending along the composite skin of the wing of FIG. 2 ;
  • FIG. 4 is a partial perspective view of a portion of a caul plate used in fabrication of the blade stringer of FIG. 3 ;
  • FIG. 5 is a perspective view of the caul plate of FIG. 4 positioned on the uncured blade stringer extending along the composite skin of the wing of FIG. 3 ;
  • FIG. 6 is a partial side elevation view of the caul plate of FIG. 4 positioned on the uncured blade stringer of FIG. 5 ;
  • FIG. 7 is a partial enlarged side elevation view of the caul plate of FIG. 6 with a reduced pressure having been applied to an outer surface of the caul plate
  • FIG. 8 is a partial perspective view of the blade stringer of FIG. 7 with the caul plate removed from the blade stringer after curing of the composite material and with controlled wrinkles positioned in the blade stringer;
  • FIG. 9 is a flow chart of method to cure a composite part having a geometric change.
  • Various parts used in the assembly of structures are constructed of composite material, which includes fibers and resin.
  • the parts are often subjected to alteration of geometric shape prior to being cured.
  • the change in geometric shape of the uncured part results in distortion of straight-lined alignment of the reinforcement fibers within the composite material used in fabricating the part.
  • the distortion of the straight-lined alignment of the fibers can occur by way of, for example, dropping of one or more plies in the construction of the composite part or by way of altering the shape of the composite part so as to conform to a shape of another part, such that the composite material is taken out of being positioned in a flat plane.
  • Changing the shape of uncured composite material being used in constructing the part by way of example of dropping plies and/or altering the shape of the composite material out of a flat configuration, alters or distorts the straight-lined alignment of the fibers within the uncured composite material from a straight lined orientation.
  • the fibers in a portion of the composite material which follows the curvature can become distorted from a straight-lined alignment.
  • a portion of the fibers within the composite material can be placed in tension and another portion of the fibers within the composite material can be placed in compression.
  • the fibers subjected to compression can become distorted and tend to bunch.
  • the cured composite part can develop undesired uncontrolled wrinkles. Should the uncontrolled wrinkling, which is indicative of reduced strength for the finished composite part, exceed engineering specifications and/or regulatory guidelines for wrinkling, additional composite material may need to be added to the part being fabricated or the part may need to be discarded.
  • aircraft 10 is an example of a structure having portions of the structure assembled with parts constructed of composite material, wherein the composite parts are subjected to geometric shape change prior to the composite part being cured.
  • portions of aircraft 10 which have composite parts which are subjected to geometric shape change prior to being cured include, for example, wings 12 , fuselage 14 , tail stabilizer 16 , tail wings 18 as well as other structural portions of aircraft 10 and as well as other portions of other structures which are assembled utilizing composite parts.
  • Wing 12 includes composite skin 20 which has an inner surface 22 , as seen in FIG. 3 , which has a contour which requires blade stringer 24 constructed of composite material 48 to change geometry or shape so as to conform to inner surface 22 of composite skin 20 .
  • Blade stringer 24 conforms to inner surface 22 of composite skin 20 so as to optimize securement of blade stringer 24 to composite skin 20 and to optimize stiffening support of blade stringer 24 to composite skin 20 .
  • Blade stringer 24 is described herein as an example of a composite part being fabricated wherein the geometry or shape of the composite part is changed prior to curing. Many other configurations of stringers or other composite parts can used so as to describe the teachings of this disclosure.
  • Inner surface 22 of composite skin 20 changes elevation or contour of inner surface 22 of composite skin 20 such as with ramp 26 which includes first curvature 28 and second curvature 29 .
  • First and second curvatures 28 , 29 are positioned at opposing ends of ramp 26 in composite skin 20 .
  • the contour or change in elevation of inner surface 22 of composite skin 20 can occur, for example, with ply drops in composite skin 20 in accommodating load demands on wing 12 and/or for accommodating size of wing 12 , as wing 12 extends away from fuselage 14 .
  • blade stringer 24 In order for blade stringer 24 to conform to inner surface 22 of composite skin 20 , the shape of blade stringer 24 is altered prior to cure of blade stringer 24 such that flanges 30 and web 32 of blade stringer 24 follow the contour or curvature of inner surface 22 of composite skin 20 as blade stringer 24 extends along ramp 26 .
  • ramp 26 of composite skin 20 is seen with first curvature 28 and second curvature 29 of composite skin 20 positioned at opposing ends of ramp 26 , as mentioned above.
  • Flange 30 of blade stringer 24 shown in FIG. 3 , underlies caul plate 46 in FIG. 6 , includes uncured composite material 48 which has fibers 34 which extend along length L of blade stringer 24 , as seen in FIGS. 3 and 6 .
  • Web 32 of blade stringer 24 includes uncured composite material 48 which has fibers 36 which also extend along length L of blade stringer 24 .
  • first curvature 28 of ramp 26 of composite skin 20 With respect to first curvature 28 of ramp 26 of composite skin 20 , upper portion 38 of fibers 34 in flange 30 are placed in tension extending along first curvature 28 and lower portion 40 of fibers 34 in flange 30 are placed in compression extending along first curvature 28 .
  • fibers 36 within web 32 which also extend along length L of blade stringer 24 , extend along first curvature 28 of composite skin 20 with upper portion 42 of fibers 36 in web 32 placed in tension and with lower portion 44 of fibers 36 in web 32 placed in compression.
  • fibers 34 of uncured composite material 48 of flange 30 of blade stringer 24 has upper portion 38 of fibers 34 in flange 30 placed in compression, which extends along second curvature 29 , and lower portion 40 of fibers 34 in flange 30 placed in compression, which extends along second curvature 29 .
  • Fibers 36 within web 32 which extend along second curvature 29 has upper portion 42 of fibers 36 in web 32 placed in compression and lower portion 44 of fibers 36 in web 32 placed in compression.
  • lower portion 40 of fibers 34 of flange 30 and lower portion 44 of fibers 36 of web 32 are positioned in compression resulting in distortion in fibers 34 , in lower portion 40 of flange 30 and in fibers 36 in lower portion 44 of web 32 from straight-lined alignment.
  • upper portion 38 of fibers 34 of flange 30 and upper portion 42 of fibers 36 of web 32 are positioned in compression resulting in fibers 34 within upper portion 38 of flange 30 and fibers 36 in upper portion 42 being distorted from straight-lined alignment.
  • Controlled wrinkling in the finished blade stringer 24 optimizes use of the finished composite part with blade stringer 24 conforming to the engineering specifications and regulatory guidelines related to amount and size of permitted wrinkling that is permitted in a finished composite part and also optimizes resulting strength of blade stringer 24 .
  • Caul plate 46 is positioned onto uncured composite material 48 , as seen in FIGS. 3 and 5 , which includes uncured composite material 48 of flange 30 and web 32 of blade stringer 24 in this example for utilization in the curing process of blade stringer 24 .
  • uncured composite material 48 of a part to be cured such as blade stringer 24
  • caul plate 46 and uncured composite material 48 are placed within a vacuum bagging (not shown) and a reduced pressure is applied within the vacuum bagging, as mentioned above, pulling fibers and resin from uncured composite material 48 into slits of caul plate 46 as will be described below.
  • each caul plate 46 has a L-shaped configuration and is positioned on opposing sides of uncured composite material 48 of blade stringer 24 , as seen in FIG. 5 .
  • Other shapes of caul plate(s) 46 can be used for accommodating other shapes of stringers or for other composite parts being fabricated, which have a geometric change of shape distorting fibers from a straight-lined alignment in forming composite parts prior to curing.
  • caul plate 46 is used in placing onto uncured composite material 48 for use during the curing process of uncured composite material 48 fabricating a composite part such as blade stringer 24 with controlled wrinkling.
  • Caul plate 46 includes first slit 50 defined by and which extends through and along caul plate 46 .
  • First slit 50 extends through caul plate 46 from surface 52 of caul plate 46 , for positioning onto surface 54 of uncured composite material 48 .
  • First slit 50 extends through caul plate 46 to an opposing surface 56 of caul plate 46 , for positioning in facing relationship away from surface 54 of uncured composite material 48 , as seen for example in FIG. 5 , with surface 52 of caul plate 46 positioned onto uncured composite material 48 .
  • At least a portion 58 of surface 52 , of caul plate 46 , which is positioned onto uncured composite material 48 of flange 30 extends in a linear direction L as seen in FIG. 5 .
  • at least a portion 60 of surface 52 of caul plate 46 which is positioned onto uncured composite material 48 of web 32 extends in linear direction L′, as seen in FIG. 5 .
  • At least a portion 62 of opposing surface 56 of caul plate 46 which is positioned facing away from composite material 48 of flange 30 extends in linear direction L, as seen in FIG.
  • At least a portion 64 of opposing surface 56 of caul plate 46 is positioned facing away from uncured composite material 48 of web 32 extends in linear direction L′, as also seen in FIG. 5 .
  • At least a portion 66 of surface 52 extends in a curvilinear direction C and a portion 68 of opposing surface 56 extends in the curvilinear direction C.
  • first slit 50 extends in a linear direction LD along portion 70 of caul plate 46 which extends in this example along flange 30 of blade stringer 24 and extends in a linear direction LD′ along portion 72 of caul plate 46 , which extends in this example along web 32 of blade stringer 24 .
  • portions 70 and 72 of caul plate 46 join one another along a curved portion 74 of caul plate 46 as seen in FIG. 4 .
  • First slit 50 extends through caul plate 46 positioned within portions 70 and 72 of caul plate 46 and within curved portion 74 of caul plate 46 , as also seen in FIG. 4 .
  • First slit 50 can be made in a variety of width dimensions and length dimensions as needed for forming controlled wrinkles within a composite part being fabricated.
  • width dimension W includes for example one hundredth of an inch (0.01 inch) up to and including five hundreds of an inch (0.05 inch).
  • Caul plate 46 includes length L and first slit 50 extends in linear direction LD along portion 70 of caul plate 46 , for positioning onto uncured composite material 48 for flange 30 of blade stringer 24 , extending in a transverse direction relative to length L of caul plate 46 as seen in FIG. 4 .
  • first slit 50 extends in linear direction LD′ along portion 72 of caul plate 46 , for positioning onto uncured composite material 48 for web 32 of blade stringer 24 , extending in a transverse direction relative to length L of caul plate 46 as also seen in FIG. 4 .
  • caul plate 46 further includes second slit 76 defined by and which extends through and along caul plate 46 positioned spaced apart from first slit 50 .
  • First slit 50 and second slit 76 extend along caul plate 46 spaced apart from one another and extending in the same direction, and as shown in FIG. 4 , parallel to one another.
  • Caul plate 46 includes end 78 and second opposing end 80 .
  • First slit 50 extends through end 78 of caul plate 46 and extends toward second opposing end 80 of caul plate 46 wherein end 82 of first slit 50 is defined by caul plate 46 positioned spaced apart from second opposing end 80 of caul plate 46 .
  • Second slit 76 extends through second opposing end 80 of caul plate 46 and extends toward end 78 of caul plate 46 wherein end 84 of second slit 76 is defined by caul plate 46 positioned spaced apart from end 78 of caul plate 46 .
  • third slit 86 is defined by and extends through and along caul plate 46 is positioned adjacent to second slit 76 with second slit 76 positioned between first slit 50 and third slit 86 .
  • Third slit 86 extends through end 78 of caul plate 46 toward second opposing end 80 of caul plate 46 .
  • End 88 of third slit 86 is defined by caul plate 46 positioned spaced apart from second opposing end 80 of caul plate 46 .
  • Fourth slit 90 is defined by and extends through and along caul plate 46 positioned adjacent to first slit 50 with first slit 50 positioned between second slit 76 and fourth slit 90 .
  • Fourth slit 90 extends through second opposing end 80 of caul plate 46 toward end 78 of caul plate 46 .
  • End 92 of fourth slit 90 is defined by caul plate 46 positioned spaced apart from end 78 of caul plate 46 .
  • the configuration of ends, 82 , 84 , 88 and 92 of first, second and third and fourth slits 50 , 76 , 86 and 90 respectively provide continuity in caul plate 46 to extend along length L of blade stringer 24 without the need to break caul plate 46 into separate pieces.
  • first, second, third and fourth slits 50 , 76 , 86 and 90 respectively are positioned in a locale of first curvature 28 of ramp 26 positioned within composite skin 20 .
  • distortion of fibers 34 and 36 within flange 30 and web 32 occur as a result of conforming blade stringer 24 to the contour of inner surface 22 of composite skin 20 prior to curing blade stinger 24 .
  • the fabricator can position slits and the size of the slits to provide controlled wrinkling in a composite part such as blade stringer 24 , such that controlled wrinkling will comply with engineering and regulatory standards for fabrication of such part.
  • slits such as first, second, third and fourth slits 50 , 76 , 86 and 90 by the fabricator will result, for example, in portion 94 of uncured composite material 48 to be pulled into first slit 50 and portion 96 of uncured composite material 48 to be pulled into third slit 86 , as seen in FIG. 7 .
  • the pulling of uncured composite material 48 occurs with vacuum bagging uncured composite material 48 and caul plate 46 and with the application of reduced air pressure being placed within the vacuum bagging.
  • Uncured composite material 48 of blade stringer 24 is pulled into first and third slits 50 , 86 along flange 30 and at the same time along first and third slits 50 , 86 (not shown) along web 32 of blade stringer 24 .
  • uncured composite material 48 is also pulled into second and fourth slits 76 , 90 along flange 30 and web 32 .
  • uncured composite material 48 pulled within first, second, third and fourth slits 50 , 76 , 86 and 90 respectively and cured the fabricator has produced wrinkles A, B, C and D of predetermined size and location, as seen in FIG.
  • method 98 for fabricating a part is shown, such as for example blade stringer 24 , constructed from uncured composite material 48 , wherein the uncured composite material 48 has a geometric change, such as first curvature 28 of composite skin 20 which imparts a curvature in uncured composite material 48 .
  • Method 98 includes a step of positioning caul plate 46 in overlying relationship to uncured composite material 48 .
  • Uncured composite material 48 has a geometric change and caul plate 46 includes first slit 50 defined by and which extends through and along caul plate 46 .
  • Method 98 further includes placing uncured composite material 48 and caul plate 46 into a vacuum bagging (not shown).
  • Method 98 further includes placing a reduced air pressure within the vacuum bagging (not shown) pulling a portion 94 of uncured composite material 48 into first slit 50 .
  • method 98 further includes heating uncured composite material 48 in an autoclave, for example, curing uncured composite material 48 and portion 94 of the uncured composite material 48 positioned within first slit 50 forming predetermined and controlled wrinkle A within cured composite material 48 ′ as seen in FIGS. 7 and 8 .
  • First slit 50 of caul plate 46 extends from surface 52 of caul plate 46 , for positioning in facing relationship to surface 54 of uncured composite material 48 , and extends through a thickness dimension of caul plate 46 to an opposing surface 56 of caul plate 46 , for positioning in facing relationship away from surface 54 of uncured composite material 48 .
  • Caul plate 46 further includes second slit 76 defined by and which extends through and along caul plate 46 positioned spaced apart from first slit 50 .
  • First slit 50 and second slit 76 extend along caul plate 46 spaced apart from one another extending in same direction, as shown for example in FIG. 4 parallel to one another.
  • First and second slits 50 , 76 can be used to form predetermined controlled wrinkles A and B as shown in FIG. 8 . Additional slits can be provided as needed to produce permitted controlled wrinkling within the composite part which will comply with engineering specifications and regulatory guidelines.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Moulding By Coating Moulds (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
US16/269,614 2019-02-07 2019-02-07 Apparatus and method to tailor fiber distortion in composite parts Abandoned US20200254702A1 (en)

Priority Applications (8)

Application Number Priority Date Filing Date Title
US16/269,614 US20200254702A1 (en) 2019-02-07 2019-02-07 Apparatus and method to tailor fiber distortion in composite parts
CA3064841A CA3064841A1 (en) 2019-02-07 2019-12-10 Apparatus and method to tailor fiber distortion in composite parts
JP2019224633A JP7469034B2 (ja) 2019-02-07 2019-12-12 複合部品内の繊維の歪みを調整する装置及び方法
EP19217732.7A EP3693155B1 (en) 2019-02-07 2019-12-18 Apparatus and method to tailor fiber distortion in composite parts
AU2020200004A AU2020200004A1 (en) 2019-02-07 2020-01-02 Apparatus and method to tailor fiber distortion in composite parts
BR102020000707-6A BR102020000707A2 (pt) 2019-02-07 2020-01-13 Placa de molde de compressão, e, método para fabricar uma peça construída a partir de material compósito não curado
CN202010080661.5A CN111531924B (zh) 2019-02-07 2020-02-05 用于应用到未固化的复合材料上的隔板及相关制造方法
US17/872,282 US11993033B2 (en) 2019-02-07 2022-07-25 Apparatus and method to tailor fiber distortion in composite parts

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US17/872,282 Active US11993033B2 (en) 2019-02-07 2022-07-25 Apparatus and method to tailor fiber distortion in composite parts

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20210178707A1 (en) * 2019-12-11 2021-06-17 The Boeing Company Caul plate for irregular surface
US20230182417A1 (en) * 2021-12-14 2023-06-15 The Boeing Company Wrinkle Mitigation in Contoured Composite Stiffeners

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3970938A1 (en) * 2020-09-17 2022-03-23 The Boeing Company Tool and method for forming contoured composite stringers having reduced wrinkling
EP4035877B1 (en) 2021-01-29 2024-05-01 The Boeing Company Forming system and method for forming a contoured composite structure

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US9278484B2 (en) 2008-04-17 2016-03-08 The Boeing Company Method and apparatus for producing contoured composite structures and structures produced thereby
US8961732B2 (en) 2011-01-03 2015-02-24 The Boeing Company Method and device for compressing a composite radius
US9272767B2 (en) 2013-04-19 2016-03-01 The Boeing Company Compacting uncured composite members on contoured mandrel surfaces
EP3196238B1 (en) 2014-09-19 2019-07-03 Toray Industries, Inc. Notched pre-preg and notched pre-preg sheet
US10399283B2 (en) * 2015-10-06 2019-09-03 The Boeing Company Method and device for producing contoured composite laminate stiffeners with reduced wrinkling
US10392132B2 (en) 2016-07-29 2019-08-27 The Boeing Company Curved aircraft substructure repair systems and methods

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20210178707A1 (en) * 2019-12-11 2021-06-17 The Boeing Company Caul plate for irregular surface
US11554559B2 (en) * 2019-12-11 2023-01-17 The Boeing Company Caul plate for irregular surface
US20230182417A1 (en) * 2021-12-14 2023-06-15 The Boeing Company Wrinkle Mitigation in Contoured Composite Stiffeners
US11806954B2 (en) * 2021-12-14 2023-11-07 The Boeing Company Wrinkle mitigation in contoured composite stiffeners

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JP7469034B2 (ja) 2024-04-16
EP3693155A1 (en) 2020-08-12
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EP3693155B1 (en) 2024-01-31
CN111531924B (zh) 2023-11-24
US11993033B2 (en) 2024-05-28
CN111531924A (zh) 2020-08-14
BR102020000707A2 (pt) 2020-10-06
CA3064841A1 (en) 2020-08-07
AU2020200004A1 (en) 2020-08-27

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