Molding process and apparatus for producing unified composite structures

Abstract

A method of forming a unitary, composite structural member, and a member formed in accordance with the process. The process involves stitching a plurality of warp knit panel sections together to generally form a plurality of independent panel sections. The sections are placed within the dies of a molding tool such that a rib portion of each section aligns. Inflatable bladders are then slipped into voids formed in between the various panel sections of the assembly. The bladders are inflated to hold the panel sections in the shape of the final product and to hold the rib portions in contact with one another. Resin is then infused into the panels that make up the assembly. The assembly is then cured. When the panels are removed from the molding tool a unitary, complexly shaped, composite structural member is formed.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application is a divisional of U.S. patent application Ser. No. 10 / 393,195 filed on Mar. 20, 2003, the disclosure of which is incorporated herein by reference.FIELD OF THE INVENTION [0002] This invention relates to molding processes and apparatus', and more particularly to a molding process and apparatus for producing large and complex structural components especially well suited for aircraft structural components through a single step molding process. BACKGROUND OF THE INVENTION [0003] Due to the size and complexity of structural components such as aircraft wings, sections of aircraft fuselage, etc., the formation of such structures using composite materials in a single step molding procedure has historically not been possible. Until recently, a process capable of holding critical dimensional features within narrow tolerance ranges for large complex composite structures did not exist. [0004] In previous manufacturing operations, t...

AI Technical Summary

Benefits of technology

"The present invention is a molding process that involves stitching together dry fiber material preforms to create a final component. The stitched-together preforms are then placed within a tool and inflated with bladders to push the fiber material against the tool's surfaces. Resin is then infused into the assembly and cured to form a single piece part. The resulting structure is stronger and more durable, and it eliminates stress concentrations at the interfaces of independent component sections. This process is efficient and effective, and it is especially useful in high-performance aircraft manufacturing applications."

Problems solved by technology

Due to the size and complexity of structural components such as aircraft wings, sections of aircraft fuselage, etc., the formation of such structures using composite materials in a single step molding procedure has historically not been possible.

The cost to manufacture the structure thus increases significantly through the additional manufacturing steps needed to fabricate separately and then assemble (i.e., often bond adhesively or mechanically attach) two or more independent component parts to form a single overall structure.

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