Reinforced internal composite structures

a composite structure and reinforcement technology, applied in the field of large-scale production, can solve the problems of reducing the volume of the product, affecting reducing the production efficiency of the product, so as to achieve the effect of sufficient rigidity and reduced volum

Inactive Publication Date: 2013-04-11
RODMAN WILLIAM L
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The present invention provides methods for manufacturing complex-shaped, three-dimensional fiber reinforced composite structures while minimizing unwanted phenomena, such as buckling, warping, and distortion. The methods involve using counteracting acting pressures applied to a structural lay-up of fiber plies and stiffeners abutted against a structural feature to maintain a desired shape of that structure during the manufacturing process. The stiffeners used in the method have a larger modulus of elasticity than the conventional pressurizable members used for the lay-up surfaces of the composite structure, allowing for the formation of desired engineering features, such as shear webs, outstanding flanges, joint reinforcements, and integral I-beams. The composite assembly includes the pressurizable members and the stiffener in a mold, with the pressurizable members having the fiber plies and the stiffener located between them, providing compressible wetted fibers with the stiffener maintaining the desired shape during pressurization.

Problems solved by technology

The aforementioned technologies may have a propensity to buckle, warp or otherwise undesirably distort various structural features of the fiber-reinforced structure.
The buckling of a shear web, for example, may distort the web into an undesired shape normal to its planar surface.

Method used

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  • Reinforced internal composite structures
  • Reinforced internal composite structures
  • Reinforced internal composite structures

Examples

Experimental program
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Embodiment Construction

[0021]A complex-shaped, three-dimensional fiber reinforced composite structure may be formed by using counteracting acting pressures applied to a structural lay-up of fiber plies. The fiber plies are arranged on pressurizable members that become an integral part of the final product, or may be removed, depending on the accessibility of the member. In a preferred embodiment, the pressurizable member is a hollow rotomolded thermoplastic member, a blow molded thermoplastic member, a superplastic formed metallic member, or a twin sheet vacuum formed member (TSVF) having an opening or vent. An opening or vent allows an inner surface of the pressurizable member to be vented or pressurized such that it is expanded or inflated against the fiber plies. Advantageously, the vented pressurizable member allows the complex-shaped, three-dimensional fiber reinforced composite structure to be produced using elevated temperature, pressure, and / or autoclave techniques. By means of the opening, pressu...

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Abstract

A complex-shaped, three-dimensional fiber reinforced composite structure may be formed by using counteracting pressures applied to a structural lay-up of wetted fibers. The wetted fibers are arranged on pressurizable members and may be configured to include internal structural features, such as shear webs. A reinforcement stiffener may be located adjacent to at least one of the pressurizable members and the wetted fibers that form the internal structural feature. The reinforcement stiffener includes a modulus of elasticity that is substantially higher than a modulus of elasticity of the resin used to wet the fibers. In one embodiment, the reinforcement stiffener may be received in a pocket of one of the pressurizable members and may include a releasing agent that permits removal of the stiffener after the composite structure has been pressurized and cured.

Description

PRIORITY CLAIM[0001]This application is a divisional of U.S. patent application Ser. No. 12 / 565,602, which claims priority from U.S. Provisional Patent Application No. 61 / 099,384 filed on Sep. 23, 2008, and the subject matter of each application is incorporated herein by reference in its entirety.BACKGROUND OF THE INVENTION[0002]The invention is generally related to producing large, complex-shaped, three-dimensional, fiber reinforced composite structures, and more specifically to reinforcing various portions of the component or structure during the manufacturing process.[0003]A composite component or structure, referred to hereinafter as simply composite structure, is a term generally used to describe any part consisting of at least two constituents that are combined yet retain their physical and chemical identities. One type of composite structure is a particulate reinforced composite (PRC) in which particulates of a selected material are embedded or bonded into a matrix. An advanc...

Claims

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Application Information

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Patent Type & AuthorityApplications(United States)
IPC IPC(8): B29C43/56
CPCB29C43/3642B29C70/446B29C2043/3649B29K2101/12B29K2105/0854B29C43/56B32B5/26B32B5/28B32B27/04B32B27/12B32B37/00B29L2031/003B32B27/08B32B27/20B32B27/281B32B27/286B32B27/32B32B27/34B32B27/38B32B27/42B32B1/00B32B2260/021B32B2260/046B32B2262/101B32B2262/105B32B2262/106B32B2307/54Y10T428/31504B33Y80/00B29C70/549
InventorRODMAN, WILLIAM L.
OwnerRODMAN WILLIAM L