methods for forming composite parts with integrated reinforcements

专利摘要:
METHODS AND SYSTEMS FOR FORMING INTEGRAL COMPOSITE PARTS WITH AN SMP APPLIANCE. The present invention relates to a method and apparatus for making a composite part, such as a fuselage or internal reinforcement, with a shape memory polymer apparatus (SMP) usable as a laminating tool. The SMP apparatus can be heated until it is malleable, shaped, and then cooled in a desired rigid tool configuration. For example, cavities can be formed in the SMP apparatus to nest components in them to connect or burrow with the composite part. The composite material and / or nested components can be heated and compressed against the SMP device. The SMP apparatus can be configured to remain rigid during the composite curing cycle. Once the composite material is cured, the SMP apparatus can be activated to a malleable state and driven away from the cured composite material.
公开号:BR112013005430B1
申请号:R112013005430-1
申请日:2011-10-07
公开日:2020-10-27
发明作者:Kodi Elizabeth Ann Caster；Delbert Leon Strelow；Jeffrey W. Priest；Carl Ray Fiegenbaum；Randy Rex Kysar；David E. Havens；Matthew C. Everhart
申请人:Spirit Aerosystems, Inc.；
IPC主号:

专利说明:

RELATED REQUESTS
[0001] This non-provisional patent application claims priority benefit from the previously filed provisional patent application titled "Bladder Style Reconfigurable Tooling" of serial number US 61 / 412,635, filed on November 11, 2010, the entirety of which is incorporated into reference title in this application. The present application also claims priority benefit from the previously filed provisional patent application entitled "Bladder Style Reconfigurable Tooling" of serial number US 61 / 425,435, filed on December 21, 2010, the entirety of which is incorporated by reference in the present order. Additionally, this application claims priority benefit from the previously filed provisional patent application entitled "Methods and systems for Fabricating Composite Parts with SMP Mandrels / Bladders" of serial number US 61 / 486,539, filed on May 16, 2011, the total of which is incorporated by reference in this application. BACKGROUND Field
[0002] The present invention relates to systems and methods for using a reusable device made of polymer with shape memory (SMP) to manufacture composite parts. RELATED TECHNIQUE
[0003] Composite parts, such as those used in the manufacture of aircraft, can be constructed using various production methods, such as filament winding, banding, coating, cut fiberglass spinning, coating, manual lamination, or other techniques of composite processing and curing processing. Most of these processes use a rigid curing tool / chuck in which the composite material is applied and then cured into a rigid composite part. Removing the rigid curing tool or mandrel from the curing composite part is generally difficult, costly, and / or time consuming, particularly if the resulting composite part has retaining geometry that prevents easy part removal. A known method for removing the mandrel requires sacrificing or destroying the mandrel by cutting, dissolving, blasting with spheres, or otherwise breaking the mandrel into smaller pieces that can be removed from within the composite part. Destroying the mandrel obviously prevents it from being used again for subsequent parts and can be harmful to an internal surface of the composite part.
[0004] Another method uses a segmented mandrel that can be disassembled and removed after the composite part is cured. However, these chucks are expensive and require a lot of time to install and remove. In addition, these segmented mandrels are each typically designed to manufacture a specific composite part and are not easily reconfigured for use in the manufacture of other composite parts.
[0005] Yet, another method uses inflatable mandrels that can be removed by deflating them after the composite part is cured. However, this method typically involves balloon-like mandrels that can only be used as an aid to bagging due to their relative lack of strength and stiffness during composite lamination.
[0006] Another alternative method involves a silicon-coated foam instrument or mandrel. This foam instrument can be covered with a silicon pouch and then wrapped with uncured composite material. During curing, the silicon pouch is inflated and the foam instrument melts. After curing, the silicon pouch can be removed and reused. However, the foam instrument is not reusable, so a new foam instrument needs to be machine-made with new foam for each curing cycle.
[0007] Consequently, there is a need for improved methods to manufacture composite parts. SUMMARY
[0008] Modalities of the present invention provide methods for making composite parts using shape memory polymer (SMP) devices. An exemplificative method may comprise applying composite material to at least a portion of an SMP apparatus, activating a modification of the SMP apparatus from a rigid state to a malleable state, heating the composite material to a material curing temperature composite, and induce a differential pressure that drives the SMP apparatus, in its malleable state, towards the composite material before and / or during curing to compress the composite material against a rigid mold. The module change can be activated by applying at least one temperature change, an electric current, water, and light to the SMP device. Once the cure is complete, the pressure can be released and the SMP device can be removed from within the resulting composite cure part.
[0001] Another exemplificative method for making a composite part may comprise the steps of applying composite material to at least a portion of an SMP apparatus, placing the composite material and SMP apparatus in a cavity within a rigid modeling tool, so that at least a portion of the composite material rests against the rigid shaping tool, place an impermeable sheet of material on the composite material and SMP apparatus, and seal the impermeable sheet of material 4IA7 to the rigid modeling tool and / or the apparatus of SMP. Thereafter, this method may comprise heating the composite material to a curing temperature of composite material, activating the SMP apparatus for modulating the module from a rigid state to a malleable state, and inducing sufficient differential pressure to drive the impermeable sheet material and the SMP apparatus, in the malleable state, towards the composite material, then compressing at least a portion of the composite material against the rigid mold before and during the curing of the composite material in the composite part.
[0002] In yet another embodiment of the present invention, a method for manufacturing a composite part with integrated reinforcements can comprise the steps of activating an SMP apparatus to a malleable state, conforming an SMP apparatus to a malleable state to correspond to a desired configuration of a first surface of the composite part to be manufactured, which includes shaping the SMP apparatus to have one or more cavities configured for placing reinforcements on it, activating the SMP apparatus to a rigid state, placing the reinforcements in the cavities, applying material composite in the SMP apparatus and exposed surfaces of the reinforcements that lie within the cavities, and look for or join the reinforcements with the composite material in the SMP apparatus by means of pressure and heat to manufacture the composite part.
[0003] In another embodiment of the present invention, a method for removing an SMP apparatus from within a composite curing part may comprise the steps of activating the SMP apparatus from a rigid state to a malleable state, inducing pressure differential that drives the SMP apparatus, in the malleable state, away from the composite curing part and towards an internal mandrel tool, and remove the internal mandrel tool with the SMP apparatus that rests on it, outside the composite part of cure. The inner chuck tool may comprise an outer surface that has varying contours so that a surface area of the outer surface is large enough to prevent the SMP apparatus from bending over itself or wrinkling when driven towards the inner chuck tool. . A maximum straight line distance between points on the outer surface may be small enough to allow the internal chuck tool to be released for removal of the cured composite part.
[0004] In yet another embodiment of the present invention, a method for manufacturing a composite part with integrated reinforcements may comprise the steps of forming or casting an SMP apparatus to correspond to a desired configuration of a first surface of the composite part to be formed, shape or fuse the SMP device to include one or more cavities configured to place the reinforcements in it, place the reinforcements in the cavities, apply composite material to the SMP device and exposed surfaces of the reinforcements that rest inside the cavities and look for or bond the reinforcements with the composite material in the SMP apparatus by means of pressure and heat to manufacture the composite part. In this embodiment of the invention, the SMP apparatus can remain in a rigid state throughout the curing or joining of the reinforcements with the composite material.
[0005] This summary is provided to introduce a selection of concepts in a simplified form that will be further described below in the detailed description. This summary is not intended to identify key resources or essential resources of the claimed subject, nor is it intended to be used to limit the scope of the claimed subject. Other aspects and advantages of the present invention will be apparent from the following detailed description of the preferred embodiments and the figures in the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The modalities of the present invention are described in detail below with reference to the accompanying drawings, in which:
[0007] Figure 1 is a perspective view of an SMP apparatus constructed in accordance with an embodiment of the present invention and shown used as a mandrel with composite material placed thereon;
[0008] Figure 2 is a vertical elevation cross-sectional view of the SMP device in Figure 1, with the SMP device inflated outward to act as a bladder, which presses the composite material into it towards an external mold ;
[0009] Figure 3 is a perspective view of another embodiment of a SMP device in a rigid, inflated state;
[00010] Figure 4 is a perspective view of an internal mandrel tool constructed in accordance with an embodiment of the present invention;
[00011] Figure 5 is an exploded perspective view of the SMP apparatus of Figure 3 after it is slid over the internal mandrel tool shown in Figure 4 and is heated to contract against the internal mandrel tool, and also illustrates seals end pieces configured to seal the SMP apparatus to the internal mandrel tool at each end thereof;
[00012] Figure 6a is a perspective view of internal reinforcements built in accordance with the modalities of the present invention and configured to be connected or bonded to a composite part;
[00013] Figure 6b is a fragmentary perspective view of a dummy skin and dummy reinforcements constructed in accordance with an embodiment of the present invention to help form the SMP apparatus of Figure 5 in a desired rigid tool configuration;
[00014] Figure 7 is a fragmentary perspective view of the dummy skin and dummy reinforcements in Figure 6, which further illustrate fortification inserts placed on and within the dummy reinforcements;
[00015] Figure 8 is an exploded perspective view of the internal mandrel tool of Figure 5 placed on a rigid external tool constructed in accordance with an embodiment of the present invention;
[00016] Figure 9 is a perspective view of the SMP apparatus of Figure 5 in the desired rigid tool configuration with the fictitious internal reinforcements resting in cavities formed therein;
[00017] Figure 10a is a perspective view of the SMP apparatus of Figure 9 in the desired rigid tool configuration with the internal reinforcements removed from the cavities formed therein;
[00018] Figure 10b is a perspective view of the SMP apparatus of Figure 5 in the desired rigid tool configuration with the internal reinforcements of Figure 6a that rest in the cavities formed therein;
[00019] Figure 11 is a perspective view of the SMP device of Figure 9 with composite material applied to it and around the internal reinforcements;
[00020] Figure 12 is a fragmentary perspective view of the SMP apparatus and the composite material of Figure 11 after the composite material is cured, which illustrates the space between the SMP apparatus and the cured composite material, since the apparatus of SMP is heated and contracted back towards the internal chuck tool;
[00021] Figure 13 is a perspective view of the composite material of Figure 12 and the internal reinforcements of Figure 6 housed or joined together in a rigid fuselage, with the internal mandrel tool, the rigid external tool, and the SMP apparatus removed from it;
[00022] Figure 14 is a flow chart of a method for forming the SMP apparatus in a desired rigid tool configuration according to an embodiment of the present invention;
[00023] Figure 15 is a flow chart of a method for making a fuselage using the SMP apparatus according to an embodiment of the present invention;
[00024] Figure 16 is a fragmentary cross-sectional view of a J-shaped beam that is formed between the two SMP devices and a rigid modeling tool, each constructed according to one embodiment of the present invention; and
[00025] Figure 17 is a flow chart of a method for making a composite reinforcement using the SMP apparatus according to an embodiment of the present invention.
[00026] The drawings do not limit the present invention to the specific modalities disclosed and described in this document. The drawings are not necessarily to scale, but rather to emphasize, since they are placed under a clear illustration of the principles of the invention. DETAILED DESCRIPTION
[00027] The following detailed description of the invention references the accompanying drawings that illustrate specific modalities in which the invention can be practiced. The modalities are designed to describe aspects of the invention in sufficient detail to enable elements skilled in the art to practice the invention. Other modalities can be used and changes can be made without departing from the scope of the present invention. The following detailed description, then, should not be considered in a limiting sense. The scope of the present invention is defined only by the appended claims, together with the full scope of equivalents to which such claims are entitled.
[00028] In this description, references to "a modality", "modality", or "modalities" mean that the resource or resources that are referred to are included in at least one modality of the technology. Separate references to "a modality", "modality", or "modalities" in this description do not necessarily refer to the same modalities and are also not mutually exclusive unless then stated and / or unless it is readily apparent to elements versed in the technique a from the description. For example, a resource, structure, action, etc. described in one modality may also be included in other modalities, but are not necessarily included. Therefore, the present technology may include a variety of combinations and / or integrations of the modalities described in this document. CREATING COMPOSITE PARTS WITH AN SMP DEVICE
[00029] One embodiment of the present invention is a method for creating composite parts. This modality of the invention can be implanted with a shape memory polymer device (SMP) 12, as best shown in Figures 1 to 2, and / or a rigid external tool 28, as later described in this document and illustrated in Figure 2 The SMP apparatus 12 can be used both as a mandrel or rigid instrument to apply composite material 14 to it, as shown in Figure 1, and a bladder to provide outward pressure to composite material 14 during a cure of composite material 14 in a hardened composite part, as shown in Figure 2.
[00030] The SMP 12 device can be formed of SMP material cast in any memory format. For example, the SMP apparatus 12 can be cast in an elongated and / or hollow configuration that has one or more open ends using any method known in the art, such as methods for forming an SMP cylinder disclosed in U.S. Patent No. 7,422 .714, incorporated by reference in this document in its entirety. For example, the SMP apparatus 12 may be a preformed SMP cylinder or cylinder open at two opposite ends. Alternatively, the SMP 12 device can have any shape in cross section, such as a trapezoid, rectangle, square, or triangle, or it can be cast in a hollow configuration. The fused format of the SMP device is referred to in this document as its memory format.
[00031] The SMP material used to form the SMP apparatus 12 can be reinforced or unreinforced SMP material. Specifically, the SMP material used to form the SMP 12 apparatus can be an epoxy, an epoxy based SMP, a styrene copolymer based SMP or any other type or combination of SMPs, such as cyanate ester, polyurethane, homopolymer of polyethylene, styrene-butadiene, polyisoprene, copolymers of stearyl acrylate and acrylic acid or methyl acrylate, norbonene or homopolymers or copolymers of dimethoxytahydronaphthalene, and malemide. For example, the SMP material used in the SMP apparatus 12 can be any of the SMPs described in US Patent No. 7,422,714, US Patent No. 6,986,855, US Patent No. 7,276,195, application for US Patent Publication No. 2008/0021188, US Patent Publication No. 2008/0021166, and / or US Patent Publication No. 2008/0269420, the totalities of which are incorporated herein reference document. However, numerous other types of SMPs exist and can be adapted to meet specific tolerance and temperature requirements.
[00032] The module of various SMP materials can be changed through several different methods, such as a change in temperature, an electric current, water, and / or light. However, the exemplary methods described in this document reveal the use of changing temperatures to transform the SMP 12 apparatus from a malleable state to a rigid state and vice versa. However, any of the activators listed above to change the SMP material module of the SMP 12 apparatus can be used for the composite part manufacturing methods described in this document without departing from the scope of the invention.
[00033] A glass transition temperature (Tg) of an SMP material is defined in this document as a threshold temperature at and / or above which the SMP material begins to transition to a lower modulus state, becoming soft and / or malleable to be deformed. Then, the SMP apparatus 12 of the present invention can be configured to begin to become flexible and conformable when it is heated above its Tg and to become rigid when cooled to a temperature below its Tg. If the SMP 12 apparatus is deformed at a temperature above Tg and then maintained in such a deformed state as its temperature drops below Tg, then the SMP 12 apparatus hardens in such a deformed state. When heated again, the SMP 12 device can, in general, return to its original fused memory format unless otherwise influenced by another force. While the module change of the SMP 12 device can start at Tg, there may be a range of transition temperatures through which the SMP 12 device can become progressively malleable.
[00034] The SMP apparatus 12 may be made of an SMP material that has any Tg appropriate for the use and methods described in this document. In some embodiments of the invention, Tg can be equal to or less than the curing temperature for the composite material 14, so that the SMP apparatus 12 can be used as an expandable bladder during curing of the composite part. In other embodiments of the invention, Tg may be greater than the curing temperature for the composite material 14 so that the SMP apparatus 12 is kept rigid during curing of the composite part.
[00035] Although the SMP 12 apparatus can be designed to have any Tg, in some exemplary embodiments of the invention, Tg can be a temperature between 37.7 ° C (100 ° F) and 371.1 ° C (700 ° F ). Specifically, Tg can be the temperature between 37.7 ° C (100 ° F) and 93.3 ° C (200 ° F), 93.3 ° C (200 ° F) and 148.8 ° C (300 ° F) ), or between 148.8 ° C (300 ° F) and 204.4 ° C (400 ° F). More specifically, Tg can be the temperature between 51.6 ° C (125 ° F) and 79.4 ° C (175 ° F), 121.1 ° C (250 ° F) and 148.8 ° C (300 ° F), or 176.6 ° C (350 ° F) and 204.4 ° C (400 ° F). In one embodiment of the invention, Tg of the SMP 12 apparatus can be approximately equal to 61.6 ° C (143 ° F), 135 ° C (275 ° F), or 190.5 ° C (375 ° F). The SMP 12 device can become progressively malleable when heated through a temperature transition range that begins or is centered around Tg and can gradually harden to its rigid state when cooled through the temperature transition range to a temperature in or below Tg.
[00036] The rigid external tool 28 can have any desired shape or configuration for the manufacture of the composite part. In some embodiments of the invention, the rigid external tool 28 may have a hollow space in which the SMP apparatus 12 and the composite material 14 can be placed. For example, the rigid external tool 28 can be a cylinder tool or an articulated bucket tool. The rigid external tool 28, as illustrated in Figure 2, can form an external surface of the composite part. In alternative embodiments of the invention, the rigid external tool 28 can be replaced by any type of mold shaped and configured to form an internal or external surface of a composite part. In some embodiments of the invention, the rigid external tool 28 can also be used to help shape or form the SMP apparatus 12. For example, the dummy skin 22, dummy internal reinforcements 23, and / or fortification inserts 26 can be placed inside, or attached to the rigid external tool 28, as described in detail below, to provide a desired mold configuration for the SMP apparatus 12.
[00037] The composite material 14 placed in the SMP apparatus 12 to form the composite part may comprise or be in the form of low temperature resin, high temperature resin, stiffened resin, pre-impregnated, wet processed fiber, dry fiber, fiber continuous, staple fiber, chopped fiber, glass, KEVLAR, carbon, and / or core. The core is defined in this document as any compensation component that separates two layers of composite material. For example, the core may comprise foam, thermoplastic, honeycomb materials, aluminum, phenolic glass fiber, carbon, Nomex, etc. The core can also be referred to as core panels, honeycomb core, or sandwich panel core. In addition, the chemical makeup of composite material 12 may include epoxy, BMI, benzoxazine, vinyl, acrylic, polyester, polyamide, phthalonitrile, and any other similar substances known in the art. The composite material 14 can be placed in the SMP apparatus 12 using automatic fabric placement, automatic fiber placement, automatic filament winding, fabric placement, manual lamination, or any other method known in the art. The composite material 14 can be configured to be hardened or cured, as in an autoclave, outside an autoclave, by means of a low temperature curing process, and / or by a high temperature curing process.
[00038] In use, the SMP device 12 can be formed in a rigid tool configuration and then composite material 14 can be applied to it. For example, the SMP 12 device can be formed by one or more internal moles placed inside the SMP 12 device and / or one or more external molds (such as the rigid external tool 28) placed outside the SMP 12 device. internal or external can comprise any number of components integrally formed or assembled together to provide a desired shape to the SMP apparatus 12, such as dummy skin 22, dummy internal reinforcements 23, and / or fortification inserts 26 placed inside or on the external tool rigid 28 in any desired configuration. However, any method of forming the SMP apparatus 12 can be used without departing from the scope of the invention.
[00039] In some embodiments of the invention, the SMP 12 apparatus can be sealed to the internal or external molds, heated, and then pressed against the internal or external molds. For example, the SMP 12 apparatus can be pressed against the molds as a form of differential pressure induced by means of inflation, vacuum, and / or any other method known in the art to propel the SMP 12 apparatus towards the mold. Specifically, the SMP 12 apparatus can be heated and inflated towards the external mold in a configuration to form an internal surface of a composite part. Once the SMP 12 device is cooled in the rigid tool configuration, as shown in Figure 1, the SMP 12 device can be removed from the internal or external molds and composite material 14 can be placed in the SMP 12 device with use of any method known in the art, such as fiber placement. The SMP apparatus 12 can be referred to in this document as being in the "rigid tool configuration" after it is formed in the desired shape for the composite material 14 to be applied to it.
[00040] In some embodiments of the invention, cavities 40 can be formed in the SMP apparatus 12 so that components (such as internal reinforcements such as composite frames, beams, or cores) can be placed in the cavities to be bonded or cured for the composite material 14. Then, the composite material 14 can be placed on and / or inside both the SMP apparatus 12 and the components to be joined or bonded to it. These cavities 40 can hold components to be joined or bonded to the composite material 14 in place during the application of the composite material 14 without the need for any mechanical fixings. Additionally or alternatively, several barriers can be used to hold the internal reinforcements in place during the application of the composite material 14. Then, pressure through the SMP apparatus 12 can compress these components or internal reinforcements against the composite material during curing, searching or gathering, then, the same together.
[00041] Additionally or alternatively, the size and shape of the SMP apparatus 12 can be configured to allow for thicker composite material 14 or additional layers of composite material 14 to be applied to it at selected locations. For example, the SMP apparatus 12 may have a portion with a smaller cross-sectional area and a portion with a larger cross-sectional area. The portion of the SMP apparatus 12 with the smaller cross-sectional area may allow a greater amount of composite material 14 to be applied to it. In general, the SMP device 12 can be shaped and configured to provide sufficient clearance and compensation between the SMP device 12 and the rigid external tool 28 so that a desired thickness of composite material 14 and / or the internal reinforcements can fit together within said compensation.
[00042] Once the composite material is applied, the SMP apparatus 12 and the composite material 14 may have heat and pressure applied to it to cure the composite material 14 and / or to bond or bond other components or reinforcements internal to the material composite 14. Additionally, heat can also be used to change the SMP 12 device module. For example, the SMP 12 device and composite material 14 can be placed in the hollow space of the rigid external tool 28 and heated and pressurized as required to cure the composite material 14. In some embodiments, the heat used during this curing process may be greater than Tg of the SMP 12 apparatus, causing the SMP 12 apparatus to be converted to its malleable state, and a pressure differential applied from inside and / or without the SMP 12 device (for example, by means of an autoclave) can cause the SMP 12 device to be propelled towards the rigid external tool 28. Specifically, the ca lor can transform the SMP 12 device from the rigid tool configuration into a bladder configuration where the SMP 12 device becomes flexible and inflatable, acting as an internal bladder to compress the composite material 12 against the rigid external tool 28 , as illustrated in Figure 2. Additionally, in some embodiments of the invention, a small differential pressure or pressurization can be applied to the SMP 12 apparatus until its temperature exceeds Tg, at which the pressure point can be increased to the full amount of pressure desired.
[00043] The SMP apparatus 12 can then be used to press the composite material 14 against the rigid external tool 28 or any alternative rigid mold surface. Differential pressure, as described in this document, can be induced using a variety of methods, with the SMP 12 apparatus sealed in an airtight manner to one of the rigid tools or molds described in this document, so that the apparatus of SMP 12 inflates towards the composite material and / or is attracted against the composite material 14 during curing. In some embodiments of the invention, the differential pressure is introduced by means of an autoclave.
[00044] Alternatively, in some embodiments of the invention, a vacuum bag or other impermeable sheet of material can be applied in order to urge the SMP 12 apparatus, in its malleable state, towards a rigid surface to compress the composite material 14 between the SMP 12 device and the rigid surface. In this embodiment of the invention, the vacuum bag or other impermeable sheet of material can be sealed to one of the rigid tools or molds described in this document, such as the rigid external tool 28. This can be particularly useful if the SMP 12 device is not impermeable, comprising any holes or tears in it, and / or cannot be sealed to the other surface so that the differential pressure can be induced between the SMP apparatus 12 and the surface to which it is sealed. For example, the vacuum bag can be sealed to the rigid external tool 28 and can be used to drive the SMP apparatus 12, in its malleable state, in a desired direction as a form of differential pressure applied to the vacuum bag.
[00045] As described above, the SMP 12 device can be configured to experience a modification in module in response to different heat activators, such as an electric current, water, and / or light. Then, in some embodiments of the invention, one of the other activators can also be applied to the SMP 12 device since the composite material 14 is being cured, so that the SMP 12 device is malleable enough to inflate or otherwise compress the composite material 14 against rigid external tool 28.
[00046] Once the composite material 14 is cured, the differential pressure can be substantially equalized as long as the temperature is kept above Tg, and then the SMP apparatus 12 in the flexible bladder configuration can be removed from inside the part composite cure. Alternatively, once the composite material 14 is cured, sufficient differential pressure to drive the SMP apparatus 12 away from the cured composite material can be induced. In some embodiments of the invention, the SMP 12 apparatus may contract back to its original or memory format, allowing for easy removal of the SMP 12 apparatus from within the resulting composite part. In other embodiments of the invention, as described later in this document, an internal mandrel placed within the SMP 12 apparatus can be configured to attract the SMP 12 apparatus (even in its malleable state) away from the composite part. In some embodiments of the invention, the SMP 12 apparatus can be propelled away from the composite curing part while still in the malleable state, which then allowed it to cool and / or become at least somewhat rigid or completely rigid again before to be removed from inside the composite curing part.
[00047] The SMP 12 apparatus can be used to form a variety of composite parts with varying geometries, such as composite parts with retaining geometries. For example, composite parts can be aircraft fuselages, wings, nacelles, panels, ducts, and aircraft structural supports or reinforcements. Examples of aircraft structural supports may include beams, frames, trapezoidal hat reinforcements, bell reinforcements, inverted hat reinforcements, J reinforcements, F reinforcements, blade reinforcements, I reinforcements, and C reinforcements. In addition, the composite parts formed with the SMP 12 device may include flat swivel, towers, impulse reversers, housings, inlets, flanges, wing tips, vertical and horizontal stabilizers, fuselage structures, warping, cables, ribs, tubular fuselage structures, control surfaces, nose sections, fairings, flaps, electrons, aerodynamic brake (spoiler), slats, torque tubes, driving rods, hoods, engine inlets, exhaust nozzles, exhaust cones, thrusters , gearboxes, transmission compartments, clamps, rotor blades, fuel tanks, landing gear, landing gear platforms, doors, sub frames, stringers, wire trays, piles, supports, stabilizer frame adores, weapon holders, control bases, instrument consoles, etc. These composite parts can be formed using the SMP 12 apparatus by first placing the composite material 14 against at least a portion of the SMP 12 apparatus when the SMP 12 apparatus is in its rigid tool configuration. Then, the composite material 14 can be compressed against and / or by the SMP apparatus 12 in a rigid or malleable state during curing of the composite material 14 in the composite part. In some embodiments of the invention, more than one SMP 12 apparatus can be used to manufacture the composite part, as described later in this document. In some embodiments of the invention, where a plurality of SMP devices are used to form the composite part, SMP devices can be configured to have different temperatures Tg or different activators to change the module of different SMP devices, as described above .
[00048] In addition, internal reinforcements can be used or bonded with any composite part, such as the composite parts listed above, with the use of the SMP 12 device, as described later in this document. The term curing is defined in this document simultaneously as curing and bonding two uncured composite parts. The term coalition is defined in this document simultaneously as curing an uncured composite part while connecting the uncured composite part to a hardened part or a previously cured composite part. Internal reinforcements can include, for example, frames, beams, or core, as defined above. The frames and beams can be elongated structural reinforcements that extend laterally and / or perpendicularly in relation to a length of a composite part. In some embodiments of the invention, the frames can pass through the beams in a grid-like configuration. Examples of some specific types of frames and beams may include trapezoidal hat reinforcements, bell reinforcements, inverted hat reinforcements, J reinforcements, F reinforcements, blade reinforcements, I reinforcements, and C reinforcements. Additionally, the SMP 12 device can be used to form a variety of other composite parts, such as trailers, automotive pipelines and pipes, hoses, tires, turbochargers, tanks, automobiles, racing vehicles, boats, yachts, bicycles, canoes, kayaks , oars, sporting goods, weapon stocks, claws, archery and accessories, golf clubs and related components, fishing rods, guitars, pipes, poles, construction supplies, wind turbine blades, engine components, furniture , sail masts, ATMs, armor, drive shafts, satellites, missiles, and space vehicle. These composite parts can be formed using methods similar to any of the methods described in this document. MANUFACTURE A FUSELAGE WITH THE SMP APPLIANCE
[00049] Another modality of the present invention is a method to manufacture an aircraft fuselage 15 with integrated internal reinforcements 24, as illustrated in Figure 13. The method of this modality can be implemented with the SMP apparatus 12, as described above, together with an internal mandrel tool 16, end seals 18.20, the fictitious skin 22, the internal reinforcements 24, the fortification inserts 26, and the rigid external tool 28, as best illustrated in Figures 2 to 12.
[00050] In this embodiment of the invention, the SMP 12 apparatus, as illustrated in Figure 3, may have the treatments and characteristics described above in reference to the embodiment of the invention illustrated in Figures 1 to 2. In addition, the SMP 12 apparatus may have a cylinder, bottle, funnel, cone, or roll shape as your fused memory shape. However, any other fused memory format can be used without departing from the scope of the invention. In some embodiments of the invention, the SMP apparatus 12 can be received in an inflated state. Specifically, the SMP 12 apparatus may have been previously heated and inflated to a diameter greater than that of its memory format, and then cooled and hardened in such an inflated state. The SMP apparatus 12 may comprise one or two open ends. In some embodiments of the invention, the SMP 12 apparatus may be approximately 2.54 cm (1 inch) to 1,066.8 cm (35 feet) in diameter and approximately 30.48 cm (1 foot) to 2,286 cm (75 feet) in length. However, the SMP apparatus 12 can have any dimensions without departing from the scope of the invention.
[00051] The internal mandrel tool 16, as illustrated in Figure 4, can be made of any durable rigid material that is kept rigid throughout the composite curing cycle. In some embodiments of the invention, the internal mandrel tool 16 can be substantially cylindrical. In addition, the internal mandrel tool 16 can be hollow, having a cylindrical wall 30 and two opposite ends 32,34 which can comprise openings (not shown) for the hollow space within the internal mandrel tool 16.
[00052] In some embodiments of the invention, one or more inflation openings 36 can be provided through the cylindrical wall 30 so that a compressed gas can be forced into the hollow internal mandrel tool 16, as through overhead lines (not shown), then providing inflation force out of the internal mandrel tool 16. The inflation openings 36 can also be configured to suction the SMP apparatus 12 against the internal mandrel tool 16 during several steps to manufacture the fuselage. 15, as described below.
[00053] In some embodiments of the invention, an outer surface of the internal mandrel tool 16 may also comprise varying contours. For example, variant contours may include a number of protrusions 38 and / or indentations for use in retrieving the SMP apparatus 12 after curing the composite part. Specifically, as shown in Figure 4, an outer surface of the cylindrical wall 30 may comprise the projections 38 in the form of a plurality of grooves or ribs circumferentially or axially separated and arranged substantially parallel to each other. Each of the grooves or ribs can extend between the opposite ends 32.34 of the internal mandrel tool 16 and can be shaped with a wavy or sinusoidal pattern that extends between the opposite ends 32.34 of the internal mandrel tool 16, as illustrated in Figure 4. In addition or alternatively, the projections 38 may be one or more concentric rings formed around the internal mandrel tool 16, or may have any other configuration. The protrusions 38 can be integrally formed or otherwise fixed to the internal mandrel tool 16.
[00054] The purpose of the variant contours or protrusions 38 can introduce a greater amount of tension to the SMP 12 device in an area with a smaller cross section. Specifically, when the SMP apparatus 12 is driven by a differential pressure induced towards the internal mandrel tool 16 to be removed from within a composite curing part, the variant contours or protrusions 38 prevent the SMP apparatus 12 from bending over yourself. For example, after its expansion outward during curing, as described later in this document, the SMP 12 apparatus can be stretched. The axial and / or rim tension induced by the varying contours or protrusions 38 can prevent the SMP apparatus 12 from bending over itself or wrinkling and damaging the SMP material.
[00055] So, essentially, the variant contours, protrusions 38, and / or indentations provide a larger surface area for the SMP 12 device for contraction without requiring an increase in size and / or cross section of the internal mandrel tool 16 In the embodiment illustrated in Figure 4, if the radius of the internal chuck tool 16 is "r", and the length is "L", then the equation for the surface area should normally be 2π * r * L. However, because of the projections 38 extending from the surface of the internal mandrel tool 16 in Figure 4, the surface area of the internal mandrel tool 16 in Figure 4 is greater than 2π * r * L.
[00056] As shown in Figure 5, end seals 18.20 can be any end equipment, seals, and / or sealants configured to provide an airtight seal between the SMP apparatus 12 and the internal mandrel tool 16 in or close to the 32,34 ends of the SMP 12 apparatus. For example, the end seals 18,20 can be mold locks formed and configured for attachment to the 32,34 ends of the internal mandrel tool 16 over portions of the SMP 12 apparatus close to the open ends of the SMP 12 device, thus forming a pressure vessel within the SMP 12 device. Due to the nature of the SMP material, heat may be required to form a suitable seal between the end seals 18 , 20, the SMP apparatus 12, and / or the internal mandrel tool 16. In some embodiments of the invention, end seals 18,20 can be substantially circular-shaped latches. The inflation pressure can be introduced by pumping compressed gas into the SMP apparatus 12 via one or more overhead lines (not shown) fed through end seals 18,20 in some embodiments of the invention. However, the pressure applied to the SMP apparatus 12 can be supplied through any openings in the end seals 18,20, the internal mandrel tool 16, and / or the rigid external tool 28 without departing from the scope of the invention. Note that in some embodiments of the invention, end seals 18,20 may be omitted or, to some extent, configured to additionally or alternatively seal the SMP apparatus 12 to the rigid external tool 28.
[00057] The dummy skin 22, as illustrated in Figures 6b and 7, can be made of any material and can have a thickness corresponding to a thickness of the uncured composite material 14 to be placed in the SMP apparatus 12. The dummy skin 22 it can be made of composite material shapes, metal, non-reinforced plastics, or any material that exhibits good dimensional stability under heat and pressure. For example, the dummy skin 22 may be formed of composite material, such as laminated graphite fiber reinforced epoxy composite. The dummy skin 22 is configured to be placed inside the rigid external tool 28, as described later in this document, during the deformation of the SMP apparatus 12 in the rigid tool configuration. In some embodiments of the invention, the dummy skin 22 may also include or be integrally formed with the dummy internal reinforcements 23.
[00058] The fictitious internal reinforcements 23, as illustrated in Figure 6b and 7, can be rigid structures dimensioned and shaped substantially identical to the internal reinforcements 24 and arranged on the fictitious skin 22 to represent the cured and uncured internal reinforcements 24 during deformation of the SMP device in the rigid tool configuration. The fictitious internal reinforcements 23 can alternatively be dimensioned and shaped to represent both internal reinforcements and fortification inserts 26 during deformation of the SMP apparatus 12 in the rigid tool configuration.
[00059] The internal reinforcements 24, as illustrated in Figure 6a and 10b, can be any substructure reinforcements configured to be joined and / or bonded to the fuselage composite material 14 or other composite part. The internal reinforcements 24 can be elongated structural components curved to be compatible with an outline of an internal surface of the fuselage. The internal reinforcements 24 may comprise cured composite material or uncured composite material in the form of pieces of internal frame, such as frames and beams. The internal reinforcements 24 can be maintained in a desired shape during curing by means of the fortification inserts 26, as described later in this document. Some examples of internal reinforcements 24 include, but are not limited to, trapezoidal hat reinforcements, bell reinforcements, inverted hat reinforcements, J reinforcements, F reinforcements, blade reinforcements, I reinforcements, C reinforcements , core reinforcements, sandwich panel core, honeycomb core and the like. In some embodiments of the invention, internal reinforcements 24 may include frames approximately 20.32 cm (8 inches) high and beams approximately 7.62 cm (3 inches) high. However, any dimensions can be used without departing from the scope of this invention.
[00060] In some embodiments of the invention, the frames can be configured to cross with the beams in a configuration similar to the grid inside the finished fuselage 15. For example, the beams can be formed to overlap the frames and / or the frames can be formed to overlap the beams, as shown in Figure 6a. The overlapping of the internal reinforcements 24 can be accomplished by dimensioning and shaping the internal reinforcements 24 to fit together like puzzle pieces. The same configurations can also be used for the fictitious internal reinforcements 23, as illustrated in Figures 6b, 7, 8 and 9.
[00061] The fortification inserts 26, as illustrated in Figure 7, can be made of a rigid material, such as a nickel and steel alloy like INVAR, and can make contact and / or be compatible with portions of the internal reinforcements 24 and / or the fictitious internal reinforcements 23 that face the SMP apparatus 12. The fortification inserts 26 can be configured to smooth sharp corners and curves of the internal reinforcements 24 and / or the fictitious internal reinforcements 23 to further facilitate the formation of the reinforcement apparatus. SMP 12. Specifically, the fortification inserts 26 may be configured to be compatible with, or rest within, one or more angles presented by one or more of the internal reinforcements 24 and / or fictional internal reinforcements 23. For example, if one of the reinforcements internal 24 or fictitious internal reinforcements 23 have a right angle, one of the fortification inserts 26 can have two surfaces meeting at a right angle and configured to be compatible with the angle straight from such internal reinforcement 24 or fictional internal reinforcement 23. Fortification inserts 26 may also have surfaces facing away from internal reinforcement 24 or fictional internal reinforcement 23 that are substantially flat and / or have more gradual angles. For example, one or more of the fortification inserts 24 can have at least one chamfered or angled surface and / or rounded edges that can make contact with the SMP apparatus 12 as it is propelled out towards the rigid external tool 28, as described later in this document. The fortification inserts 26 can also be curved, longitudinal, to be substantially compatible with a curve of the internal reinforcements 24, the fictional internal reinforcements 23, and / or the internal surface of the rigid external tool 28.
[00062] Internal reinforcements 24 and / or fictitious internal reinforcements 23, together with fortification inserts 26, can be configured to form cavities 40, such as grooves or channels, in the SMP apparatus 12, as illustrated in Figure 10 and later described in this document. In some embodiments of the invention, the fictitious internal reinforcements 23 and / or the fortification inserts 26 can be configured to form the cavities 40 in the SMP apparatus 12, and subsequently be replaced by the internal reinforcements 24. For example, since the SMP apparatus 12 is in the rigid tool configuration, the dummy skin 22, dummy internal reinforcements 23, and / or fortification inserts 26 can be removed from cavities 40 and replaced with uncured internal reinforcements 24, configured against the fortification inserts 26 , to be inspected within the fuselage 15. Alternatively, since the SMP apparatus 12 is in the rigid tool configuration, the dummy skin 22, dummy internal reinforcements 23, and / or fortification inserts 26 can be removed from cavities 40 and replaced by pre-cured internal reinforcements 24, configured against the fortification inserts 26 to be connected with the fuselage 15.
[00063] In an exemplary embodiment of the invention, as illustrated in Figures 6a, 6b and 7, the internal reinforcements 24 and / or the fictional internal reinforcements 23 may comprise J-42 reinforcements supported on at least two sides by corresponding fortification inserts 26 . In addition, the internal reinforcements 24 and / or the fictitious internal reinforcements 23 in this exemplary embodiment may comprise frames 44 that have a substantially "T" shaped cross-section, with frames 44 also each supported on at least two sides by corresponding 26 fortification inserts. As illustrated in Figure 7, the fortification inserts 26 and / or portions of the fictional internal reinforcements 23 can be held in place and held together by mechanical locks 46, such as straps and connecting screws. However, the internal reinforcements 24 and / or the fictional internal reinforcements 23 can have any known configurations and the fortification inserts 26 can be of any shape and configuration to be compatible with them.
[00064] The rigid external tool 28, as illustrated in Figure 8, can be a rigid tool that has an internal surface configured to form a shape of an outer surface of the fuselage 15. For example, the rigid external tool 28 can be a tool articulated bucket, as illustrated in Figure 2 or as illustrated in Figure 8, and can have two halves, which include a lower articulated bucket and an upper articulated bucket. Together, the two halves can form a hollow cylindrical shape delimited by the internal surface of the rigid external tool 28. However, the rigid external tool 28 can comprise any plurality of portions which, when joined together, can form an internal surface configured to form the shape the outer surface of the fuselage 15.
[00065] In general, a method for manufacturing the fuselage 15 may include the steps of forming the SMP apparatus 12 in the rigid tool configuration with the cavities 40 for the internal reinforcements 24, placing the cured and uncured internal reinforcements 24 and inserts of fortification 26 in cavities 40 in the SMP 12 apparatus, place the uncured composite material 14 in the SMP 12 apparatus, and then place that SMP 12 apparatus and the uncured composite material 14 in the rigid external tool 28. The method can , then, include the curing steps of the composite material 14 by means of pressure and heat while simultaneously inflating or otherwise expanding the SMP apparatus 12 to compress the composite material 14 against the rigid external tool 28 during the curing process, then , once the composite material 14 is cured, propel the SMP apparatus 12 into a reduced cross-section, and extract the SMP apparatus 12 from within the resulting fuselage. Internal reinforcements 24 are therefore linked and / or bonded to the composite fuselage, eliminating the need for mechanical locks to secure internal reinforcements 24 to the fuselage. The methods described in this document for seeding or bonding the internal reinforcements 24 to the fuselage can also be used to sew or attach reinforcements or other components to any composite part known in the art, such as any of the various aircraft components listed in this document.
[00066] The flowchart in Figure 14 describes the steps of an exemplary method 1400 to form the SMP apparatus 12 in the rigid tool configuration used to manufacture the fuselage 15. In some alternative deployments, the functions noted in the various blocks can occur outside the order declared in Figure 14. For example, two blocks shown in succession in Figure 14 can, in fact, be executed substantially concurrently, or the blocks can sometimes be executed in reverse order depending on the functionality involved.
[00067] Method 1400 can comprise the steps of receiving the SMP 12 device in the inflated state, as illustrated in Figure 3, or receiving the SMP 12 device in its memory format and then heating and inflating the SMP device 12 in its inflated state, as stated in block 1402. This expansion of the SMP 12 device can also be accomplished by using several other activators to change the SMP 12 device module and / or various other forces or techniques to expand the SMP 12 device to the desired size. The SMP 12 device can then be large enough to be slid over the internal mandrel tool 16. Alternatively, the SMP 12 device can be fused to a memory format large enough to fit over the mandrel tool. internal 16. The next step in method 1400 may be to slide the internal mandrel tool 16 into the SMP 12 device or to slide the SMP 12 device into the internal mandrel tool 16, as stated in block 1404. Yet, in another alternative mode of invention, the SMP apparatus 12 can be received in a contracted state and can already be conformed to the internal mandrel tool 16 of Figure 4.
[00068] Once the SMP apparatus 12 is positioned on the internal mandrel tool 16, method 1400 may comprise heating the SMP apparatus 12 above Tg in which the SMP material becomes malleable and conformable, as stated in the block 1406. Above the threshold temperature Tg, the SMP 12 device can naturally contract back towards its original shape and memory size, causing the SMP 12 device to contract around and in the form of the internal chuck tool 16 , as shown in Figure 5. In addition or alternatively, vacuum can be applied from inside the internal mandrel tool 16, through the inflation openings, and can suction the heated and malleable SMP device 12 against the mandrel tool internal 16. In some embodiments of the invention, the internal mandrel tool 16 may have chamfered or angled portions 48, at each of the opposite ends 32,34 to which the SMP apparatus 12 can be formed. Any excess material that extends outward beyond the chamfered or angled portions 48 may need to be thrown or cut.
[00069] Method 1400 may further comprise the step of applying end seals 18,20 to the SMP apparatus 12 and the internal mandrel tool 16, as stated in block 1408, creating a pressure vessel between the internal mandrel tool 16 and the SMP 12 device. Specifically, as the SMP 12 device contracts, end portions of the SMP 12 device can be pressed inwardly towards the internal mandrel tool 16 and / or its chamfered or angled portions 48 and locked at the same time by the end seals 18.20, as mold locks. In some embodiments of the invention, end seals 18,20 may be compatible with the bevel or angled portions 48 of the internal mandrel tool 16, sandwiching portions of the SMP apparatus 12 between end seals 18,20 and the end tool internal mandrel 16 to form an airtight seal. In some alternative embodiments of the invention, the step of applying end seals 18,20 may be omitted or the SMP apparatus 12 may be sealed in other shapes or to other surfaces to allow a differential pressure to act on the SMP apparatus 12.
[00070] The next step in method 1400 may comprise placing the dummy internal reinforcements 23 and / or fortification inserts 26 on the dummy skin 22 in a configuration corresponding to the desired locations of the internal reinforcements 24 within the fuselage, as stated in block 1410 and illustrated in Figure 7. The dummy skin 22, dummy internal reinforcements 23, and / or the fortification inserts 26 can be covered with a thin film or some other substance to prevent them from being glued together and / or to the SMP device 12 Method 1400 may then comprise placing the dummy skin 22 on the rigid external tool 28, as stated in block 1412. Specifically, the dummy skin 22 can be applied to the internal surface of the rigid external tool 28 to imitate or serve as a retainer location for the thickness of the composite material 14 which will later be placed on the SMP apparatus 12. This ensures that the SMP apparatus 12 with the composite material 14 applied the same in a desired thickness will still fit inside the rigid external tool 28.
[00071] The fortification inserts 26 can be positioned on the fictitious skin 22 which rests on the rigid external tool 28 together with the fictitious internal reinforcements 23, which can be shaped and configured to emulate the size and configuration of the cured and uncured internal reinforcements 24. The fictitious internal reinforcements 23 can subsequently be removed from cavities 40 and replaced by cured and uncured internal reinforcements 24. Cured and uncured internal reinforcements 24 together with the fortification inserts 26 can then be placed in the grooves or cavities 40 to join or sew the internal reinforcements 24 with the composite material 14 that manufactures the fuselage 15.
[00072] As noted above, the fictitious internal reinforcements 23 can be omitted and / or replaced by the internal reinforcements 24 at any of the steps described in this document in an uncured or cured state. For example, internal reinforcements 24 and / or fortification inserts can be used to form cavities 40. In one embodiment of the invention, internal reinforcements 24 can be pre-cured and / or cured during the forming of the SMP apparatus 12 and they can later be bonded to the composite material 14 during its curing, then manufacturing the fuselage 15.
[00073] Method 1400 may further comprise the steps of placing the SMP apparatus 12, together with the internal mandrel tool 16, inside the rigid external tool 28, as declared in block 1414 and illustrated in Figure 8, and then heating and pressurize the SMP 12 device, as stated in block 1416. Heat and pressure can force the SMP 12 device to inflate and press against the dummy skin 22, dummy internal reinforcements 23, internal reinforcements 24, and / or fortification inserts 26. As mentioned above, the SMP 12 device can be heated at or above Tg to change the SMP 12 device module to make it conformable and expandable. However, other methods can also be used to change the SMP 12 device module, as described in this document. In addition, in alternative embodiments of the invention, the steps of method 1410 to 1414 can be replaced by a step of placing the SMP apparatus 12 inside any rigid external mold shaped and configured to imitate an internal surface of the composite part that is formed and comprising protrusions to form the desired cavities 40 in the SMP apparatus 12.
[00074] The pressure or differential pressure can be induced in a number of ways, such as by means of a forced compressed gas applied through the inflation openings 36 of the internal mandrel tool 16, as illustrated in Figure 4. For example, the pressure required to expand the SMP 12 device may depend on the thickness and / or overall size of the SMP 12 device. In addition, the type of SMP material used and / or the design of the SMP 12 device can also affect the ease or difficulty in tensioning the SMP apparatus 12. In some embodiments of the invention, pressure in the range of 6.8 to 1034.2 kPa (1 to 150 pound-force per square inch (psig)) or pressure in a narrower range of 206.8 kPa to 620.5 kPa (30 to 90 psig) can be applied to inflate the SMP 12 device. For example, approximately 310.2 kPa (45 psig) can be applied inside the SMP 12 device to inflate the SMP device 12. In addition, in any of the steps of the method described in this document In which the SMP 12 apparatus is heated and pressurized, a low differential pressure can be induced as the heat is increased to or above Tg to prevent the SMP 12 apparatus from collapsing away from the composite material 14 as it begins. to soften. Then, at some point after the SMP 12 device exceeds Tg, the differential pressure can be increased to the desired complete amount. For example, a low pressure of approximately 34.4 to 68.9 kPa (5 to 10 psi) can be applied inside the SMP 12 apparatus until sufficient heat has been applied to make the SMP 12 apparatus sufficiently malleable, to such an extent. point where the pressure applied to it can be increased to the curing cycle pressure, such as 206.8 to 620.5 kPa (30 to 90 psi).
[00075] Thereafter, method 1400 may comprise cooling the SMP 12 device to harden it in the rigid tool configuration, as stated in block 1418. The inflation pressure can continue to be applied depending on the temperature of the SMP 12 device. cooled to a point below Tg so that the SMP device is hardened in its rigid tool inflated configuration. The SMP apparatus 12 is therefore shaped according to the fictitious skin 22, fictitious internal reinforcements 23, internal reinforcements 24, and / or fortification inserts 26, which form the cavities 40, cavities, or grooves in the SMP apparatus 12 As stated in block 1420, method 1400 can then comprise removing the SMP device 12 and internal mandrel tool 16 from the rigid external tool 28. The dummy skin 22 can also be removed from the SMP device 12, as illustrated in Figure 9. Figure 10a further illustrates the SMP apparatus 12 resulting in the rigid tool configuration after the dummy internal reinforcements 23 are removed, thus revealing the cavities 40 formed by the 1400 method. Figure 10b illustrates the SMP apparatus 12 resulting in the rigid tool configuration with the internal reinforcements 24 placed where the fictitious internal reinforcements 23 were located in Figure 9.
[00076] The flowchart of Figure 15 describes the steps of an exemplary method 1500 to manufacture the fuselage 15 using the SMP 12 device in more detail. In some alternative deployments, the functions noted in the various blocks may occur outside the order stated in Figure 15. For example, two blocks shown in succession in Figure 15 may, in fact, be executed substantially concurrently, or the blocks may, some sometimes be performed in reverse order depending on the functionality involved.
[00077] As illustrated in Figure 15, method 1500 may first include the step of forming SMP apparatus 12 in the rigid tool configuration, as stated in block 1502 and in the method steps in Figure 14. As noted above, this step may require forming the cavities 40 in the SMP apparatus 12 in a configuration corresponding to the desired locations of the internal reinforcements 24 within the finished fuselage 15. A variety of methods can be used to form the SMP apparatus 12 in the rigid tool configuration desired with the cavities 40, cavities, or grooves formed in it.
[00078] Since the SMP apparatus 12 is formed in the rigid tool configuration, method 1500 for manufacturing the fuselage 15 may include the step of placing cured and uncured internal reinforcements 24 and fortification inserts 26 in the cavities in the apparatus of SMP 12, as stated in block 1504 and illustrated in Figure 10b. However, in some embodiments of the invention, if the internal reinforcements 24 have already been positioned on or between the fortification inserts 26 during the heating and formation of the SMP apparatus 12 in the rigid tool configuration, then the internal reinforcements 24 and fortification inserts 26 can remain within the resulting cavities 40, cavities, or grooves that they have created in the SMP apparatus 12, and step 1504 can be omitted.
[00079] In some embodiments of the invention, internal reinforcements 24 may be uncured material applied and / or wrapped around one or more SMP reinforcement apparatus, made of SMP material as described above for the SMP apparatus 12. In this way, both the internal reinforcements 24 and the composite or fuselage part 15 can be cured using SMP material. However, the SMP material used for the SMP reinforcement apparatus may have a different activator and / or a different Tg than that of the SMP 12 apparatus used to form the fuselage 15. Thus, either the reinforcement SMP apparatus or the SMP apparatus 12 for the fuselage 15 may remain rigid during curing while the other of the reinforcing SMP apparatus and the SMP apparatus 12 is used as an internal bladder during curing.
[00080] Method 1500 can then comprise a step of applying a portion of the uncured composite material 14 to the SMP apparatus 12, as stated in block 1506 and illustrated in Figure 11. Specifically, composite material 14 can be applied either in the SMP apparatus 12 as well as in the internal reinforcements 24 that rest in the cavities 40, so that at least a portion of the internal reinforcements 24 comes into contact and can bind or bond to the composite material 14 of the fuselage 15, as described later in this document. The uncured composite material 14 can be placed in the SMP apparatus 12 using any method known in the art, such as automatic fabric placement, automatic fiber placement, automatic filament winding, and / or manual lamination. As mentioned above, composite material 14 may comprise or be in the form of low temperature resin, high temperature resin, stiffened resin, prepreg, wet processed fiber, dry fiber, continuous fiber, staple fiber, chopped fiber, glass, KEVLAR, carbon, and / or core. In some embodiments of the invention, the barrier and / or release agent can be placed between the SMP apparatus 12 and the composite material 14, so that they can be more easily separated after curing the composite material 14. The barrier or release agent can be a film, a plastic, etc. The barrier or release agent can also, for example, have a bondable side and a release side.
[00081] Method 1500 for manufacturing The fuselage 15 can then comprise placing the SMP apparatus 12 and the uncured composite material 14 on the rigid external tool 28, as stated in block 1508. Subsequently, the method may include the steps of cure the composite material 14 by means of pressure and heat, as stated in block 1510, while simultaneously inflating the SMP apparatus 12 to compress the composite material 14 during the curing process, as declared in 1512. In some embodiments of the invention, inflation pressure can be provided by means of the internal mandrel tool 16 and the heat can be raised to a composite curing temperature above Tg. the inflation of the SMP device 12 can compress the composite material 14 during the curing cycle, and compress the cured and uncured internal reinforcements 24 between the SMP device 12 and the rigid external tool 28. In addition or alternatively, the inflation of the device SMP 12 can apply pressure directly to one or more of the fortification inserts 26 so that the fortification inserts 26 apply compressive force directly to portions of the internal reinforcements 24 positioned between the fortification inserts 26. The inflation of the SMP apparatus 12 it can also compress the cured and uncured internal reinforcements 24 into the composite material 14 of the fuselage, thus joining or boring the internal reinforcements 24 to the fuselage.
[00082] In another embodiment of the invention, a seal can be formed between the rigid external tool 28 and the SMP apparatus 12 with the use of mechanical seals, adhesive, or any known method for sealing peripheral portions of the SMP apparatus 12 to the tool rigid external tool 28. The rigid external tool 28 can be ventilated to further accentuate the differential pressure created by autoclave when curing the composite material 14. This can eliminate the need for an airtight seal with the internal mandrel tool 16. Note that other methods to compress the SMP apparatus 12 against the composite material 14 can be used without departing from the scope of the invention. In addition, the heat and differential pressure described in this document can be supplied by autoclave (not shown) or any other combination of heating and pressure techniques known to manufacture composite parts.
[00083] Once the composite material 14 is cured, method 1500 may comprise removing the inflation pressure from within the SMP 12 apparatus, as stated in block 1514, and extracting the SMP 12 apparatus from within the resulting fuselage, as stated in block 1516. The SMP apparatus 12 can be contracted around the internal mandrel tool 16 once the pressure is removed, while the heat is maintained above Tg. For example, the vacuum can be applied from inside the internal mandrel tool 16 to suction the SMP apparatus 12 back against the internal mandrel tool 16. As illustrated in Figure 12, the SMP apparatus 12 is therefore away from the cured composite material 14. Then extracting the inner mandrel tool 16 from inside the cured fuselage and inner reinforcements 24 results in the extraction of the SMP apparatus 12 which contracts against the inner mandrel tool 16 after the inflation pressure is removed. .
[00084] Finally, method 1500 can comprise the steps of removing the fortification inserts 26 from the cured internal reinforcements 24, as stated in block 1518, and extracting the fuselage from the rigid external tool 28, as declared in block 1520. For example, portions of the rigid external tool 28 can be mechanically disconnected from each other, allowing the fuselage 15 and its integrated internal reinforcements 24 to be removed from the rigid external tool 28.
[00085] In an alternative embodiment of the invention, the SMP 12 apparatus can remain rigid during curing. For example, once the uncured composite material 14 is applied to the SMP apparatus 12, they can be vacuum-sealed or sealed within a flexible waterproof material (not shown) and cured. In this alternative embodiment, the curing temperature of the composite material 14 can be lower than the temperature Tg at which the SMP 12 apparatus begins to become malleable, so that the SMP 12 apparatus is kept rigid throughout the curing cycle. . So, instead of using the SMP 12 device as a bladder during healing, the SMP 12 device can remain rigid during healing, with the compressive strength of the vacuum bag or impermeable material being used to cure or collect the material fuselage composite 14 and the internal reinforcements 24. Thus, once the composite material 14 is cured, the vacuum bag can be removed from the surroundings of the resulting fuselage, and the temperature of the SMP apparatus 12 can be raised above Tg so that the SMP 12 device can be malleable and / or contract towards its memory format to be removed from inside the fuselage. MANUFACTURE REINFORCEMENTS WITH THE SMP APPLIANCE
[00086] Another embodiment of the invention, as best illustrated in Figures 16 to 17, is a method for making a reinforcement 50, such as the internal reinforcements 24, described above, a frame, and / or a beam. In this embodiment of the invention, the method can be implemented using the SMP apparatus 12, a rigid shaping tool 52, and an impermeable sheet of material 54 as a vacuum bag to manufacture the reinforcement, as illustrated in Figure 16.
[00087] The SMP 12 apparatus illustrated in Figure 16 can have the same treatments and characteristics as the SMP 12 apparatus described for the embodiment of the invention illustrated in Figures 1 to 2. In addition, the SMP 12 apparatus can be formed in one desired rigid tool configuration using any desired method, such as the techniques described above. In some embodiments of the invention, the SMP apparatus 12 can be cast with a memory shape substantially corresponding to a desired shape or contour of at least one surface of the resulting reinforcement 50. For example, if the reinforcement 50 to be manufactured is a beam with a trapezoidal cross-section, then, the SMP apparatus 12 can be fused with a memory format that has a substantially trapezoidal cross-section. Alternatively, the SMP apparatus 12 can be cast in any elongated shape and can subsequently be inserted into a hollow mold, heated, and inflated therein, and then cooled and hardened in the shape provided by the hollow mold.
[00088] The rigid shaping tool 52 can be similar or identical in functionality and design to the rigid external tool 28 described above and can be made of any material that can remain rigid during curing of composite material 14, such as steel. Alternatively, the rigid shaping tool 52 may be made of an SMP material configured to remain rigid during curing of the composite material 14. For example, the rigid shaping tool 52 may be the SMP apparatus 12 illustrated in Figure 10a and the Tg of the SMP apparatus 12 illustrated in Figure 16 may differ from the Tg of the rigid modeling tool 52 in this alternative embodiment of the invention. The rigid shaping tool 52 can be configured to form at least one desired outer surface of the reinforcement. For example, the rigid shaping tool 52 can comprise a cavity 56 formed therein where the uncured composite material 14 can be placed, forming at least one wall of the reinforcement 50. As illustrated in Figure 16, the cavity 56 can be a recess with a bottom and two side walls that extend at angles of not 90 ° from the bottom.
[00089] The waterproof sheet of material 54 can be a vacuum bag or any other flexible waterproof material that can be sealed to the rigid shaping tool 52 and / or the SMP apparatus 12. For example, the waterproof sheet of material 54 can be placed on the composite material 14 and sealed to the rigid shaping tool 52, creating a substantially hematic seal between the impermeable sheet of material 54 and the rigid shaping tool 52. The impermeable sheet of material 54 may also comprise a vacuum port ( not shown) that extends through it to allow air evacuation and ventilation. When air is removed from between the rigid shaping tool 52 and the impermeable sheet of material 54, the impermeable sheet of material 54 can compress the composite material 14 placed between them. Additionally or alternatively, the SMP 12 device can be pressurized by autoclave and / or compressed gas, then inflating the SMP 12 device towards the rigid shaping tool 52 and the impermeable sheet of material 54. In addition, a sheet size (not shown) can be placed between the impermeable sheet of material 54 and composite material 14 to better control the contour and surface finish of composite material 14. Other composite bagging techniques known in the art can also be used in the present document without departing from the scope of the invention.
[00090] In an alternative embodiment of the invention, the impermeable sheet of material 54 can be replaced by a permeable sheet of material that can be placed on composite material 14 and the SMP apparatus 12. In that embodiment of the invention, the permeable sheet of material can be physically pressed towards the composite material 14 while the pressure of the SMP apparatus 12 during curing compresses the composite material 14. In yet another alternative embodiment of the invention, the impermeable sheet of material 54 can be replaced by a covering tool rigid that can be permeable or impermeable and can be fastened, pressed against it, or mechanically fixed to the rigid modeling tool 52 and on the composite material 14.
[00091] The flowchart in Figure 17 describes the steps of an example 1700 method for fabricating a composite reinforcement using the SMP 12 device. In some alternative deployments, the functions noted in the various blocks may occur outside the order stated in the Figure 17. For example, two blocks shown in succession in Figure 17 can, in fact, be executed substantially concurrently, or the blocks can sometimes be executed in reverse order depending on the functionality involved.
[00092] Method 1700 for fabricating reinforcement 50 using the SMP 12 apparatus can comprise the steps of forming the SMP 12 apparatus in the rigid tool configuration, as stated in block 1702, and then applying at least a portion of the SMP device 12 with the composite material 14, as stated in block 1704. In some embodiments of the invention, the rigid tool configuration of the SMP device 12 may correspond to an internal shape and / or angle of the reinforcement 50 to be formed in the same. In other embodiments of this invention, the material 14 can be placed on or wrapped in the SMP 12 apparatus first, and then, the SMP 12 apparatus can be formed in the rigid tool configuration, using any modeling techniques described herein. document or known in the art.
[00093] Then, method 1700 may comprise placing the SMP apparatus 12 applied with composite material 14 in cavity 56 of the rigid modeling tool 52, as stated in block 1706. Alternatively, composite material 14 can be deposited in cavity 56 of the rigid shaping tool 52 and then the SMP apparatus 12 in the rigid tool configuration can be placed on top of the composite material 14 within the cavity 56 of the rigid shaping tool 52.
[00094] However, a number of techniques can be employed to bring the composite material 14 into contact with the SMP apparatus 12, and to place both in the cavity of the rigid shaping tool 52, without departing from the scope of this invention. In addition, in some embodiments of the invention, more than one SMP apparatus can be used to manufacture reinforcement 50. For example, as shown in Figure 16, two SMP apparatus 58.60 that have the properties of the SMP apparatus 12 , as described above, are shaped or molded to support opposite surfaces of composite material 14 to fabricate reinforcement 50 on a beam in J-shaped configuration. Specifically, reinforcement 50 can be an elongated reinforcement that has a substantially shaped cross-section de J. The composite material 14 can be positioned between the two SMP apparatus 58.60 and the rigid shaping tool 52 as illustrated in Figure 16 with the use of manual lamination or any other methods known in the art. Then, a laminated skin 62 can be placed on the two SMP devices 58.60, making contact with a top end of the composite material 14 that manufactures the J-shaped cross section of the reinforcement 50. In this embodiment of the invention, the skin laminate 62 and composite material 14 can be joined as described later in this document.
[00095] Therefore, in general, method 1700 may comprise the step of placing another layer of composite material or laminated skin 62 on the SMP apparatus 12, making contact with at least a portion of the composite material 14 that rests within the cavity 56 of the rigid modeling tool 52, as stated in block 1708. Subsequently, the method may comprise placing the impermeable sheet of material 54 on composite material 14 and / or laminated skin 62, as stated in block 1710, and sealing the sheet impermeable material 54 to the rigid modeling tool 52, as stated in block 1712, thus forming an airtight boundary around the composite material 14. The hermetic boundary can also be formed on and / or against the SMP apparatus 12, while it leaves at least one ventilation opening (not shown) for the SMP 12 device, so that the space inside the SMP 12 device is kept exposed to the atmosphere outside the airtight limit.
[00096] Then, the 1700 method can comprise a step of inducing a differential pressure to propel the impermeable sheet of material 54 towards the rigid shaping tool 52, as stated in block 1714. For example, this step may involve removing air between the waterproof sheet of material 54 and the rigid shaping tool 52, such as by means of a vacuum, which can press the waterproof sheet of material 54 towards or against the composite material 14 and / or the laminated skin 62. Posteriorly or simultaneously to the step declared in block 1714, method 1700 may comprise the step of heating the composite material 14 and the SMP apparatus 12 to a temperature for curing the composite material 14, as stated in block 1716. The curing temperature of composites may be higher than Tg, so that the SMP 12 device can become malleable and can push or inflate outward, pressing against the composite material 14. The SMP 12 device can then behave in a similar way similar to an internal vacuum bag. Additionally or alternatively, gas or air pressure can be introduced into the SMP apparatus to cause or help inflate it out to compress the composite material 14.
[00097] In some alternative embodiments of the invention, at least one of the SMP devices 58.60 can be replaced by a rigid tool of the same shape. In other alternative embodiments of the invention, the two SMP apparatus 58.60 can be replaced by rigid tools of the same shape and the rigid shaping tool 52 can be replaced by the SMP apparatus 12 of Figure 10a. In general, any combination of SMP devices and rigid modeling tools can be used to form the composite parts described and declared in this document.
[00098] Once the composite material 14 is cured, the method can comprise the steps of removing the impermeable sheet of material 54 from the rigid modeling tool 52, as stated in block 1718. In some embodiments of the invention, method 1700 can also understand or continue to heat or reapply heat to the SMP 12 apparatus, as stated in block 1720, so that the SMP 12 apparatus can be contracted or otherwise propelled away from the cured reinforcement 50. If gas pressure or air has been introduced to help inflation the SMP 12 device, this pressure can also be removed. The SMP 12 device can, of course, be contracted back to its original memory format, remaining soft and malleable until cooled. Then, method 1700 may include a step of removing the SMP apparatus 12 from the cured composite material 14 or reinforcement 50 while it is in its soft, malleable state, as stated in block 1722. Alternatively, the SMP apparatus 12 may be contracted or propelled away from the cured reinforcement 50 while in its malleable state, but then cooled and hardened before being removed from within the cured reinforcement 50.
[00099] Note that, once removed from cured reinforcement 50, the SMP 12 device can then be reconfigured to any desired rigid tool configuration within the voltage limitations of the SMP 12 device and reused to create another reinforcement. In general, the SMP 12 device is reconfigurable and reusable. Conversely, internal mandrel pouches known in the art cannot be reused or do not offer the desired durability and are more prone to failure. Internal mandrel pouches also lack the reinforcement needed to be used as a laminating tool to apply composite material 14 to it. Specifically, other types of mandrels used in traditional reinforcement forming applications are often required to be removed or washed from the cured reinforcement and are therefore also not reusable. Advantageously, the SMP apparatus 12 can be used both as the rigid lamination tool for laminating composite material, and as an inner pouch or bladder during curing of composite material 14, and can then be removed and reused for multiple cycles.
[000100] Although the invention has been described with reference to the preferred embodiment illustrated in the accompanying drawings, it is noted that equivalents can be employed and substitutions made in this document without departing from the scope of the invention as stated in the claims. For example, any case of vacuum or inflation force that is applied into or out of the SMP 12 apparatus, as described in this document, is merely exemplary and can be replaced by any methods known in the art to create the differential pressure that it can propel the SMP apparatus 12 towards a desired mold and / or composite material 12. Additionally, while various shapes, configurations, and instruments have been described in this document to conform the SMP apparatus 12 to a desired rigid tool configuration, note that any mold or combination of molds and rigid instrument can be used to define a shape of the SMP 12 apparatus using one or more of the steps of the method described in this document.
[000101] In addition, although the Figures and exemplary modalities provided in this document describe the manufacture of composite parts for aircraft, the training tools and methods described in this document can be used to manufacture composite parts for automobiles, boats, sport and the like without departing from the scope of the invention.
[000102] Having then described the various modalities of the invention, what is claimed as new and is to be protected by the Patent Letters includes the following:

权利要求:
Claims (22)
[0001]
1. Method for making a composite part (15) with integrated reinforcements, characterized by the fact that the method comprises: placing a polymer device with shape memory (SMP) (12) inside an external mold; fix the ends of the SMP apparatus (12) to at least one of an internal mandrel tool (16) and the external mold; drive the SMP device (12) to a malleable state and induce a pressure differential sufficient to drive the SMP device (12), in the malleable state, towards the external mold, thus molding the SMP device (12) with a desired configuration of a first surface of the composite part (15) to be formed and include one or more cavities (40) configured for placing the reinforcements therein; activate the SMP device (12) to a rigid state; place the reinforcements in the cavities (40) formed in the SMP apparatus (12); apply composite material (14) to the SMP device (12) and exposed surfaces of the reinforcements that rest within the cavities (40); and cooking or joining the reinforcements with the composite material (14) in the SMP apparatus (12) by means of pressure and heat to manufacture the composite part (15), the SMP apparatus (12) being kept in a rigid state throughout the curing or joining of the reinforcements with the composite material (14).
[0002]
2. Method, according to claim 1, characterized by the fact that curing or joining the reinforcements with the composite material (14) comprises: sealing an impermeable sheet of material (54) around the composite material (14); compressing the impermeable sheet of material (54) against the composite material (14) by inducing a differential pressure towards and / or into the impermeable sheet of material (54); and heating the composite material (14) to a composite curing temperature, with the SMP apparatus (12) in the rigid state while the impermeable sheet of material (54) is compressed against the composite material (14).
[0003]
3. Method, according to claim 1, characterized by the fact that the reinforcements include at least one of the frames, beams, composite core and additional layers of composite material (14).
[0004]
4. Method, according to claim 1, characterized by the fact that the reinforcements are pre-cured before placement in the cavities (40).
[0005]
5. Method, according to claim 1, characterized by the fact that the reinforcements are not cured prior to placement in the cavities (40).
[0006]
6. Method, according to claim 1, characterized by the fact that it further comprises: activating the SMP device (12) from the rigid state to a malleable state; and removing the SMP apparatus (12) from inside the composite part (15).
[0007]
7. Method according to claim 6, characterized by the fact that the SMP apparatus (12) is configured to be activated to the malleable state when heated above a temperature Tg, in which the curing temperature of composite material (14 ) is less than Tg, so that the SMP apparatus (12) is kept rigid during the curing of the composite material (14) in the composite part (15).
[0008]
8. Method, according to claim 1, characterized by the fact that it also comprises placing rigid fortification inserts (26) in the cavities (40) between the SMP apparatus (12) and the internal reinforcements before applying the composite material ( 14) to the SMP apparatus (12), in which the cavities (40) are dimensioned and shaped to allow both the rigid fortification inserts (26) and the internal reinforcements to rest on them.
[0009]
9. Method for manufacturing a composite part (15) with integrated reinforcements, characterized by the fact that the method comprises: activating a polymer device with shape memory (SMP) (12) to a malleable state, in which the SMP device (12) is located inside an external mold, in which the ends of the SMP apparatus (12) are sealed to at least one of an internal mandrel tool (16) and the external mold; induce a pressure differential sufficient to drive the SMP apparatus (12), in the malleable state, against the external mold, thus molding the SMP apparatus (12) with a desired configuration of a first surface of the composite part (15) to be formed and to include one or more cavities (40) configured to place the reinforcements in them; activate the SMP device (12) to a rigid state; place the reinforcements in the cavities (40); apply composite material (14) to the SMP apparatus and exposed surfaces of the reinforcements that rest within the cavities (40); and cooking or joining the reinforcements with the composite material (14) in the SMP apparatus (12) by means of pressure and heat to manufacture the composite part (15), which includes the steps of: sealing an impermeable sheet of material (54) around the composite material (14); compressing the impermeable sheet of material (54) towards the composite material (14) by inducing a differential pressure towards and / or inside the impermeable sheet of material (54); and heating the composite material (14) to a curing temperature of the composite, with the SMP apparatus (12) in the rigid state while the impermeable sheet of material (54) compresses the composite material (14).
[0010]
10. Method, according to claim 9, characterized by the fact that the reinforcements are internal reinforcements.
[0011]
11. Method according to claim 9, characterized by the fact that the reinforcements include at least one of the frames, beams, core and additional layers of composite material (14).
[0012]
12. Method according to claim 9, characterized by the fact that the composite part (15) is a monolithic aircraft fuselage, a wing, a nacelle, an aircraft panel, an aircraft duct, aircraft structural supports, an aircraft component made of solid laminates, integrally reinforced laminates, or reinforced core sandwich structure, or internal reinforcements for an aircraft component.
[0013]
13. Method, according to claim 9, characterized by the fact that the reinforcements are pre-cured before placement in the cavities (40).
[0014]
14. Method according to claim 9, characterized by the fact that the reinforcements are not cured prior to placement in the cavities (40).
[0015]
Method according to claim 9, characterized in that it further comprises: removing the impermeable sheet of material (54) after the composite material (14) is cured; activate the SMP device (12) from the rigid to the malleable state; and removing the SMP apparatus (12) from inside the composite part (15) while the SMP apparatus (12) is in the malleable state.
[0016]
16. Method, according to claim 9, characterized by the fact that the SMP apparatus (12) is configured to change to the malleable state when heated above a temperature Tg, with the curing temperature of composite material (14) it is smaller than Tg, so that the SMP apparatus (12) is kept rigid during the curing of the composite material (14) in the composite part (15).
[0017]
17. Method according to claim 9, characterized by the fact that the ends of the SMP apparatus (12) are sealed to the internal mandrel tool (16) and the SMP apparatus (12) is located inside the external mold.
[0018]
18. Method, according to claim 9, characterized by the fact that it comprises placing rigid fortification inserts (26) in the cavities (40) between the SMP apparatus (12) and the reinforcements before applying composite material (14) to the SMP apparatus (12), in which the cavities (40) are dimensioned and shaped to allow both the rigid fortification inserts (26) and the reinforcements to rest in them.
[0019]
19. Method for manufacturing a composite part (15) with integrated reinforcement features, characterized by the fact that the method comprises: placing a polymer device with shape memory (SMP) (12) on an internal mandrel tool (16) ; seal the ends of the SMP device (12) to the internal mandrel tool (16); place the SMP apparatus (12) and the internal mandrel tool (16) in an external mold; activate the SMP device (12) to a malleable state; inflating the SMP apparatus (12) towards the external mold, thus molding the SMP apparatus (12) in the malleable state to generally correspond to a desired configuration of a first surface of the composite part (15) to be formed; and to include one or more cavities (40) configured for placing internal reinforcements in them; activate the SMP device (12) to a rigid state; separate the SMP apparatus (12), in its rigid state, and the external mold from each other; place the internal reinforcements in the cavities (40); apply composite material (14) to the SMP device (12) and exposed surfaces of the internal reinforcements that rest within the cavities (40); inspect or join the internal reinforcements with the composite material (14) in the SMP apparatus (12) by means of pressure and heat to manufacture the composite part (15), which includes the steps of: sealing an impermeable sheet of material (54) around the composite material (14), compress the impermeable sheet of material (54) towards the composite material (14) by inducing differential pressure out and / or into the impermeable sheet of material, and heating the composite material ( 14) at a composite curing temperature, with the SMP apparatus (12) in the rigid state while the impermeable sheet of material (54) compresses the composite material (14); removing the impermeable sheet of material (54) from the composite part (15); activate the SMP device (12) from the rigid to the malleable state; and removing the SMP apparatus (12) from inside the composite part (15) while the SMP apparatus (12) is in the malleable state.
[0020]
20. Method according to claim 19, characterized by the fact that the internal reinforcements include at least one of the frames, beams, core and additional layers of composite material (14).
[0021]
21. Method, according to claim 19, characterized by the fact that the SMP apparatus (12) is configured to start changing to the malleable state when heated above a temperature Tg, the curing temperature of composite material ( 14) is smaller than Tg, so that the SMP apparatus (12) is kept rigid during the curing of the composite material (14) in the composite part (15).
[0022]
22. Method, according to claim 19, characterized by the fact that it comprises placing rigid fortification inserts (26) in the cavities (40) between the SMP apparatus (12) and the internal reinforcements before applying the composite material ( 14) to the SMP apparatus (12), the cavities (40) being dimensioned and shaped to allow both the rigid fortification inserts (26) and the internal reinforcements to rest on them.

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EP2637838B1|2015-08-26|

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US20120119412A1|2012-05-17|

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EP2637838A2|2013-09-18|

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ES2548827T3|2015-10-21|

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JP2014504218A|2014-02-20|

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WO2012064442A2|2012-05-18|

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EP2637838A4|2014-07-23|

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US20120118487A1|2012-05-17|

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WO2012064443A8|2013-10-31|

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BR112013005430A2|2016-06-07|

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JP5745081B2|2015-07-08|

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KR101514585B1|2015-04-22|

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CN103180123B|2015-07-08|

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法律状态:
2018-04-03| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2019-08-20| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2020-01-28| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|

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2020-06-02| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2020-10-27| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 07/10/2011, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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US41263510P| true| 2010-11-11|2010-11-11|

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US61/412,635|2010-11-11|

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US201061425435P| true| 2010-12-21|2010-12-21|

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US61/425,435|2010-12-21|

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US201161486539P| true| 2011-05-16|2011-05-16|

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US61/486,539|2011-05-16|

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US13/238,733|US8945325B2|2010-11-11|2011-09-21|Methods and systems for forming integral composite parts with a SMP apparatus|

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US13/238,733|2011-09-21|

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PCT/US2011/055442|WO2012064443A2|2010-11-11|2011-10-07|Methods and systems for forming integral composite parts with a smp apparatus|

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