BACKGROUND OF THE INVENTION
The embodiments described herein relate generally to an
apparatus for manufacturing a component, and more particularly, to methods and
systems for manufacturing a flanged composite components.
Components often have flanges to increase the stiffness
thereof and/or to facilitate assembly with other parts. Some conventional processes
have been implemented to form flanges on components. In some known processes,
flanges include separate metallic pieces that are bolted in position.
Composite components have been used in a variety of fields,
such as the aerospace industry. Some processes deposit composite materials in a
cylindrical configuration to form tubular composite components. However, current
processes for forming flanges on composite components are labor intensive, and the
quality of the flanges can be operator-dependent. Conventionally, operators
sequentially stack composite materials in the flanged configuration by hand, which
can be a slower process than laying up in the cylindrical configuration.
Moreover, it can be slow and difficult to lay up flanges from
composite materials automatically or semi-automatically due to inherent machine
limitations such as roller dimensions, the complexity of the motions and the intricacy
of the manipulation during material placement of composite materials. More
particularly, difficulties are encountered during use of current machines and tools to
fabricate small bends or angles within the composite materials. Known machines and
tools can be limited to fabricating flanges having large fillet bends, commonly 10
inches or larger for the bend radii of flanges, which can be impractical for some
applications.
BRIEF DESCRIPTION OF THE INVENTION
In one aspect, a method of manufacturing a flanged composite
component is provided. The method includes coupling a composite structure to a first
composite material. The method includes coupling a second composite material to
the composite structure and placing a first expansion device within the composite
structure. A forming element is coupled to at least one of the first composite material,
the composite structure, and the second composite material against the mold. The
method includes coupling a pressure element to the forming element to define a space
among the mold, the forming element, and the pressure element. The method
includes expanding the first expansion device to impart a force to the second
composite material to move the second composite material away from the composite
structure and into the space to facilitate forming a first flange.
In another aspect, a composite component is provided. The
composite component includes a first composite material and a composite structure
coupled to the first composite material. A second composite material is coupled to
the composite structure. The second composite material includes a flange integrally
coupled to the composite structure and is positioned substantially orthogonal with
respect to the composite structure. The flange includes an interface having a bend
radius that is less than about 10 inches.
In yet another aspect, an apparatus for manufacturing a
flanged composite component is provided. The apparatus includes a mold configured
to couple to a composite material and includes a forming element coupled to the
mold. A pressure element is coupled to the forming element to define a space among
the mold, the forming element, and the pressure element. The apparatus includes a
expansion device coupled to the mold and disposed within the space, wherein the
expansion device is configured to impart a forming force to the forming element and
the pressure element. A positioner is disposed within the composite material and in
contact with the expansion device and configured to facilitate positioning the
expansion device within the space.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 illustrates a side cross sectional view of an exemplary
component forming apparatus having a mold, a forming element, a pressure element,
and an expansion device, and illustrates a composite material coupled to the mold.
Fig. 2 illustrates a front perspective view of a flanged
component formed by the exemplary apparatus shown in Fig. 1.
Fig. 3 illustrates a side cross sectional view of the exemplary
mold, forming element, pressure element, and expansion device in a position for
forming an exemplary flange from the composite material.
Fig. 4 illustrates a side cross sectional view of the exemplary
mold, another forming element, another pressure element and another expansion
device, and illustrates an exemplary formed flange.
Fig. 5 illustrates a side cross sectional view of the exemplary
mold, forming element, pressure element and expansion device shown in Fig. 4 for
forming another exemplary flange from the composite material.
Fig. 6 illustrates a side cross sectional view of exemplary
flanges formed from the composite material.
Fig. 7 illustrates an exemplary flowchart illustrating a method
of manufacturing a flanged component.
DETAILED DESCRIPTION OF THE INVENTION
Fig. 1 illustrates a side cross sectional view of an exemplary
component forming apparatus 10. Fig. 2 illustrates a front perspective view of a
flanged component 12 formed by apparatus 10 shown in Fig. 1. Component 12
includes a composite material 14 having a first flange 18 and a second flange 20.
Alternatively, fewer than two flanges or more than two flanges can be used to enable
component 12 to function as described herein. Flanges 18, 20 are formed from and
integrally coupled to composite material 14 (shown in Fig. 1).
In one embodiment, apparatus 10 includes a mold 22, a
forming element 24, a pressure element 26, a first expansion device 28, and a second
expansion device 30. Moreover, apparatus 10 includes a first positioner element 32
that is coupled to first expansion device 28 and a second positioner 33 that is coupled
to second expansion device 30 and includes a temperature control device 34 which is
configured to heat a space 68 and composite material 14 having a thickness 108.
Mold 22 includes a mandrel 36 and a support element 38.
Mandrel 36 is configured to support composite material 14 and support element 38 is
configured to support mandrel 36 during component formation as will be discussed.
In one embodiment, mandrel 36 and support element 38 are annular shaped and are
formed from a variety of materials such as, but not limited to, metals and metal alloys
having predetermined stiffnesses. Alternatively, mandrel 36 and support element 38
can have any shape and material composition that enables apparatus 10 to function as
described herein.
In one embodiment, mandrel 36 includes a first side 40, a
second side 42, and a surface 44 between first and second sides 40 and 42. Mandrel
36 further includes a first portion 46 and second portion 48 which are positioned
substantially orthogonal with respect to each other. Moreover, first portion 46
includes a first end 50 and a second end 52. First end 50 is angled with respect to
second end 52. Temperature control device 34 is configured to apply heat to space 68
and to heat composite material 14 having thickness 108 andlor to remove heat from
composite material 14. In one embodiment, temperature control device 34 is
configured to direct heated forced air onto composite material 14. Alternatively, any
type of temperature control device can be used to heat andlor cool to enable apparatus
10 to function as described herein.
Support element 38 includes a first portion 56 and a second
portion 58. Second portion 58 is coupled to mandrel second portion 48 and extends
beyond mandrel second portion 48 such that support element 38 is configured to react
to forming forces generated during component formation. In one embodiment, support
element 38 includes an annular ring shape. Alternatively, support element 38 may
include a disk shape. Support element 38 may have any shape that enables apparatus
10 to function as described herein.
Forming element 24 is configured to contain at least one first
and second expansion devices 28 and 30 during component formation. Forming
element 24 includes a first portion 60 and a second portion 62 which are positioned
substantially orthogonal with respect to each other. Each portion 60 and 62 has a
respective side 63 and 64 orientated toward mandrel 36. In one embodiment, first
portion 60 is coupled to pressure element 26 and second portion 62 is coupled to
support element 38. Second portion 62 includes a bottom 65 that is spaced away from
mandrel 36 to define an opening 66 between second portion 62 and mandrel 36. In
addition, space 68 is defined by at least mold 22, forming element 24, and pressure
element 26.
Pressure element 26 is coupled to forming element 24 and
configured to apply pressure to at least one of first and second expansion devices 28
and 30 during component formation. More particularly, in an embodiment, pressure
element 26 is adjustably coupled to forming element 24 by a fastener 70. In one
embodiment, fastener 70 includes an adjustable screw. Alternatively, any adjusting
mechanism that enables pressure element 26 to couple to forming element 24 can be
used that enables apparatus 10 to function as described.
Pressure element 26 includes a top 74, a bottom 76, a first
side 78, and a second side 80. Pressure element 26 further includes a curvilinear end
84 between bottom 76 and second side 80. In one embodiment, curvilinear end 84 is
configured as a convex curve to facilitate curving outward towards space 68. Further,
in one embodiment, curvilinear end 84 includes a bend radius that is less than about
10 inches. Alternatively, curvilinear end 84 may include a bend radius that is more
than about 10 inches. Moreover, in one embodiment, curvilinear end 84 includes a
bend radius that is between about 1 inch and about 5 inches. Further, in one
embodiment, curvilinear end 84 includes a bend radius that is less than about 1 inch.
Each expansion device 28 and 30 includes a flexible material
such as, but not limited to, butyl materials, silicone rubber, fluoro-elastomers, and
nylon bagging films. In an embodiment, expansion devices 28 and 30 include a
bladder. Moreover, expansion devices 28 and 30 include a valve (not shown) that is
configured to pass a substance (not shown) into expansion devices 28 and 30 for
inflation. The valve is coupled to a source (not shown) to facilitate delivering
substance into expansion devices 28 and 30. The substance may include a
compressible and/or incompressible fluid such as, for example, air or water.
Moreover, positioner 32 is in contact with first expansion device 28 and second
positioner 33 is in contact with second expansion device 30. First positioner 32 is
configured to facilitate positioning first expansion device 28 during component
formation and second positioner 33 is configured to facilitate positioning second
expansion device 30 during component formation.
Composite material 14 is coupled to mandrel 36. Composite
material 14 includes a material having two or more constituent materials with
different physical andlor chemical properties. In one embodiment, composite material
14 includes a matrix material (not shown) and a reinforcement material (not shown).
The matrix material surrounds and supports the reinforcement material, and may
include metal and/or non-metal materials. Non-metal material includes materials such
as, but not limited to, polyester resin, acrylic resin, vinyl ester resin, epoxy resin,
polyurethane resin, phenolic resin, polyamide resin, and mixtures thereof. The
reinforcement material imparts mechanical and physical properties to enhance the
matrix material properties. Reinforcement material includes structures such as, for
example, fibers or plies. Fiber includes material such as, but not limited to, glass
fiber, graphite fiber, carbon fiber, ceramic fiber, aromatic polyamide fiber, and
mixtures thereof. One or more fibers may be pre-impregnated with the one or more
resins prior to be deposited or placed on mandrel 36.
Composite material 14 includes a first composite material 86,
a second composite material 88, and a composite structure 90. Composite structure
90 is coupled to first composite material 86 and to second composite material 88. In
one embodiment, composite structure 90 includes a first layer of fibers 92, a second
layer of fibers 94, and a honeycomb structure 96. Honeycomb structure 96 is coupled
to and positioned between first and second fiber layers 92 and 94. Honeycomb
structure 96 includes a plurality of walls 98 defining cells 100 within structure 96. In
one embodiment, composite structure 90 is coupled to first composite material 86 by
interweaving first composite material 86 with first layer of fibers 92. Moreover,
composite structure 90 is coupled to second composite material 88 by interweaving
second composite material 88 with second layer of fibers 94. Alternatively, any
coupling mechanism can be used to join composite structure 90 to first and second
composite materials 86 and 88.
First composite material 86 includes a plurality of fibers 102
and second composite material 88 includes a plurality of fibers 103. In one
embodiment, fibers 102 and 103 include the same material composition.
Alternatively, fibers 102 of first composite material 86 can have a different material
composition than fibers 103 of second composite material 88. In one embodiment,
second composite material 88 includes a higher number of fibers 103 and a greater
thickness 104 than a number of fibers 102 and a thickness 106 of first composite
material 86. Thicknesses 104 and 106 of first composite material 86 and second
composite material 88 are varied to produce components 14 having varied physical
properties. Alternatively, the number of fibers 102 and thickness 106 of first
composite material 86 can be the same as or greater than the number of fibers 103 and
thickness 106 of second composite material 88.
In one embodiment, first composite material 86 is coupled to
mandrel second side 42. First composite material 86 may be deposited on second side
42 using any variety of techniques (not shown) such as, for example, tape placement,
fiber placement, and/or hand or automatic lay up. Composite structure 90 is
configured to extend away from mandrel 36 and towards space 68. Moreover, second
composite material 88 is deposited between forming element 24 and mandrel 36 and
between pressure element 26 and mandrel 36.
Expansion devices 28 and 30 are inserted within fibers 103
and first and second positioners 32 and 33 are positioned within a portion of fibers
103. First expansion device 28 is positioned within second composite material 88
such that thickness 108 of fibers 103 between first expansion device 28 and a top
layer 105 of fibers 103 is less than a thickness 1 10 of fibers 103 between second
expansion device 30 and a top layer 107 of fibers 103. Thicknesses 108 and 1 10 of
fibers 103 are varied to produce flanges 18 and 20 having varied sizes. Alternatively,
thicknesses 108 and 110 of fibers 103 can be substantially the same to produce
flanges 18 and 20 with similar sizes. First expansion device 28, in a deflated state, is
configured to position a first portion 109 of fibers 103 of second composite material
88 into space 68 and toward curvilinear end 84 of pressure element 26. Second
expansion device 30, in a deflated state, is configured to position a second portion 11 1
of fibers 103 of second composite material 88 within opening 66 and towards second
portion 62 of forming element 24.
Fig. 3 illustrates a side cross sectional view of mold 22,
forming element 24, pressure element 26, and first expansion device 28 in a position
1 12 for forming first flange 18 from composite material 14. First expansion device 28
is shown in an inflated state with substance 114 delivered into first expansion device
28 through the valve (not shown) to inflate first expansion device 28. In one
embodiment, first expansion device 28 is inflated at a predetermined, controlled rate
to facilitate minimizing andlor eliminating local laminate deformations (not shown) to
second composite material 88. While inflated, first expansion device 28 is confined
in space 68 by at least one of forming element 24, pressure element 26 and first
positioner 32.
Support element 38 is configured tq react to inflation of
expansion device 28 and apply a force to resist movement of forming element 24.
Similarly, fastener 70 is configured to react to inflation of expansion device 28 and
apply a force to resist movement of pressure element 26. First expansion device 28 is
configured to impart a forming force against the first portion 109 of fibers 103 of
second composite material 88. More particularly, first expansion device 28 is
configured to controllably bend fibers 103 about curvilinear end 84 to form first
flange 18. In one embodiment, first flange 18 is formed having a first portion 116, a
second portion 11 8, and an interface 120 therebetween. First portion 116 is
positioned substantially orthogonal to second portion 1 18 and interface 120 includes a
bend radius that is less than about 10 inches. In one embodiment, interface 120
includes bend radius between about 1 inch to about 5 inches. Alternatively, interface
120 may include a bend radius that is more than about 10 inches. Moreover, in one
embodiment, interface 120 includes a bend radius that is between about 1 inch and
about 5 inches. Further, in one embodiment, interface 120 includes a bend radius that
is less than about 1 inch.
Fig. 4 illustrates a side cross sectional view of mold 22,
another forming element 24', another pressure element 26' and another support
element 38' in another position 122 along mold 22 and illustrates first flange 18, with
first expansion device 28 and first positioner 32 removed. Forming element 24',
pressure element 26' and forming element 38' are similar to respective forming
element 24, pressure element 26 and forming element 38 (shown in Fig. 1). In the
exemplary embodiment, forming element 24', pressure element 26' and forming
element 38' are sized differently than corresponding forming element 24, pressure
3element 26 and forming element 38 (shown in Fig. 1) to facilitate compensating for
new position 122 along mold 22. More particularly, forming element 24, pressure
element 26 and forming element 38 (shown in Fig. 1) are removed from mold 22 and
forming element 24', pressure element 26' and forming element 38' are adjustably
coupled to one another and to mold 22. Moreover, curved end 84' of pressure
element 26' is also sized differently than corresponding curved end 84 (shown in Fig.
I). Alternatively, curved end 84' may be similarly sized as curved end 84 (shown in
Fig. 1).
First flange 18 is shown as integrally formed from and
coupled to second composite material 88. Forming element 24' and pressure element
26' are shown position 122 with respect to mandrel 36 and away from first flange 18.
More particularly, second expansion device 30, positioner 33, and second portion 1 1 1
of fibers 103 are positioned within space 67. Moreover, bottom 76 and curvilinear
end 84' of pressure element 26 are positioned to be in contact with fibers 103.
Second expansion device 30, in a deflated position, positions second portion 11 1 of
fibers 103 into space 67.
Fig. 5 illustrates a side cross sectional view of mold 22,
forming element 24', pressure element 26' and support element 38' and second
expansion device 30 for forming second flange 20 from composite material 88.
Second expansion device 30 is shown in an inflated state with substance 114
delivered into second expansion device 30 through the valve (not shown) to inflate
second expansion device 30. In one embodiment, second expansion device 30 is
inflated at a predetermined controlled rate to facilitate minimizing and/or eliminating
local laminate deformations (not shown) to second composite material 88. While
inflated, second expansion device 30 is confined in space 67 by at least one of second
positioner 33, forming element 24', pressure element 26' and support element 38'.
Support element 38' is configured to react to inflation of
expansion device 30 and apply force to resist movement of forming element 24'.
Similarly, fastener 70 is configured to react to inflation of expansion device 30 to
apply a force to resist movement of pressure element 26'. Second expansion device
30 is configured to impart a forming force against second portion 11 1 of fibers 103.
Expansion device 30 is configured to controllably bend second portion 11 1 of fibers
103 about curvilinear end 84' to facilitate forming second flange 20. More
particularly, second flange 20 is formed having a first portion 126, a second portion
128, and an interface 130 therebetween. First portion 126 is positioned substantially
orthogonal to second portion 128 and interface 130 includes a bend radius that is less
than about 10 inches. In one embodiment, interface 130 includes a bend radius from
about 1 inch to about 5 inches. Alternatively, interface 130 may include a bend radius
that is more than about 10 inches. Moreover, in one embodiment, interface 130
includes a bend radius that is between about 1 inch and about 5 inches. Further, in
one embodiment, interface 130 includes a bend radius that is less than about 1 inch.
Fig. 6 illustrates a side cross sectional view of flanges 18 and
20 formed from composite material 14. In one embodiment, second flange 20 has a
thickness 132 that is different than a thickness 134 of first flange 18. In the
exemplary embodiment, thickness 132 is greater than thickness 134. Alternatively,
second flange 20 has a thinner thickness or substantially the same thickness as first
flange 18. Varying the thicknesses of flanges 18 and 20 facilitates in providing
different physical properties to component 12 (shown in Fig. 1).
Fig. 7 is an exemplary flowchart 700 illustrating a method
702 of manufacturing a flanged composite component, for example component 12
(shown in Fig. 2). Method 702 includes placing 704 a first composite material, such
as first composite material 86 (shown in Fig. I), on a mold, for example mold 22
(shown in Fig. 1). A composite structure, such as composite structure 90 (shown in
Fig. I), is coupled 706 to the first composite material. Method 702 includes coupling
708 a second composite material, for example second composite material 88 (shown
in Fig. l), to the composite structure. In one embodiment, coupling the composite
structure to the first composite material includes interweaving 705 at least one fiber of
the composite structure to at least one fiber of the first composite material and
coupling the second composite material to the composite structure includes
interweaving 707 at least one fiber of the second composite material to at least one
fiber of the composite structure.
Method 702 further includes positioning 7 10 a forming
element, for example forming element 24 (shown in Fig. I), to hold at least one of the
first composite material, the composite structure and the second composite material.
A pressure element, such as pressure element 26 (shown in Fig. I), is coupled 712 to
the forming element to define a space, for example space 68 (shown in Fig. l), among
at least the mold, the forming element, and the pressure element. Method 702 also
includes inserting 714 a positioner, for example first positioner 32 (shown in Fig. l),
within the second composite material. In addition, method 702 includes placing 71 5 a
first expansion device, for example first expansion device 28 (shown in Fig. I), within
the second composite material. The first positioner 32 is placed in contact with the
first expansion device.
Method 702 further includes heating 716 the second
composite material, for example second composite material 88. In the exemplary
method 702, heating 716 the second composite material includes directing forced hot
air toward second composite material. More particularly, forced hot air is directed to
outer fibers, such as fiber portion 11 1 of second composite material. Heating 716
may include any type of heat addition to enable apparatus to function as described
herein. Alternatively, heating 716 may include heating first composite material
and/or composite structure. The first expansion device is controllably expanded 71 8
at a predetermined rate to impart a force to the second composite material to move the
second composite material away from the composite structure and into the space to
facilitate forming a first flange, such as first flange 18 (shown in Fig. 1). Method 702
also includes forming 720 the first flange having a bend radius that is less than about
10 inches. Alternatively, method 702 may include manufacturing a bend radius for
the first flange that is more than about 10 inches. Moreover, method 702 includes
manufacturing a bend radius that is between about 1 inch and about 5 inches. Method
702, in one embodiment, includes manufacturing a bend radius that is less than about
1 one. Method 702 includes cooling 722 the second composite material, for example
second composite material 88. In the exemplary method 702, cooling 722 the second
composite material includes directing forced air toward second composite material.
More particularly, forced hot air is directed to outer fibers, such as outer fibers 107 of
second composite material. Cooling 722 may include any type of heat removal to
enable apparatus to function as described herein. Alternatively, cooling 722 may
include cooling first composite material and/or composite structure.
Method 702 further includes moving 724 the forming element
and the pressure element along the mandrel. A second 'expansion device, such as
second expansion device 30 (shown in Fig. I), is confined within a space, for example
space 67 (shown in Fig. 4). Method 702 includes heating 725 the second composite
material, fro example second composite material 88 (shown in Fig. 5). Moreover,
method 702 includes heating a second portion of the fibers of the second composite m
material, for example second portion 11 1 of fibers 103 (shown in Fig. 5). Method 702
includes expanding 726 the second expansion device to impart a force to the second
composite material to move the second composite material away from the composite
structure and into the space to facilitate forming a second flange, such as second
flange 20 (shown in Fig. 1). Method 702 also includes forming the second flange
having a bend radius that is less than about 10 inches. Alternatively, method 702 may
include manufacturing a bend radius for the second flange that is more than about 10
inches. Method 702 includes cooling 728 the second composite material after
expanding the second expansion device. Alternatively, method 702 may include
cooling the first composite material and/or the composite structure.
A technical effect of the systems and methods described
herein includes at least one of: a method of manufacturing a flanged composite
component from a first composite material, a second composite material, and a
composite structure; a flanged composite component; and an apparatus for
manufacturing a flanged composite component.
Exemplary embodiments of an apparatus and methods for
manufacturing flanged composite components are described above in detail. The
methods and systems are not limited to the specific embodiments described herein,
but rather, components of systems and/or steps of the methods may be utilized
independently and separately from other components and/or steps described herein.
For example, the methods may also be used in combination with other manufacturing
systems and methods, and are not limited to practice with only the systems and
methods as described herein. Rather, the exemplary embodiment can be implemented
and utilized in connection with many other component formation applications.
Although specific features of various embodiments of the
invention may be shown in some drawings and not in others, this is for convenience
only. In accordance with the principles of the invention, any feature of a drawing
may be referenced andlor claimed in combination with any feature of any other
drawing.
This written description uses examples to disclose the
invention, including the best mode, and also to enable any person skilled in the art to
practice the invention, including making and using any devices or systems and
performing any incorporated methods. The patentable scope of the invention is
defined by the claims, and may include other examples that occur to those skilled in
the art. Such other examples are intended to be within the scope of the claims if they
have structural elements that do not differ from the literal language of the claims, or if
they include equivalent structural elements with insubstantial differences from the
literal language of the claims.
PARTS LIST
10
12
14
18
20
22
24
2 6
28
30
3 2
33
3 4
36
3 8
40
42
44
46
4 8
50
5 2
56
5 8
60
62
63
64
Apparatus
Component
Composite material
First flange
Second flange
Mold
Forming element
Pressure element
First expansion device
Second expansion device
First positioner
Second positioner
Temperature control device
Mandrel
Forming element
First side
Second side
Surface
Portion
Second portion
First end
Second end
First portion
Second portion
First portion
Second portion
Respective side
Respective side
6 5
66
6 7
68
70
74
76
7 8
80
84
8 6
88
90
92
94
96
98
100
1 02
103
1 04
105
106
107
108
109
110
111
112
114
116
Bottom
Opening
Space
Space
Fastener
TOP
Bottom
First side
Second side
Curvilinear end
First composite material
Second composite material
Composite structure
First layer of fibers
Second layer of fibers
Honeycomb structure
Plurality of walls
Cells
Plurality of fibers
Fibers
Thicknesses
Top layer
Thickness
Outer fibers
Thickness
First portion
Thickness
Second portion
Position
Substance
First portion
118
120
122
126
128
130
132
134
700
702
704
705
706
707
708
7 10
712
7 14
715
716
7 18
720
722
724
Second portion
Interface
Position
First portion
Second portion
Interface
Thickness
Thickness
Exemplary flowchart
Method
Placing a first composite material on a mold
Interweaving at least one fiber of the composite structure to at least one
fiber of the first composite material
Coupling a composite structure to the first composite material
Interweaving at least one fiber of the second composite material to at
least one fiber of the composite structure
Coupling a second composite material to the composite structure
Positioning a forming element to couple at least one of the first
composite material, the composite structure and the second composite
material against the mold
Coupling a pressure element to the forming element to define a space by
the mold, the forming element and the pressure element
Inserting a positioner within the second composite material
Placing a first expansion device between the second composite material
and the composite structure
Heating the second composite material
Expanding the first expansion device at a pre-determined controlled rate
to impart a force to the second composite material to move the second
composite material away from the composite structure and into the space
to facilitate forming a first glance
Forming the first flange having a bend radius that is less than about 10
inches
Cooling at least one of the first composite material, the composite
structure and the second composite material
Moving the forming element and pressure element along the mandrel and
725
726
728
confining a second expansion device within a space
Heating the second composite material
Expanding the second expansion device to impart a force to the second
composite material to move the second composite material away from
the composite structure and into the space to facilitate forming a second
flange
Cooling the second composite material

We Claims:
1. A composite component (12) comprising:
a first composite material (86);
a composite structure (90) coupled to said first composite material; and
a second composite material (88) coupled to said composite structure,
said second composite material comprising a first flange (18) integrally coupled to
said composite structure and is positioned substantially orthogonal with respect to
said composite structure, said first flange comprising an interface having a bend
radius that is less than about 10 inches.
2. The composite component (12) of Claim 1, wherein said first
composite material (86) and said second composite material (88) comprise a fiber and
a resin.
3. The composite component (12) of Claim 1, wherein said
composite structure (90) comprises a honeycomb configuration.
4. The composite component (12) of Claim 1, wherein said first
composite material (86) has a thickness that is different than said second composite
material (88).
5. The composite component (12) of Claim 1, wherein said bend
radius is less than about 1 inch.
6. The composite component (12) of Claim 1 , wherein said
second composite material (88) comprises a second flange (20) having a thickness
that is different than said first flange (1 8).
7. An apparatus (10) for manufacturing a flanged composite
component (1 2), said apparatus comprising:
a mold (22) configured to couple to a composite material (1 74);
a forming element (24) coupled to said mold;
a pressure element (26) coupled to said forming element to define a
space among said mold, said forming element and said pressure element;
an expansion device (28,30) is disposed within said composite
material, said expansion device is configured to impart a forming force to said
forming element and said pressure element; and
a positioner (32,33) is disposed within said composite material and in
contact with said expansion device and configured to facilitate positioning said
expansion device within said space.
8. The apparatus (10) of Claim 7, further comprising a
temperature control device (34).
9. The apparatus (10) of Claim 7, wherein said pressure element
(26) comprises a first side (40) and a second side (42), said second side comprising a
curvilinear end that is orientated toward the space.
10. The apparatus (10) of Claim 9, wherein said pressure element
(26) is adjustably coupled to said forming element (24) and is configured to
adjustably position said curvilinear end within the space.
MANISHA S I ~ N~AIHR
Agent for the Applicant [INIPA-7401
LEX ORBIS
Intellectual Property Practice
709171 0, Tolstoy House,
15-17, Tolstoy Marg,
New Delhi- 11 000 1