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EP-4741143-A1 - METHODS AND TOOLING FOR GAP RESIN INFUSION OF COMPOSITES

EP4741143A1EP 4741143 A1EP4741143 A1EP 4741143A1EP-4741143-A1

Abstract

Resin infusion tooling systems and methods of resin infusion are presented. A resin infusion tooling system comprises a heating tool bed comprising a plurality of cavities formed between a plurality of bed segments movable relative to each other, and a plurality of seals configured to seal the plurality of bed segments together for resin infusion of a plurality of dry stringer preforms in the plurality of cavities. The plurality of cavities is expandable by movement of the plurality of bed segments relative to each other.

Inventors

  • O'BRIEN, Faith
  • WITT, David Sorensen
  • BELCHER, Stephen L.
  • CHEN, Daniel Hung Han
  • HUYNH, Dat Van
  • HERNANDEZ, ANDRES

Assignees

  • The Boeing Company

Dates

Publication Date
20260513
Application Date
20251024

Claims (15)

  1. A resin infusion tooling system (202, 302, 906, 2301) comprising: a heating tool bed (204, 303, 802, 902) comprising a plurality of cavities (208, 314, 916) formed between a plurality of bed segments (210, 304, 804, 904, 2302) movable relative to each other, wherein the plurality of cavities (208, 314, 916) is expandable by movement of the plurality of bed segments (210, 304, 804, 904, 2302) relative to each other; and a plurality of seals (224, 322) configured to seal the plurality of bed segments (210, 304, 804, 904, 2302) together for resin infusion (256) of a plurality of dry stringer preforms (246, 503, 1101, 1504, 1902, 2214) in the plurality of cavities (208, 314, 916).
  2. The resin infusion tooling system (202, 302, 906, 2301) of claim 1 further comprising: hinges (232, 328, 824) connecting the plurality of bed segments (210, 304, 804, 904, 2302) to enable fanning movement of the plurality of bed segments (210, 304, 804, 904, 2302) relative to each other, or lateral actuators (234, 920) configured to move the plurality of bed segments (210, 304, 804, 904, 2302) laterally relative to each other.
  3. The resin infusion tooling system (202, 302, 906, 2301) of claim 1 or 2 further comprising: a number of inserts (206, 1404, 1806) configured to receive the plurality of dry stringer preforms (246, 503, 1101, 1504, 1902, 2214) and hold the plurality of dry stringer preforms (246, 503, 1101, 1504, 1902, 2214) within the plurality of cavities (208, 314, 916).
  4. A resin infusion tooling system (202, 1401, 1701, 2204, 2301) comprising: a heating tool bed (204, 1402, 1702, 1912) comprising a plurality of cavities (208, 314, 916, 1410, 1704, 1914) configured to support a plurality of dry stringer preforms (246, 503, 1101, 1504, 1902, 2214) during resin infusion (256); and a number of inserts (206, 1404, 1806) configured to receive the plurality of dry stringer preforms (246, 503, 1101, 1504, 1902, 2214) and hold the plurality of dry stringer preforms (246, 503, 1101, 1504, 1902, 2214) within the plurality of cavities (208, 314, 916, 1410, 1704, 1914).
  5. The resin infusion tooling system (202, 1401, 1701, 2204, 2301) of claim 4, wherein the number of inserts (206, 1404, 1806) comprises a plurality of inserts (208) comprising stringer inserts (274, 1711, 2210), wherein each insert unit of the stringer inserts (274, 1711, 2210) has a respective cavity configured to receive a dry stringer preform of the plurality of dry stringer preforms (246, 503, 1101, 1504, 1902, 2214).
  6. The resin infusion tooling system (202, 1401, 1701, 2204, 2301) of claim 5, wherein the stringer inserts (274, 1711, 2210) comprise separable insert units (276) with halves separable from each other; or wherein the stringer inserts (274, 1711, 2210) comprise whole insert units (288) with respective cavities expandable by hinges (232, 328, 824).
  7. The resin infusion tooling system (202, 1401, 1701, 2204, 2301) of claim 5 or 6, wherein the plurality of inserts (208) further comprise panel inserts (296, 1712, 2208) positioned between the stringer inserts (274, 1711, 2210) and configured to support a panel preform (254) positioned over the stringer inserts (274, 1711, 2210) and the panel inserts (296, 1712, 2208).
  8. The resin infusion tooling system (202, 1401, 1701, 2204, 2301) of claim 4, wherein the number of inserts (206, 1404, 1806) comprises a unitary flexible insert (266) with cavities configured to slide into the plurality of cavities (208, 314, 916, 1410, 1704, 1914) of the heating tool bed (204, 1402, 1702, 1912).
  9. The resin infusion tooling system (202, 1401, 1701, 2204, 2301) of claim 4, wherein the heating tool bed (204, 303, 802, 902) comprises a plurality of bed segments (210, 304, 804, 904, 2302) movable relative to each other, wherein the plurality of cavities (208, 314, 916) is expandable by movement of the plurality of bed segments (210, 304, 804, 904, 2302) relative to each other.
  10. A method (2400) of performing resin infusion (256) comprising: placing (2402) blades (253) of a plurality of dry stringer preforms (246, 503, 1101, 1504, 1902, 2214) into a plurality of cavities (208, 314, 916) between a plurality of bed segments (210, 304, 804, 904, 2302) of a heating tool bed (204, 303, 802, 902); moving (2404) the plurality of bed segments (210, 304, 804, 904, 2302) of the heating tool bed (204, 303, 802, 902) towards each other to contract the plurality of cavities (208, 314, 916); placing (2406) a panel preform (254) over the plurality of dry stringer preforms (246, 503, 1101, 1504, 1902, 2214) and in contact with bases of the plurality of dry stringer preforms (246, 503, 1101, 1504, 1902, 2214); sealing (2408) a tool lid to the heating tool bed (204, 303, 802, 902) to form a resin infusion (256) chamber; and resin infusing (2410) the plurality of dry stringer preforms (246, 503, 1101, 1504, 1902, 2214) and the panel preform (254) to form a reinforced panel (260).
  11. The method (2400) of claim 10, wherein (2414) moving the plurality of bed segments (210, 304, 804, 904, 2302) towards each other comprises moving the plurality of bed segments (210, 304, 804, 904, 2302) in multiple axes to move in a fan motion; or wherein (2416) moving the plurality of bed segments (210, 304, 804, 904, 2302) towards each other comprises moving the plurality of bed segments (210, 304, 804, 904, 2302) laterally.
  12. The method (2400) of claim 10, wherein (2412) placing the plurality of dry stringer preforms (246, 503, 1101, 1504, 1902, 2214) into the plurality of cavities (208, 314, 916) comprises placing the plurality of dry stringer preforms (246, 503, 1101, 1504, 1902, 2214) into a number of inserts (206, 1404, 1806) and placing the number of inserts (206, 1404, 1806) holding the plurality of dry stringer preforms (246, 503, 1101, 1504, 1902, 2214) into the heating tool bed (204, 303, 802, 902).
  13. A method (2500) of performing resin infusion (256) comprising: placing (2502) blades (253) of a plurality of dry stringer preforms (246, 503, 1101, 1504, 1902, 2214) into a number of inserts (206, 1404, 1806); positioning (2504) the blades (253) of the plurality of dry stringer preforms (246, 503, 1101, 1504, 1902, 2214) within a plurality of cavities (208, 314, 916, 1410, 1704, 1914) of a heating tool bed (204, 1402, 1702, 1912) using the number of inserts (206, 1404, 1806); placing (2506) a panel preform (254) over the plurality of dry stringer preforms (246, 503, 1101, 1504, 1902, 2214) on the heating tool bed (204, 1402, 1702, 1912) such that the panel preform (254) is in contact with bases of the plurality of dry stringer preforms (246, 503, 1101, 1504, 1902, 2214); resin infusing (2508) the plurality of dry stringer preforms (246, 503, 1101, 1504, 1902, 2214) and the panel preform (254) to form a reinforced panel (260); and removing (2510) the reinforced panel (260) from the heating tool bed (204, 1402, 1702, 1912) by removing the reinforced panel (260) from the number of inserts (206, 1404, 1806).
  14. The method (2500) of claim 13, wherein (2514) positioning the blades (253) of the plurality of dry stringer preforms (246, 503, 1101, 1504, 1902, 2214) within the plurality of cavities (208, 314, 916, 1410, 1704, 1914) comprises lowering the number of inserts (206, 1404, 1806) into the plurality of cavities (208, 314, 916, 1410, 1704, 1914) of the heating tool bed (204, 1402, 1702, 1912); or wherein (2516) positioning the blades (253) of the plurality of dry stringer preforms (246, 503, 1101, 1504, 1902, 2214) within the plurality of cavities (208, 314, 916, 1410, 1704, 1914) comprises actuating the number of inserts (206, 1404, 1806) within the plurality of cavities (208, 314, 916, 1410, 1704, 1914) of the heating tool bed (204, 1402, 1702, 1912); or wherein (2518) positioning the blades (253) of the plurality of dry stringer preforms (246, 503, 1101, 1504, 1902, 2214) within the plurality of cavities (208, 314, 916, 1410, 1704, 1914) comprises moving a plurality of bed segments (210, 304, 804, 904, 2302) of the heating tool bed (204, 303, 802, 902) towards each other to contract the plurality of cavities (208, 314, 916).
  15. The method (2500) of claim 13, wherein (2512) placing the blades (253) of the plurality of dry stringer preforms (246, 503, 1101, 1504, 1902, 2214) into the number of inserts (206, 1404, 1806) comprises placing the plurality of dry stringer preforms (246, 503, 1101, 1504, 1902, 2214) into a plurality of independently movable stringer inserts (274, 1711, 2210).

Description

CROSS-REFERENCE TO RELATED APPLICATION This application claims the benefit of U.S. Provisional Patent Application Serial No. 63/717,666, filed November 7, 2024, and entitled "Methods and Tooling for Gap Resin Infusion of Composites," which is incorporated herein by reference in its entirety. BACKGROUND INFORMATION 1. Field: The present disclosure relates generally to composite manufacturing and more specifically to methods and tooling for gap resin infusion of composites. 2. Background: To manufacture reinforced composite panels, composite stringers are joined to composite panels. Composite stringers and panels can be presented as prepreg composite materials or dry fiber preforms. The composite stringers are longitudinal components with a cross-section having a C-shape, T-shape, I-shape, or other desirable cross-sectional shape. The thickness of the composite material is substantially less than the length of the composite stringer. The thin composite material in contrast to the length of the composite stringer increases the difficulty of lifting, positioning, and placing the composite stringer into processing tools. Therefore, it would be desirable to have a method and apparatus that takes into account at least some of the issues discussed above, as well as other possible issues. For example, it would be desirable to provide a method and apparatus for processing composite stringers. SUMMARY An embodiment of the present disclosure provides a resin infusion tooling system. The resin infusion tooling system comprises a heating tool bed comprising a plurality of cavities formed between a plurality of bed segments movable relative to each other, and a plurality of seals configured to seal the plurality of bed segments together for resin infusion of a plurality of dry stringer preforms in the plurality of cavities. The plurality of cavities is expandable by movement of the plurality of bed segments relative to each other. Another embodiment of the present disclosure provides a resin infusion tooling system. The resin infusion tooling system comprises a heating tool bed comprising a plurality of cavities configured to support a plurality of dry stringer preforms during resin infusion, and a number of inserts configured to receive the plurality of dry stringer preforms and hold the plurality of dry stringer preforms within the plurality of cavities. Still another embodiment of the present disclosure provides a method of performing resin infusion. Blades of a plurality of dry stringer preforms are placed into a plurality of cavities between a plurality of bed segments of a heating tool bed. The plurality of bed segments of the heating tool bed are moved towards each other to contract the plurality of cavities. A panel preform is placed over the plurality of dry stringer preforms and in contact with bases of the plurality of dry stringer preforms. A tool lid is sealed to the heating tool bed to form a resin infusion chamber. The plurality of dry stringer preforms and the panel preform are resin infused to form a reinforced panel. Yet another embodiment of the present disclosure provides a method of performing resin infusion. Blades of a plurality of dry stringer preforms are placed into a number of inserts. The blades of the plurality of dry stringer preforms are positioned within a plurality of cavities of a heating tool bed using the number of inserts. A panel preform is placed over the plurality of dry stringer preforms on the heating tool bed such that the panel preform is in contact with bases of the plurality of dry stringer preforms. A tool lid is sealed to the heating tool bed to form a resin infusion chamber. The plurality of dry stringer preforms and the panel preform are resin infused to form a reinforced panel. A further embodiment of the present disclosure provides a method of performing resin infusion. Blades of a plurality of dry stringer preforms are placed into a number of inserts. The blades of the plurality of dry stringer preforms are positioned within a plurality of cavities of a heating tool bed using the number of inserts. A panel preform is placed over the plurality of dry stringer preforms on the heating tool bed such that the panel preform is in contact with bases of the plurality of dry stringer preforms. The plurality of dry stringer preforms and the panel preform are resin infused to form a reinforced panel. The reinforced panel is removed from the heating tool bed by removing the reinforced panel from the number of inserts. The features and functions can be achieved independently in various embodiments of the present disclosure or may be combined in yet other embodiments in which further details can be seen with reference to the following description and drawings. BRIEF DESCRIPTION OF THE DRAWINGS The novel features believed characteristic of the illustrative embodiments are set forth in the appended claims. The illustrative embodiments, however, as well as a preferred mode of use, furth