US-20260124813-A1 - METHODS AND TOOLING FOR GAP RESIN INFUSION OF COMPOSITES

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

• Faith O'BRIEN
• David Sorensen Witt
• Stephen L. Belcher
• Daniel Hung Han Chen
• Dat Van Huynh
• Andres Hernandez

Assignees

• THE BOEING COMPANY

Dates

Publication Date

20260507

Application Date

20250620

Claims (20)

1. 1 . A resin infusion tooling system comprising: a heating tool bed comprising a plurality of cavities formed between a plurality of bed segments movable relative to each other, wherein the plurality of cavities is expandable by movement of the plurality of bed segments 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.
2. 2 . The resin infusion tooling system of claim 1 further comprising: hinges connecting the plurality of bed segments to enable fanning movement of the plurality of bed segments relative to each other.
3. 3 . The resin infusion tooling system of claim 1 further comprising: lateral actuators configured to move the plurality of bed segments laterally relative to each other.
4. 4 . The resin infusion tooling system of claim 1 further comprising: 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.
5. 5 . A resin infusion tooling system comprising: 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.
6. 6 . The resin infusion tooling system of claim 5 , wherein the number of inserts comprises a plurality of inserts comprising stringer inserts, wherein each insert unit of the stringer inserts has a respective cavity configured to receive a dry stringer preform of the plurality of dry stringer preforms.
7. 7 . The resin infusion tooling system of claim 6 , wherein the stringer inserts comprise separable insert units with halves separable from each other.
8. 8 . The resin infusion tooling system of claim 6 , wherein the stringer inserts comprise whole insert units with respective cavities expandable by hinges.
9. 9 . The resin infusion tooling system of claim 6 , wherein the plurality of inserts further comprise panel inserts positioned between the stringer inserts and configured to support a panel preform positioned over the stringer inserts and the panel inserts.
10. 10 . The resin infusion tooling system of claim 5 , wherein the number of inserts comprises a unitary flexible insert with cavities configured to slide into the plurality of cavities of the heating tool bed.
11. 11 . The resin infusion tooling system of claim 5 , wherein the heating tool bed comprises a plurality of bed segments movable relative to each other, wherein the plurality of cavities is expandable by movement of the plurality of bed segments relative to each other.
12. 12 . A method of performing resin infusion comprising: placing blades of a plurality of dry stringer preforms into a plurality of cavities between a plurality of bed segments of a heating tool bed; moving the plurality of bed segments of the heating tool bed towards each other to contract the plurality of cavities; placing a panel preform over the plurality of dry stringer preforms and in contact with bases of the plurality of dry stringer preforms; sealing a tool lid to the heating tool bed to form a resin infusion chamber; and resin infusing the plurality of dry stringer preforms and the panel preform to form a reinforced panel.
13. 13 . The method of claim 12 , wherein moving the plurality of bed segments towards each other comprises moving the plurality of bed segments in multiple axes to move in a fan motion.
14. 14 . The method of claim 12 , wherein moving the plurality of bed segments towards each other comprises moving the plurality of bed segments laterally.
15. 15 . The method of claim 12 , wherein placing the plurality of dry stringer preforms into the plurality of cavities comprises placing the plurality of dry stringer preforms into a number of inserts and placing the number of inserts holding the plurality of dry stringer preforms into the heating tool bed.
16. 16 . A method of performing resin infusion comprising: placing blades of a plurality of dry stringer preforms into a number of inserts; positioning the blades of the plurality of dry stringer preforms within a plurality of cavities of a heating tool bed using the number of inserts; placing a panel preform 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; resin infusing the plurality of dry stringer preforms and the panel preform to form a reinforced panel; and removing the reinforced panel from the heating tool bed by removing the reinforced panel from the number of inserts.
17. 17 . The method of claim 16 , wherein positioning the blades of the plurality of dry stringer preforms within the plurality of cavities comprises lowering the number of inserts into the plurality of cavities of the heating tool bed.
18. 18 . The method of claim 16 , wherein positioning the blades of the plurality of dry stringer preforms within the plurality of cavities comprises actuating the number of inserts within the plurality of cavities of the heating tool bed.
19. 19 . The method of claim 16 , wherein positioning the blades of the plurality of dry stringer preforms within the plurality of cavities comprises moving a plurality of bed segments of the heating tool bed towards each other to contract the plurality of cavities.
20. 20 . The method of claim 16 , wherein placing the blades of the plurality of dry stringer preforms into the number of inserts comprises placing the plurality of dry stringer preforms into a plurality of independently movable stringer inserts.

Description

CROSS-REFERENCE TO RELATED APPLICATION This application claims the benefit of U.S. Provisional Patent Application Ser. No. 63/717,666, filed Nov. 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. 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, further objectives, and features thereof will best be understood by reference to the following detailed description of an illustrative embodiment of the present disclosure when read in conjunction with the accompanying drawings, wherein: FIG. 1 is an illustration of an aircraft in accordance with an illustrative embodiment; FIG. 2 is an illustration of a block diagram of a manufacturing environment in accordance with an illustrative embodiment; FIG. 3 is an illustration of a cross-sectional view of a resin infusion tooling system comprising a heating tool bed with a plurality of bed segments in accordance with an illustrative embodiment; FIG. 4 is an illustration of a cross-sectional view of a re