Process for forming a single piece co-cure composite wing
View Patent ↗A single piece co-cured composite wing is disclosed. The wing has a flying surface and structural members. In one embodiment the structural members may be a plurality of spars. The spars may have various shapes to increase the buckling strength. The spars may be wave shaped, such as a sinusoidal shape. The flying surface and the structural members are co-cured in order to form a single piece, integral wing structure. A process for manufacturing a single piece co-cured wing is also disclosed. The process may include laying out composite sheets for the flying surface of the wing. Then, the composite material of the spars is arranged around a plurality of pressurizable forms. Finally, the composite material is cured in a clamshell frame.
1. A process for forming a single-piece co-cured composite wing structure having a flying surface and at least one structural member, the process comprising:
situating a first flying surface composite material in alignment with a controlling surface of a first clamshell frame;
aligning a plurality of forms to the first clamshell frame, wherein a composite material is positioned between selective forms, wherein the composite material positioned between selective forms creates a spar wherein the spar is comprised of two substantially C-shaped composite sections positioned in opposing orientations to form an I-beam, wherein selective forms each include a shrinkable core, and wherein selective forms are pressurizable;
situating a second flying surface composite material between the plurality of forms and a controlling surface of a second clamshell frame;
closing the first and second clamshell frames together; and
curing the composite material.
2. The process, as recited in claim 1 , wherein the spar is sinusoidal shaped.
3. The process, as recited in claim 1 , wherein the forms are a foam core surrounded by a membrane.
4. The process, as recited in claim 3 , wherein membrane of the selective pressurizable forms are capable of receiving a positive pressure during a curing process.
5. The process, as recited in claim 3 , wherein the foam core shrinks during a curing process.
6. The process, as recited in claim 3 , wherein shape of the foam core controls the shaping of the composite material.
7. The process, as recited in claim 1 , wherein the selective pressurizable forms compress the first flying surface and the second flying surface against the controlling surfaces of the clamshell frames.
8. The process, as recited in claim 1 , wherein the selective pressurizable forms compress against adjacent forms.
9. The process, as recited in claim 1 , wherein the first flying surface and the second flying surface are part of a single sheet of composite material.
10. The apparatus, as recited in claim 1 , wherein the wing structure is at least one of an ailerons, a wing tip, a horizontal stabilizer, a vertical stabilizer, a flap, an elevators and a canard.
11. The process, as recited in claim 1 , further comprising applying a layer of primer to the controlling surface of the first clamshell frame and to the controlling surface of the second clamshell frame.
12. A process for forming a single-piece co-cured composite wing structure having a flying surface and at least one structural member, the process comprising:
situating a first flying surface composite material in alignment with a controlling surface of a first clamshell frame;
aligning a plurality of forms to the first clamshell frame, wherein a composite material is positioned between selective forms, wherein selective forms each include a core, and wherein selective forms are pressurizable;
situating a second flying surface composite material between the plurality of forms and a controlling surface of a second clamshell frame;
closing the first and second clamshell frames together;
curing the composite material; and
shrinking the core of selective forms.
13. A process for forming a single-piece co-cured composite wing structure having a flying surface and at least one structural member, the process comprising:
situating a first flying surface composite material in alignment with a controlling surface of a first clamshell frame;
aligning a plurality of forms to the first clamshell frame, wherein a composite material is positioned between selective forms, wherein selective forms each include a core and a membrane, and wherein selective forms are pressurizable;
situating a second flying surface composite material between the plurality of forms and a controlling surface of a second clamshell frame;
closing the first and second clamshell frames together;
curing the composite material;
expanding the membrane of selective forms; and
shrinking the core of selective forms.