Metal and composite leading edge assemblies
Various components and methods related to a leading edge assembly are disclosed. The leading edge assembly can include an outer strike shell and a foam core. The foam core can be located inside the outer strike shell. The leading edge assembly can include a heating element with a plurality of sensors and wires. A method of manufacturing a leading edge assembly can include forming a composite layer, applying a metallic layer to the composite layer, installing an electronic device, and inserting a foam core into a cavity bounded by the composite layer and/or the electronic device.
1. A method for manufacturing a leading edge assembly, the method comprising:
forming a composite layer;
applying a metal layer to an exterior surface of the composite layer;
installing an electronic component to an interior surface of the composite layer;
injecting a foam core material into a cavity bounded by the interior surface of the composite layer and/or the electronic component;
forming a channel in the foam core material, the channel configured to engage with a portion of an air inlet component; and
curing the foam core material in the cavity.
2. The method of manufacturing of claim 1 , wherein forming the composite layer comprises laying-up multiple layers of a composite on a curved surface of a mold.
3. The method of manufacturing of claim 2 , wherein the composite comprises glass reinforced resin.
4. The method of manufacturing of claim 2 , wherein forming the composite layer further comprises applying a vacuum to the layers of composite.
5. The method of manufacturing of claim 1 , wherein applying the metal layer to the exterior surface of the composite layer comprises using vapor deposition to deposit a metal to the exterior surface of the composite layer.
6. The method of manufacturing of claim 1 , wherein applying the metal layer to the exterior surface of the composite layer comprises plating the exterior surface of the composite layer with a metal.
7. The method of manufacturing of claim 6 , wherein plating the exterior surface of the composite layer with a metal comprises using electroless or electrolytic nickel plating.
8. The method of manufacturing of claim 1 , wherein installing the electronic component to the composite layer comprises embedding a heating element in the composite layer.
9. The method of manufacturing of claim 1 , further comprising forming a front mold and a rear mold from a master plug, wherein the front mold includes a curved surface and the rear mold includes a protrusion, the protrusion configured to form the channel.
10. The method of manufacturing of claim 1 , wherein injecting the foam core material into the cavity bounded by the interior surface of the composite layer comprises injecting the foam core material as a liquid into the cavity via a port in a rear mold structure.
11. The method of manufacturing of claim 1 , further comprising installing the composite layer in an outer mold before injecting the foam core material.