Patent ID: 9522504
Filing Date: 2016-12-20
CPC Classification: B29C,B29D,B29L,B32B,B64C,Y02T,Y10T

Claim Text:
1. A method for manufacturing an integrated composite trailing edge of an aircraft, the trailing edge comprising: an integrated main structure comprising: a set of sandwich type lower panels attachable to the lower flanges of the integrated main structure, the method comprising the following steps: a) providing a set of prepreg laminated preforms of composite material over a set of tool modules, said tool modules having a hollow located at their upper part for receiving a sandwich core, the tool modules being configured so that each prepreg laminated perform configures a double C-shaped laminated preform having an upper section with a recess corresponding with the hollow, two primary flanges and two secondary flanges, the upper section configured for partly forming a segment of the upper cover of the integrated main structure, the two primary flanges configured for partly forming the ribs and the two secondary flanges configured for forming the lower flanges of the integrated main structure, b) providing a set of sandwich cores into the recesses of the double C-shaped laminated preforms, c) aligning the set of tool modules so that adjacent primary flanges are located together, d) providing rovings to fill up the space in the radii between adjacent primary flanges, e) providing a prepreg laminate on top of the aligned set of tool modules, f) providing lower prepreg laminates against two consecutive secondary flanges, and g) applying a curing process to co-cure said laminated preforms so that the integrated main structure of the trailing edge is formed, wherein, during the forming process, a membrane is located over the tool module being pressed against the tool module by means of the vacuum provided by a general air port, while a male tool presses the flat prepreg laminate against the hollow of the tool module for forming the recess of the C-shaped laminated preform, wherein, during the forming process, a membrane is located over the tool module, the membrane being pressed against the tool module for forming the recess of the C-shaped laminated preform by means of a vacuum provided by at least two air ports located in the proximity of the hollow.