Patent ID: 7431196
Filing Date: 2008-10-07
Classification: B29C,B29D,B29K,B29L,Y10T

Abstract:
1. A method for forming a lip for a nacelle defining a complex contour having opposite inner and outer mold line surfaces and defining a center extending along an arc, the method comprising: forming a first skin member to substantially define a desired convex contour of the outer mold line surface of the lip; forming a second skin member to substantially define a desired concave contour of the inner mold line surface of the lip; subsequent to said forming steps, disposing a cellular core member between the first and second skin members and connecting a periphery of the skin members to form a preform defining a first gas chamber between the skin members; disposing the first skin member of the preform against a contour surface of a die; providing a pressurized fluid against the second skin member of the preform to urge the second skin member toward the contour surface of the die, thereby urging the first skin member of the preform against the contour surface of the die; injecting a pressurized fluid in the first chamber to support the cellular core member while providing a pressurized fluid against the second skin member; and heating the preform to a bonding temperature while providing a pressurized fluid against the second skin member such that the skin members and the core member are bonded to form the lip with the preform restrained against the contour surface of the die.