Patent ID: 8668800
Filing Date: 2014-03-11
Classification: B29C,B29L,Y02P

Abstract:
1. A method for manufacturing a complex hollow composite part with at least one internal structure comprising the following steps: a. selecting a mold with a part cavity suitable for laying up composite laminated layers; b. selecting at least two inner mandrels to be placed inside said part cavity and used to form an internal structure made of composite laminated material, each said inner mandrel being made of at least three jig plates aligned edge to edge and slidingly engaged, at least one said jig plate being tapered enabling said inner mandrel to collapse when at least one said jig plate is slidingly removed from said part; c. applying layers of dry fiber, wet fiber, pre-preg, film infusion, or laminated material around each said inner mandrel; d. inserting said inner mandrels covered with dry fiber, wet fiber, pre-preg, film infusion, or laminated material into said mold cavity; e. selecting two elastomeric envelopes each filled with spherical material, each said envelope configured to become rigid when evacuated and expand when heated; f. positioning said envelopes inside said mold cavity and on opposite sides of said inner mandrels; g. laying up said layers of dry fiber, wet fiber, pre-preg, film infusion, or laminated material around said envelopes and said inner mandrels; h. closing said mold; i. heating and curing said part inside said mold; and, j. removing said envelopes and said inner mandrels from said part.