Patent ID: 6849150
Filing Date: 2005-02-01
Classification: B29C,B29D,B29K,B29L,B33Y,B64C,Y02T

Abstract:
1. A method of forming a structural assembly, comprising the step of: affixing a first pre-cured assembly to a 3-D woven textile pre-form impregnated with an uncured resin, an adhesive film being located between said first pre-cured assembly and said pre-form, said pre-form having a base and first and second legs extending from the base, the base having first and second ends having tapered sections that are tapered in thickness, and the first and second lees having ends that have tapered sections that are tapered in thickness, said first pre-cured assembly being located on a side of the base opposite the first and second legs; affixing a second pre-cured assembly between said first and second legs of said 3-D woven textile pre-form with an additional adhesive film being located between said second pre-cured assembly and inner surfaces of said first and second legs of said pre-form; curing said resin and said adhesive films to form the structural assembly; wherein said curing is performed by placing a leg side of a first pressure intensifier of flexible material against an exterior surface of said first leg and placing a base side of said first pressure intensifier against said base, said leg side of said first pressure intensifier extending past aim end of said first leg, and said base side of said first pressure intensifier extending past a first end of said base, and placing a leg side of a second pressure intensifier of flexible material against an exterior surface of said second leg and placing a base side of said second pressure intensifier against said base, said leg side of said second pressure intensifier extending past an end of said second leg, and said base side of said second pressure intensifier extending past a second end of said base, each of said pressure intensifiers having an exterior side that extends from an edge of said base side to an edge of said leg side, inserting said first and second pre-cured assemblies along with said pre-form, adhesive films, and pressure intensifiers into a vacuum bag, then evacuating the vacuum bag, causing the pressure intensifiers to press said base and legs of said pre-form against portions of said pre-cured assemblies; and wherein each of said leg sides and each of said base sides of said first and second pressure intensifiers are straight surfaces located in a single plane and spaced from said tapered sections prior to evacuating the vacuum bag.