Patent ID: 8197625
Filing Date: 2012-06-12
Classification: B29C,B29D,B29K,Y10T

Abstract:
1. A method for manufacturing a composite structure of a desired shape, comprising the steps of: a) providing a first subcomponent made of a first composite material; b) providing a preformed tool made of a second composite material, said preformed tool having the desired shape; c) positioning said preformed tool on said first subcomponent; d) shaping a preimpregnated composite material by applying the preimpregnated composite material over said preformed tool to conform a shape of the preimpregnated composite material at least to the shape of the preformed tool whereby to form a second subcomponent, the first and second subcomponents forming an assembly comprising the preformed tool embedded therewithin; e) curing the assembly under suitable pressure and/or temperature conditions to form the composite structure, wherein the preimpregnated composite material comprises a resin and the preformed tool comprises a material that bonds directly with the resin of the preimpregnated composite material during the curing step; and wherein step (d) comprises folding the preimpregnated composite material to form first and a second section sections with surfaces facing each other and in an upper end portion protruding beyond an uppermost end of said tool bringing said facing surfaces into contact so as to produce said upper end portion made exclusively of the preimpregnated composite material which extends from the uppermost end of the tool to an uppermost end of the structure.