METHOD FOR PROTOTYPING AND MANUFACTURING HIGH-CONTOUR STRUCTURES OF ORIENTED THERMOPLASTICS AND ORIENTED THERMOPLASTIC COMPOSITES

Abstract

A method for manufacturing high-contour structures by utilizing high pressure differential and applied consolidation temperatures, without the use of a heated press.

Claims

1. A method for making fully three-dimensional composite high contour structures and shapes comprising: forming a composite having high contour shapes that do not have draft a angle, or curve back upon themselves; said composite comprising linearly oriented thermoplastics; said linearly oriented thermoplastic composite having properties or features for structural attachment to create larger assemblies; said structure is rugged and resists projectiles, shrapnel, and pressure blasts.

2. A method for producing a rugged radome closure comprising: forming a rugged radome closure that has a spherical portion and a cylindrical portion with a joggle at the base; precluding pressing or filament winding manufacturing methods to manufacture ruggedized and ballistic protective closures; providing ballistic protection; fabricating said rugged radome closure out of materials that are applied to light-weight ballistic protection armor; converting said materials into radome shapes.

3. The method of claim 2 wherein said fabrication process uses an autoclave or like process that contains ply stack; said ply stack laid upon a net tool shape; said ply stack darted and nested with other layers that provide a near even thickness of linearly oriented thermoplastic material.

4. The method of claim 2 wherein said method is used for items that are filament wound or pressed.

5. The method of claim 2 wherein said ply stack is contained or isolated from atmospheric air by a vacuum bag, flexible caul, inflatable mandrel or similar gas barrier.

6. The method of claim 5 wherein said autoclave or like process reduces pressure within said ply stack relative to pressure chamber atmosphere.

7. The method of claim 6 wherein said process is accomplished by applying vacuum to said stack or applying pressure to said pressure chamber atmosphere; inflating a Blatter or mandrel thus creating a pressure differential across gas barrier.

8. The method of claim 7 wherein said vacuum bag or pressure isolation material does not have to be removable and is ride-away tooling or an inner or outer coating.

9. The method of claim 2 wherein said thermoplastics comprise: High Density Polyethylene, Ultra High Molecular Weight Polyethylene, Polypropylene, Aramid or any combination thereof.

10. A method for producing complex curvature radome closures comprising: cutting choice material fabric or tape into unique two-dimensional (flat) shapes; laying said flat shapes into a three-dimensional mold to yield a desired near-net-shape three dimensional complex curvature radome closure after consolidation; forming said consolidation of layers into a solid laminate by exposing said layers to pressure or a combination of pressure and temperature.

11. The method of claim 10 wherein said pressure is generated by compression molding, vacuum, a pressurized vessel or similar method.

12. A method of making a tool comprising: providing a tool type of any shape and any material; contouring said tool including any complex curvature and draft angles; goring or cutting a parent material comprised of plies of two-dimensional linearly oriented thermoplastic to conform to said tool surface; forming a material by having multiple layers of said linearly oriented thermoplastic stacked to mark required composite structure; providing consolidation where temperature is applied utilizing a vacuum bag and pressure differential in an apparatus.

13. The method of claim 12 wherein said apparatus is an autoclave.

14. A method for manufacturing a tool comprising: cutting a two-dimensional material to conform to a three-dimensional shape; laying said two-dimensional material on said tool; debulking and consolidating said material to maintain part of shape and contour of said tool; applying a vacuum bag or gas barrier material to isolate said composite from local atmosphere; applying heat, vacuum or combination of both to create pressure differential that consolidates said composite stack against tool surface.

15. The method of claim 14 wherein said vacuum is from an autoclave, applied to part or vented to atmosphere while high pressure is accumulated in local atmosphere.

16. The method of claim 2 wherein said joggle is 90.

17. The method of claim 12 wherein said complex curvature and draft angles are greater than 90.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] FIG. 1 shows a RCOTM workflow Diagram.

[0024] FIG. 2 shows a Manufacturing workflow Diagram.

[0025] FIG. 3 shows a three-dimensional high contour structure.

DETAILED DESCRIPTION

[0026] FIG. 1 shows a flow chart wherein at first stage 10 a tool type is made of any shape and composed of any material. In second stage 20, the tool is contoured including any complex curvature and draft angles. In a preferred embodiment the curvature and draft angles are greater than 90. In stage 30, a parent material comprised of plies of two dimensional linearly oriented thermoplastic is gored or cut to conform to the tool surface. In stage 40, the material is formed by having multiple layers of the linearly oriented thermoplastic stacked to mark the required composite structure. In Stage 50 there is consolidation where temperature is applied and consolidation is achieved utilizing a vacuum hag and pressure differential in an apparatus such as an autoclave.

[0027] FIG. 2 shows a manufacturing workflow diagram where in Step 100 a tool is manufactured and/or prepped for layup. In Step 110 a two-dimensional material is cut to conform to a three-dimensional shape. Multiple patterns can be used. In Step 120, a two-dimensional material is laid up on a tool. Debulking and intermediate consolidations may be used to maintain part of the shape and contour. In Step 130, a vacuum bag or a gas barrier material is applied to isolate the composite stack from the local atmosphere. In Step 140, heat is applied and in the circumstance of an autoclave, vacuum is applied to the part or vented to the atmosphere while high pressure is accumulated in the local atmosphere to create a pressure differential that consolidates the composite stack against the tool surface.

[0028] FIG. 3 shows a three-dimensional high contour structure that comprises a linearly oriented thermoplastic composite 200, a sealant/stress normalization layer 210, a segmented capture ring 220 and a continuous ring 230 for attachment to a larger assembly.