US 12,240,189 B2
Methods and systems for manufacturing composite components
Michael Dean Dearman, Weatherford, TX (US); Jared Mark Paulson, Fort Worth, TX (US); Paul K. Oldroyd, Azle, TX (US); and Paul Sherrill, Grapevine, TX (US)
Assigned to Bell Helicopter Textron Inc., Fort Worth, TX (US)
Filed by Bell Helicopter Textron Inc., Fort Worth, TX (US)
Filed on Mar. 27, 2018, as Appl. No. 15/937,009.
Prior Publication US 2019/0299543 A1, Oct. 3, 2019
Int. Cl. B29C 64/00 (2017.01); B29C 33/38 (2006.01); B29C 33/44 (2006.01); B29C 35/02 (2006.01); B29C 53/82 (2006.01); B29C 70/44 (2006.01); B29C 70/48 (2006.01); B29L 31/30 (2006.01)
CPC B29C 70/44 (2013.01) [B29C 33/3857 (2013.01); B29C 33/44 (2013.01); B29C 35/0227 (2013.01); B29C 53/824 (2013.01); B29C 70/48 (2013.01); B29L 2031/3076 (2013.01)] 12 Claims
OG exemplary drawing
 
2. A method of forming composite components, the method comprising:
disposing composite laminate over an integrated mandrel, wherein the mandrel comprises a deformable portion and a non-deformable portion;
infusing the composite laminate with a resin;
causing gelation of the infused resin by applying a first environmental condition to the composite laminate and the integrated mandrel, wherein neither the deformable portion or non-deformable portion of the integrated mandrel deforms when the first environmental condition is applied;
causing at least a portion of the integrated mandrel to deform by applying a second environmental condition to the composite laminate and the integrated mandrel, wherein the non-deformable portion of the integrated mandrel does not deform when the second environmental condition is applied, wherein the deformable portion of the integrated mandrel comprises one or more deposits of an element which catalyzes with a surrounding material of the integrated mandrel when exposed to the surrounding material of the integrated mandrel, and wherein the deformation is caused at least in part by catalyzation of the one or more deposits with the surrounding material of the integrated mandrel;
forming a composite structure by curing the composite laminate infused with resin; and
removing the deformed integrated mandrel from the composite structure after forming the composite structure.