Methods for fabricating composite structures having mounting flanges

Abstract

Methods for fabricating a composite structure having at least one mounting flange involving providing a composite structure forming tool having a first endplate and a second endplate, fabricating a composite structure preform about the tool, the composite structure preform having at least one mounting flange preform circumferentially oriented thereabout, placing at least one extended flange shoe having a first side and a second side circumferentially about the composite structure preform so that the first side lies adjacent to the first endplate, removeably coupling the first endplate to the first extended flange shoe, placing at least one flange shoe circumferentially about the composite structure preform adjacent to the second end of the extended flange shoe, removeably coupling the flange shoe to the extended flange shoe to form a cavity about the mounting flange preform, and curing the composite structure preform having the at least one mounting flange preform to obtain a composite structure having at least one mounting flange.

1 . A method for fabricating a composite structure having at least one mounting flange comprising:
 providing a composite structure forming tool having a first endplate and a second endplate;   fabricating a composite structure preform about the tool, the composite structure preform having at least one mounting flange preform circumferentially oriented thereabout;   placing at least one extended flange shoe having a first side and a second side circumferentially about the composite structure preform so that the first side lies adjacent to the first endplate;   removeably coupling the first endplate to the first extended flange shoe;   placing at least one flange shoe circumferentially about the composite structure preform adjacent to the second end of the extended flange shoe;   removeably coupling the flange shoe to the extended flange shoe to form a cavity about the mounting flange preform; and   curing the composite structure preform having the at least one mounting flange preform to obtain a composite structure having at least one mounting flange.   
     
     
         2 . The method of  claim 1  wherein the extended flange shoe is constructed of any material having a greater thermal coefficient of expansion than the composite structure preform. 
     
     
         3 . The method of  claim 1  wherein the flange shoe is constructed of any material having a greater thermal coefficient of expansion than the composite structure preform. 
     
     
         4 . The method of  claim 1  wherein the composite structure preform is a fan casing. 
     
     
         5 . The method of  claim 1  wherein the extended flange shoe is constructed of a material selected from the group consisting of metals, alloys and combinations thereof. 
     
     
         6 . The method of  claim 1  wherein the flange shoe is constructed of a material selected from the group consisting of metals, alloys and combinations thereof. 
     
     
         7 . The method of  claim 1  wherein the flange shoe comprises a substantially L-shaped cross-section. 
     
     
         8 . The method of  claim 1  wherein the extended flange shoe comprises a substantially U-shaped cross-section. 
     
     
         9 . A method for fabricating a composite structure having mounting flanges comprising:
 providing a composite structure forming tool having a first endplate and a second endplate;   fabricating a composite structure preform about the tool, the composite structure preform having a first mounting flange preform and a second mounting flange preform circumferentially oriented thereabout;   placing a first extended flange shoe having a first side and a second side circumferentially about the composite structure preform so that the first side lies adjacent to the first endplate;   removeably coupling the first endplate to the first extended flange shoe;   placing a first flange shoe circumferentially about the composite structure preform adjacent to the second end of the first extended flange shoe;   removeably coupling the first flange shoe to the first extended flange shoe to form a cavity about the first mounting flange preform;   placing a second extended flange shoe having a first side and a second side circumferentially about the composite structure preform so that the first side lies adjacent to the second endplate;   removeably coupling the second endplate to the second extended flange shoe;   placing a second flange shoe circumferentially about the composite structure preform adjacent to the second side of the second extended flange shoe;   removeably coupling the second flange shoe to the second extended flange shoe to form a cavity about the second mounting flange preform; and   curing the composite structure preform having the mounting flange performs to obtain a composite structure having mounting flanges.   
     
     
         10 . The method of  claim 9  wherein the extended flange shoes are constructed of any material having a greater thermal coefficient of expansion than the composite structure preform. 
     
     
         11 . The method of  claim 9  wherein the flange shoes are constructed of any material having a greater thermal coefficient of expansion than the composite structure preform. 
     
     
         12 . The method of  claim 9  wherein the composite structure preform is a fan casing. 
     
     
         13 . The method of  claim 9  wherein the extended flange shoes are constructed of a material selected from the group consisting of metals, alloys and combinations thereof. 
     
     
         14 . The method of  claim 9  wherein the flange shoes are constructed of a material selected from the group consisting of metals, alloys and combinations thereof. 
     
     
         15 . The method of  claim 9  wherein the flange shoes comprise a substantially L-shaped cross-section. 
     
     
         16 . The method of  claim 9  wherein the extended flange shoes comprise a substantially U-shaped cross-section. 
     
     
         17 . A method for fabricating a composite structure having adjacent mounting flanges comprising:
 providing a composite structure forming tool having a first endplate and a second endplate;   fabricating a composite structure preform about the tool, the composite structure preform having a first mounting flange preform adjacent to a second mounting flange preform circumferentially oriented thereabout;   placing a first extended flange shoe having a first side and a second side circumferentially about the composite structure preform so that the first side lies adjacent to the first endplate;   removeably coupling the first endplate to the first extended flange shoe;   placing a second extended flange shoe having a first side and a second side circumferentially about the composite structure preform so that the first side of the second extended flange shoe is adjacent to the second side of the first extended flange shoe;   removeably coupling the second extended flange shoe to the first extended flange shoe to form a cavity about the first mounting flange preform;   placing a first flange shoe circumferentially about the composite structure preform adjacent to the second side of the second extended flange shoe;   removeably coupling the first flange shoe to the second extended flange shoe to form a cavity about the second mounting flange preform; and   curing the composite structure preform having the adjacent mounting flange preforms to obtain a composite structure having adjacent mounting flanges.   
     
     
         18 . The method of  claim 1  wherein the flange shoes comprise a substantially L-shaped cross-section. 
     
     
         19 . The method of  claim 1  wherein the extended flange shoes comprise a substantially U-shaped cross-section.