System and method for fabricating a composite material assembly

Abstract

A method for fabricating a composite material assembly includes: a) providing an assembly system, b) laying down a first module on a first mold, the first module comprising a first laminate covering a first laminate support structure, c) laying down a second module on a second mold, the second module comprising a second laminate covering a second laminate support structure and extending over the at least one removable insert, d) removing the at least one removable insert from the second mold, and e) assembling the first mold with the second mold while overlapping a section of the second laminate extending over the at least one removable insert over the first laminate.

1 .- 11 . (canceled) 
     
     
         12 . A method for fabricating a composite material assembly comprising the steps of:
 a) providing an assembly system comprising:
 a first mold for receiving a first module made of composite material, said first mold comprising: 
 a first composite material laminate support structure having first and second opposite edges; and 
 a first attachment interface for attachment of the first mold to an adjacent mold; and 
 a second mold for receiving a second module made of composite material, said second mold comprising: 
 a second composite material laminate support structure having first and second opposite edges; 
 a second attachment interface for attachment of the second mold to the first mold; and 
 at least one removable insert extending beyond at least one of said first and second edges of the second mold; 
   b) laying down the first module on the first mold, the first module comprising a first laminate covering the first laminate support structure;   c) laying down the second module on the second mold, the second module comprising a second laminate covering the second laminate support structure and extending over the at least one removable insert;   d) removing the at least one removable insert from the second mold;   e) assembling the first mold with the second mold while overlapping a section of the second laminate extending over the at least one removable insert over the first laminate.   
     
     
         13 . The method according to  claim 12 , wherein the first and second molds are portions of a cylindrical structure. 
     
     
         14 . The method according to  claim 12 , wherein the first laminate has a first interface profile shaped to fit into a complementary second interface profile of the section of the second laminate extending over the at least one removable insert and overlapping over the first laminate, for forming a joint between the first and second modules. 
     
     
         15 . The method according to  claim 12 , wherein the at least one removable insert comprises a laminate overhang support surface, said laminate overhang support surface being oriented at an offset angle of at least 10° with respect to a tangential direction of the second laminate of the second mold, at the at least one of said first and second edges of the second mold where the at least one removable insert is positioned, towards an inner side of the second mold. 
     
     
         16 . The method according to  claim 15 , wherein the offset angle is between 10° and 15°. 
     
     
         17 . The method according to  claim 12 , wherein the assembly system further comprises a flexible elastomeric seal at a joint interface between the first and second molds. 
     
     
         18 . The method according to  claim 12 , further comprising the step of, prior to step b), applying a release agent to the first and second molds prior to layup of the first and second modules thereon. 
     
     
         19 . The method according to  claim 12 , further comprising the step of f) curing the assembled first and second modules. 
     
     
         20 . An aircraft fuselage comprising a composite material assembly fabricated according to  claim 12 . 
     
     
         21 . The aircraft fuselage according to  claim 20 , wherein the fuselage is a solid laminate. 
     
     
         22 . The aircraft fuselage according to  claim 20 , wherein the fuselage is a sandwich structure. 
     
     
         23 . The aircraft fuselage according to  claim 20 , wherein the fuselage is a combination of a solid laminate in some locations and a sandwich structure in other locations. 
     
     
         24 . The aircraft fuselage according to  claim 20 , comprising at least one component selected from the group comprising floor attachments, cockpit windshields, cabin windows and passenger door surrounding structures.