Moldable Fly-Away Tool Structure System

Abstract

A composite structure includes a first face sheet, a second face sheet, and a foam member located between the first face sheet and the second face sheet. The foam member has a molded contour, the mold contour being configured to provide tooling surface for at least one of the first face sheet and the second face sheet prior to curing of the composite structure. A method of making the foam member includes creating a mold tool having an interior surface which resembles the desired outer contour of the foam member. A mixture is poured into a pour opening in the mold tool. The mixture is allowed to polymerize into a foam as the foam expands and distributes within the mold tool. Vent openings in the mold tool are selectively tailored to control the density of the foam member. The foam member is cured in the mold tool.

What is claimed is: 
     
         1 . A method of making a foam member for a rigid composite structure, comprising:
 creating a mold tool having an interior surface which resembles the desired outer contour of the foam member;   pouring a liquid mixture into a pour opening in the mold tool;   allowing the liquid mixture to polymerize into a foam so as to expand and distribute within the mold tool;   selectively configuring one or more vent openings in the mold tool so as to selectively dictate the density of the foam member so as to tailor a strength of the foam member so that the foam member is able to rigidly support a skin member during a subsequent curing cycle of the skin member; and   curing the foam member in the mold tool.   
     
     
         2 . The method according to  claim 1 , wherein the one or more vent openings are located near the extremities of the mold tool. 
     
     
         3 . The method according to  claim 1 , wherein the one or more vent openings are located in a lid member of the mold tool. 
     
     
         4 . The method according to  claim 1 , further comprising:
 applying a release agent in the mold tool prior to pouring the liquid mixture into the pour opening.   
     
     
         5 . The method according to  claim 1 , wherein the selectively configuring the one or more vent openings allow volatiles to escape during expansion of the liquid mixture into the foam. 
     
     
         6 . The method according to  claim 1 , wherein the selectively configuring the one or more vent openings includes selectively sizing a diameter of the vent openings. 
     
     
         7 . The method according to  claim 1 , wherein the selectively configuring the one or more vent openings includes selectively generating a quantity of the one or more vent openings. 
     
     
         8 . A method of making a composite structure, comprising:
 providing an uncured composite lower face sheet;   providing an uncured composite upper face sheet;   providing an at least partially cured foam member, the foam member being rigid by having a foam body of uninterrupted foam, an outer molded surface of the foam member being an outer surface of the foam body;   laying up the uncured composite lower face sheet onto a surface;   positioning the foam member at a desired location on the lower face sheet;   laying up the uncured composite upper face sheet onto the lower face sheet and the foam member so that the outer molded surface of the foam member supports a portion of the upper face sheet at a desired geometry; and   curing the composite lower face sheet and the composite upper face sheet while the foam member supports the portion of the upper face sheet.   
     
     
         9 . The method according to  claim 8 , wherein the step of providing the at least partially cured foam member comprises:
 creating a mold tool having an interior surface which resembles the desired outer molded surface of the foam member;   pouring a mixture into a pour opening in the mold tool;   allowing the mixture to polymerize into a foam as the foam expands and distributes within the mold tool;   selectively configuring one or more vent openings in the mold tool so as to selectively control the density of the foam member; and   curing the foam member in the mold tool.   
     
     
         10 . The method according to  claim 8 , further comprising:
 selectively tailoring a volume of the mixture to correspond with the density of the foam member.   
     
     
         11 . The method according to  claim 8 , further comprising:
 applying an adhesive between the lower face sheet and the foam member, as well as between the upper face sheet and the foam member.   
     
     
         12 . The method according to  claim 8 , wherein the selectively configuring one or more vent openings in the mold tool includes locating the one or more vent openings near an extremity of the mold tool.