Multi-segment tool and method for composite formation

Abstract

A multi-segment tool and tooling system for vacuum forming a composite part. A tool can include a first tool having first and second surfaces. A second tool can have an opening positioned on a first tool in a location other than the first surface or the second surface. The first tool and second tool can receive at least a portion of a preform composite. The first tool can have a vacuum barrier attached to the first surface and to the second surface encapsulating the preform composite and the second tool. A tooling system can include a first tool having a core and a base with a core extending upwards from the base. A second tool can be positioned upon the core where the core extends above the second tool. A vacuum barrier sealed to the base and the core can include a composite, the first tool and the second tool.

We claim: 
     
       1. A method of forming a composite part comprising the steps of:
 providing a first tool; 
 providing a second tool having a top, a bottom and an opening connecting the top and bottom; 
 lowering the second tool onto the first tool such that the first tool protrudes through into the opening and a top edge of the first tool extends above the top of the second tool; 
 applying a composite preform on at least a portion of the second tool; 
 applying a composite preform directly on at least a portion of the first tool, in addition to on at least a portion of the second tool; 
 vacuum sealing the composite preform by securing a vacuum barrier to the first tool, while the preform and second tool are encapsulated within the vacuum barrier; and 
 curing the preform to form a composite part. 
 
     
     
       2. The method of forming a composite part of  claim 1 , further comprising the steps of:
 removing the vacuum barrier from the first tool; 
 removing the second tool; and 
 removing the cured composite part from the first tool. 
 
     
     
       3. The method of forming a composite part of  claim 1 , further comprising the steps of:
 aligning the first tool and second tool to minimize seams in the resulting composite part. 
 
     
     
       4. The method of forming a composite part of  claim 3 , where the first tool and second tool are aligned by using alignment guides. 
     
     
       5. The method of forming a composite part of  claim 1 , further comprising:
 providing a third tool, that mates with the second tool to form a profile for receiving the preform. 
 
     
     
       6. The method of forming a composite part of  claim 1  where the second tool is axially removed from the first tool. 
     
     
       7. The method of forming a composite part of  claim 1  where the composite part is an integrally formed 360 degree part having an annular opening therein. 
     
     
       8. The method of forming a composite part of  claim 5  where
 the first tool comprises a base and a core, and the second tool and the third tool are positioned at least partially on the core; and 
 the composite part is formed on the second and third tool. 
 
     
     
       9. The method of forming a composite part of  claim 8  where the core of the first tool has a ridge that at least partially receives the second tool. 
     
     
       10. The method of forming a composite part of  claim 4  where the guides at least partially align both the second tool and a third tool. 
     
     
       11. The method of forming a composite part of  claim 1 , comprising securing the vacuum barrier to a top portion of the first tool and also to a bottom portion of the first tool, wherein the second tool is located between the top portion of the first tool and the bottom portion of the first tool. 
     
     
       12. The method of forming a composite part of  claim 1 , comprising securing the vacuum barrier to a top portion of the first tool and also to a base supporting the first tool, wherein the second tool is located between the top portion of the first tool and the base supporting the first tool. 
     
     
       13. A method of forming a composite part comprising the steps of:
 providing a first tool having a top portion provided with a top edge and a bottom portion provided with a bottom edge; 
 providing a second tool having a top, a bottom and an opening connecting the top and bottom; 
 lowering the second tool onto the first tool such that the first tool protrudes through the opening with the top edge of the first tool extending above the top of the second tool and the bottom edge of the first tool extending below the bottom of the second tool; 
 providing a third tool, that mates with the second tool to form a profile for receiving perform a preform; 
 applying a composite preform on at least a portion of the second tool and also on at least a portion of the first tool; 
 securing a vacuum barrier to at least one of the top portion and the bottom portion of the first tool such that the preform and second tool are encapsulated within the vacuum barrier; and 
 curing the preform to form a composite part. 
 
     
     
       14. The method of forming a composite part of  claim 13 , further comprising the steps of:
 removing the third tool after the preform is cured to form the composite part; 
 then removing the composite part from the first and second tool. 
 
     
     
       15. The method of forming a composite part of  claim 13 , comprising securing the vacuum barrier to both the top portion and the bottom portion of the first tool. 
     
     
       16. The method of forming a composite part of  claim 13 , comprising securing the vacuum barrier to the top portion of the first tool and also to a base supporting the first tool. 
     
     
       17. The method of forming a composite part of  claim 13 , comprising securing the vacuum barrier to both the top portion and the bottom portion of the first tool. 
     
     
       18. The method of forming a composite part of  claim 13 , comprising securing the vacuum barrier to the top portion of the first tool and also to a base supporting the first tool. 
     
     
       19. A method of forming a composite part comprising the steps of:
 providing a first tool; 
 providing a second tool having a top, a bottom and an opening connecting the top and bottom; 
 positioning the first tool and second tool relative to each other such that the first tool protrudes through into the opening and a top edge of the first tool extends above the top of the second tool; 
 applying a composite preform on at least a portion of the second tool; 
 applying a composite preform directly on at least a portion of the first tool, in addition to on at least a portion of the second tool; 
 vacuum sealing the composite preform by securing a vacuum barrier to the first tool, while the preform and second tool are encapsulated within the vacuum barrier; and 
 curing the preform to form a composite part.