Moulding tool and method of manufacturing a part

Abstract

A tool set comprising: a moulding tool comprising a moulding surface and a mandrel recess in the moulding surface; a first mandrel configured to fit into the mandrel recess and form a first component; and a second mandrel configured to fit into the mandrel recess and form a second component which has a different shape or size to the first component. A method of manufacturing a part, the method comprising: arranging a set of components on one or more inner mould line tools; forming a layer around the inner mould line tool(s); fitting a pair of outer mould line tools on opposite sides of the inner mould line tool(s); moulding the part by compressing the layer and the components between the inner and outer mould line tools; and removing the inner mould line tool(s) from the part.

1 - 31 . (canceled) 
     
     
         32 . A method of manufacturing a part, the method comprising:
 forming a component on a mandrel;   fitting the mandrel into a mandrel recess of a moulding tool;   arranging a panel with a first portion of the panel engaging a moulding surface of the moulding tool and a second portion of the panel engaging the component on the mandrel;   bonding the first portion of the panel to the component by compressing them against the mandrel; and   moulding the second portion of the panel by compressing it against the moulding surface of the moulding tool.   
     
     
         33 . A method of manufacturing first and second parts, the method comprising:
 manufacturing the first part by the method of  claim 32 , wherein the component is a first component, the mandrel is a first mandrel, and the panel is a first panel;   removing the first mandrel from the mandrel recess; and   manufacturing the second part by repeating the method of claim  1 , wherein the component is a second component, the mandrel is a second mandrel, and the panel is a second panel.   
     
     
         34 . A moulding tool comprising a moulding surface, and a mandrel recess in the moulding surface, wherein the mandrel recess has a mandrel locator configured to engage with a mandrel so as to locate the mandrel at a desired position in the mandrel recess. 
     
     
         35 . The tool of  claim 34  wherein the mandrel locator is configured to engage with the mandrel by means of a male/female connection. 
     
     
         36 . The tool of  claim 35  wherein the mandrel locator comprises a hole in the mandrel recess. 
     
     
         37 . The tool of  claim 34  comprising a plurality of mandrel recesses formed in the moulding surface. 
     
     
         38 . The tool of  claim 37  wherein the mandrel recesses are formed in a contiguous piece of material. 
     
     
         39 . The tool of  claim 37  comprising:
 two or more stringer mandrel recesses in the moulding surface, each configured to receive a respective stringer mandrel; and   one or more additional mandrel recesses in the moulding surface, each configured to receive a mandrel for an additional component.   
     
     
         40 . A method of manufacturing the moulding tool of  claim 34 , the method comprising forming each mandrel recess by removing material from the moulding tool. 
     
     
         41 . A tool set comprising:
 a moulding tool comprising a moulding surface, and a mandrel recess in the moulding surface, and   a mandrel configured to fit into the mandrel recess and form a component.   
     
     
         42 . A tool set comprising:
 the moulding tool of  claim 37 ;   two or more stringer mandrels each configured to fit into a respective one of the stringer mandrel recesses and form a respective stringer; and   one or more additional mandrels each configured to fit into a respective one of the additional mandrel recesses and form a respective additional component.   
     
     
         43 . A method of manufacturing a part, the method comprising:
 arranging a set of components on a moulding tool; and   simultaneously compressing the set of components on the moulding tool against a panel so as to bond the components to the panel,   wherein the set of components includes a plurality of stringers, and one or more additional components.   
     
     
         44 . The method of  claim 43  further comprising:
 arranging a second set of components on the moulding tool; and   compressing the second set of components on the moulding tool against a second panel so as to bond the second set of components to the second panel,   wherein the second set of components are compressed against the second panel at the same time that the first set of components are compressed against the first panel.   
     
     
         45 . A tool set comprising:
 at least two inner mould line tools;   at least two outer mould line tools; and   one or more spacers, each adapted to be removably fitted between the inner mould line tools so as to maintain a desired spacing between the inner mould line tools.   
     
     
         46 . A method of manufacturing a part, the method comprising:
 arranging a first set of components on an outer face of a first inner mould line tool;   arranging a second set of components on an outer face of a second inner mould line tool;   fitting one or more spacers between the inner mould line tools, with the spacer(s) engaging inner faces of the inner mould line tools so as to maintain a desired spacing between the inner mould line tools;   forming a layer around the inner mould line tools;   fitting outer mould line tools on opposite sides of the inner mould line tools;   moulding the part by compressing the layer and the components between the inner and outer mould line tools;   removing the spacer(s);   disengaging the inner mould line tools from the part after the spacer(s) have been removed; and   removing the inner mould line tools from the part.   
     
     
         47 . A method of manufacturing a part, the method comprising:
 arranging a set of components on one or more inner mould line tools;   forming a layer around the inner mould line tool(s);   fitting a pair of outer mould line tools on opposite sides of the inner mould line tool(s);   moulding the part by compressing the layer and the components between the inner and outer mould line tools; and   removing the inner mould line tool(s) from the part.   
     
     
         48 . The method of  claim 46  wherein the layer is formed by wrapping around the or each inner mould line tool. 
     
     
         49 . The method of  claim 48  wherein the or each inner mould line tool is rotated as the layer is wrapped around the inner mould line tool(s). 
     
     
         50 . The method of  claim 47  wherein the layer is formed by wrapping around the or each inner mould line tool. 
     
     
         51 . A tool set comprising:
 the moulding tool of  claim 34 ; and   a mandrel configured to fit into the mandrel recess and form a component.