Multi-sectional composite tooling

Abstract

A multi-sectional composite tooling for use in molding large composite structures. The tooling includes at least two tooling sections that are made from quasi-isotropic sheet molding compound. The two tooling sections are seamed together with a scarf plug at the tooling surface. The scarf plug is composed of specially oriented layers of consolidated quasi-isotropic sheet molding compound. The scarf plug is made from the same type of quasi-isotropic sheet molding compound that is used to make the tooling sections.

What is claimed: 
     
         1 . A multi-sectional tooling for use in molding a large composite structure that has a molded surface, said multi-sectional tooling comprising:
 a first tooling section comprising a first tool surface which is shaped to form a first portion of the molded surface of said large composite structure, a first side surface and a first scarf surface extending at an angle from said first tooling surface to said first side surface, said first scarf surface having a first exterior edge located at said first tooling surface and a first interior edge located at said first side surface, said first tooling section comprising multiple layers of cured quasi-isotropic sheet molding compound, said layers of sheet molding compound each comprising a plurality of randomly oriented chips wherein said chips comprise unidirectionally oriented fibers and a cured resin;   a second tooling section comprising a second tooling surface which is shaped to form a second portion of the molded surface of said large composite structure, a second side surface and a second scarf surface extending at an angle from said second tooling surface to said second side surface, said second scarf surface having a second exterior edge located at said second tooling surface and a second interior edge located at said second side surface, said second tooling section comprising multiple layers of cured quasi-isotropic sheet molding compound, said layers of sheet molding compound each comprising a plurality of randomly oriented chips wherein said chips comprise unidirectionally oriented fibers and a cured resin, wherein said first tooling section and second tooling section are located adjacent to each other so that said first scarf surface and said second scarf surface form a scarf seam between said first and second tooling sections, said scarf seam having an apex extending along said first and second interior edges and an exterior boundary extending between said first and second exterior edges, said exterior boundary being coincident with a tooling seam surface extending between said first tooling surface and second tooling surface;   a sealant layer located between said first and second side surfaces, said sealant layer being located outside of said scarf seam; and   a scarf plug that fills said scarf seam, said scarf plug comprising a first scarf plug layer which comprises a layer of cured quasi-isotropic sheet molding compound comprising a plurality of randomly oriented chips wherein said chips comprise unidirectionally oriented fibers and a cured resin, said first scarf plug layer having an interior side and an exterior side wherein the interior side of said first scarf plug layer is located adjacent to said first and second scarf surfaces and extends from said first exterior edge to said apex and from said apex to said second exterior edge and wherein said exterior side of said first scarf plug layer has a surface contour in the shape of a chevron extending from said first exterior edge to said second exterior edge, said scarf plug comprising a plurality of additional scarf plug layers located between the exterior side of said first scarf plug layer and the exterior boundary of said scarf seam, each of said additional scarf plug layers comprising a layer of cured quasi-isotropic sheet molding compound comprising a plurality of randomly oriented chips wherein said chips comprise unidirectionally oriented fibers and a cured resin and wherein each of said additional scarf plug layers has an interior side and an exterior side, said additional scarf plug layers being located in said scarf plug such that the interior side of each additional scarf plug layer is located next to the exterior side of an adjacent additional scarf plug layer that is closer to said first scarf plug layer and wherein the interior side of one of said additional scarf plug layers is located next to the exterior side of said first scarf plug layer and follows the surface contour of said first scarf plug layer and wherein said additional scarf plug layers form said tooling seam surface.   
     
     
         2 . A multi-sectional tooling for use in molding a large composite structure according to  claim 1  wherein the angle between the first scarf surface and said exterior boundary is between 25 degrees and 35 degrees and wherein the angle between the second scarf surface and said exterior boundary is between 25 degrees and 35 degrees. 
     
     
         3 . A multi-sectional tooling for use in molding a large composite structure according to  claim 2  wherein the angle between the first scarf surface and said exterior boundary is between 30 degrees and wherein the angle between the second scarf surface and said exterior boundary is 30 degrees. 
     
     
         4 . A multi-sectional tooling for use in molding a large composite structure according to  claim 1  wherein the first tooling section, second tooling section and scarf plug are made from layers of sheet molding compound having the same areal weight. 
     
     
         5 . A multi-sectional tooling for use in molding a large composite structure according to  claim 1  wherein the areal weight of the layers of sheet molding compound used to make the first tooling section and second tooling section have an areal weight that is greater than the areal weight of the layers of sheet molding compound used to make said scarf plug. 
     
     
         6 . A multi-sectional tooling for use in molding a large composite structure according to  claim 1  wherein the first tooling section, second tooling section and scarf plug each comprises chips comprising carbon fibers and cured bismaleimide resin. 
     
     
         7 . A multi-sectional tooling for use in molding a large composite structure according to  claim 1  wherein the exterior boundary of said scarf seam extending between said first and second exterior edges is from 2 cm to 10 cm wide. 
     
     
         8 . A multi-sectional tooling for use in molding a large composite structure according to  claim 1  wherein a first layer of scarf plug adhesive is located between said first scarf surface and the interior side of said first scarf plug layer and a second layer of scarf plug adhesive is located between said second scarf surface and the interior side of said first scarf plug layer. 
     
     
         9 . A consolidated uncured scarf plug for use in sealing a seam in a multi-sectional tooling which is used to mold large composite structures that have a molded surface, Wherein said multi-sectional tool has a first tooling section comprising a first tooling surface which is shaped to form a first portion of the molded surface of the large composite structure, a first side surface and a first scarf surface extending at an angle from the first tooling surface to the first side surface, the first scarf surface having a first exterior edge located at the first tooling surface and a first interior edge located at the first side surface, the first tooling section comprising multiple layers of cured quasi-isotropic sheet molding compound, the layers of sheet molding compound each comprising a plurality of randomly oriented chips wherein said chips comprise unidirectionally oriented fibers and a cured resin, said multi-sectional tooling further including a second tooling section comprising a second tooling surface which is shaped to form a second portion of the molded surface of the large composite structure, a second side surface and a second scarf surface extending at an angle from the second tooling surface to the second side surface, the second scarf surface having a second exterior edge located at the second tooling surface and a second interior edge located at the second side surface, the second tooling section comprising multiple layers of cured quasi-isotropic sheet molding compound, the layers of sheet molding compound each comprising a plurality of randomly oriented chips wherein the chips comprise unidirectionally oriented fibers and a cured resin, wherein the first tooling section and second tooling section are located adjacent to each other so that said first scarf surface and the second scarf surface form a scarf seam between the first and second tooling sections, the scarf seam haying an apex extending along the first and second interior edges, the scarf seam having an exterior boundary extending between the first and second exterior edges, wherein the consolidated uncured scarf plug is used to overfill the scarf seam, the consolidated uncured scarf plug comprising:
 a first consolidated scarf plug layer which comprises a layer of consolidated quasi-isotropic sheet molding compound comprising a plurality of randomly oriented chips wherein said chips comprise unidirectionally oriented fibers and an uncured resin, said first consolidated scarf plug layer having an interior side and an exterior side wherein the interior side of said first consolidated scarf plug layer is shaped to be located adjacent to the first and second scarf surfaces and extend from the first exterior edge to the apex and from the apex to the second exterior edge and wherein said exterior side of said first consolidated scarf plug layer has a surface contour extending from said first exterior edge to said second exterior edge that is in the shape of a chevron haying an interior angle, said consolidated uncured scarf plug comprising a plurality of additional consolidated scarf plug layers located on the exterior side of said first consolidated scarf plug layer, each of said additional consolidated scarf plug layers comprising a consolidated quasi-isotropic sheet molding compound comprising a plurality of randomly oriented chips wherein said chips comprise unidirectionally oriented fibers and an uncured resin and wherein each of said additional consolidated scarf plug layers has an interior side and an exterior side, said additional consolidated scarf plug layers being located in said consolidated uncured scarf plug such that the interior side of each additional consolidated scarf plug layer is located next to the exterior side of an adjacent additional consolidated scarf plug layer that is closer to said first consolidated scarf plug layer and wherein the interior side of one of said additional consolidated scarf plug layers is located next to the exterior side of said consolidated first scarf plug layer and follows the surface contour of said first consolidated scarf plug layer, said additional consolidated scarf plug layers being shaped to extend past the exterior boundary of the scarf seam and overfill said scarf seam when said consolidate uncured scarf plug is placed within said scarf seam.   
     
     
         10 . A consolidated uncured scarf plug according to  claim 9  wherein the interior angle of said chevron is between 110 degrees and 130 degrees. 
     
     
         11 . A consolidated uncured scarf plug according to  claim 10  wherein the interior angle of said chevron is 120 degrees. 
     
     
         12 . A consolidated uncured scarf plug according to  claim 9  wherein said first consolidated scarf plug layer and said additional consolidated scarf plug layers each comprises chips comprising carbon fibers and uncured bismaleimide resin. 
     
     
         13 . A consolidated uncured scarf plug according to  claim 9  wherein the first consolidated scarf plug layer and additional consolidated scarf plug layers are sized and shaped to over fill a scarf seam where the exterior boundary of the scarf seam is from 2 cm to 10 cm wide. 
     
     
         14 . A consolidated uncured scarf plug according to  claim 9  wherein the first consolidated scarf plug layer and said additional scarf plug layers are made from layers of consolidated quasi-isotropic sheet molding compound having the same areal weight. 
     
     
         15 . A method for seaming a multi-sectional tooling that is used in molding a large composite structure that has a molded surface, said method comprising the steps of:
 providing a first tooling section comprising a first tooling surface which is shaped to form a first portion of the molded surface of said large composite structure, a first side surface and a first scarf surface extending at an angle from said first tooling surface to said first side surface, said first scarf surface having a first exterior edge located at said first tooling surface and a first interior edge located at said first side surface, said first tooling section comprising multiple layers of cured quasi-isotropic sheet molding compound, said layers of sheet molding compound each comprising a plurality of randomly oriented chips wherein said chips comprise unidirectionally oriented fibers and a cured resin;   providing a second tooling section comprising a second tooling surface which is shaped to form a second portion of the molded surface of said large composite structure, a second side surface and a second scarf surface extending at an angle from said second tooling surface to said second side surface, said second scarf surface having a second exterior edge located at said second tooling surface and a second interior edge located at said second side surface, said second tooling section comprising multiple layers of cured quasi-isotropic sheet molding compound, said layers of sheet molding compound each comprising a plurality of randomly oriented chips. wherein said chips comprise unidirectionally oriented fibers and a cured resin;   locating said first tooling section and second tooling section adjacent to each other so that said first scarf surface and said second scarf surface form a scarf seam between said first and second tooling sections, said scarf seam having an apex extending along said first and second interior edges and an exterior boundary extending between said first and second exterior edges;   placing a layer of sealant layer between said first and second side surfaces, said sealant layer being located outside of said scarf semi, and   overfilling said scarf seam with a consolidated uncured scarf plug which comprises a first consolidated scarf plug layer that is composed of a layer of consolidated quasi-isotropic sheet molding compound comprising a plurality of randomly oriented chips wherein said chips comprise unidirectionally oriented fibers and an uncured resin, said first consolidated scarf plug layer haying an interior side and an exterior side wherein the interior side of said first consolidated scarf plug layer is located adjacent to the first and second scarf surfaces and extends from the first exterior edge to the apex and from the apex to the second exterior edge and wherein said exterior side of said first consolidated scarf plug layer has a surface contour extending from said first exterior edge to said second exterior edge that is in the shape of a chevron having an interior angle that is the same as the angle between the first scarf surface and the second scarf surface at the apex of said scarf seam said consolidated scarf plug comprising a plurality of additional consolidated scarf plug layers located on the exterior side of said first consolidated scarf plug layer, each of said additional consolidated scarf plug layers comprising a consolidated quasi-isotropic sheet molding compound comprising a plurality of randomly oriented chips wherein said chips comprise unidirectionally oriented fibers and an uncured resin and wherein each of said additional consolidated scarf plug layers has an interior side and an exterior side, said additional consolidated scarf plug layers being located in said consolidated scarf plug such that the interior side of each additional consolidated scarf plug layer is located next to the exterior side of an adjacent additional consolidated scarf plug layer that is closer to said first consolidated scarf plug layer and wherein the interior side of one of said additional consolidated scarf plug layers is located adjacent to the exterior side of said first consolidated scarf plug layer and follows the surface contour of said consolidated first scarf plug layer, wherein one or more of said additional consolidated scarf plug layers extend past the exterior boundary of the scarf seam in order to overfill said scarf seam;   curing said consolidated uncured scarf plug that has overfilled said scarf seam to form a cured oversized scarf plug which includes a portion that extends past the exterior boundary of the scarf seam; and   removing the portion of said cured oversized scarf plug that extends past the exterior boundary of the scarf seam to thereby form a tooling seam surface that extends between said first tooling surface and said second tooling surface.   
     
     
         16 . A method for seaming a multi-sectional tooling according to  claim 15  wherein the angle between the first scarf surface and said exterior boundary is between 25 degrees and 35 degrees and wherein the angle between the second scarf surface and said exterior boundary is between 25 degrees and 35 degrees. 
     
     
         17 . A method for seaming a multi-sectional tooling according to  claim 16  wherein the angle between the first scarf surface and said exterior boundary is between 30 degrees and wherein the angle between the second scarf surface and said exterior boundary is 30 degrees. 
     
     
         18 . A method for seaming a multi-sectional tooling according to  claim 15  which includes the additional steps of locating a first layer of scarf plug adhesive between said first scarf surface and the interior side of said first scarf plug layer and locating a second layer of scarf plug adhesive between said second scarf surface and the interior side of said first scarf plug layer. 
     
     
         19 . A method for seaming a multi-sectional tooling according to  claim 15  wherein the areal weight of the layers of sheet molding compound used to make the first tooling section and second tooling section have an areal weight that is greater than the areal weight of the layers of consolidated quasi-isotropic sheet molding compound used to make said consolidated uncured scarf plug. 
     
     
         20 . A method for seaming a multi-sectional tooling according to  claim 13  wherein the first tooling section and second tooling section each comprises chips comprising carbon fibers and cured bismaleimide resin and said consolidated uncured scarf plug comprises carbon fibers and uncured bismaleimide resin.