| 主权项 |
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. |
