Abstract: A reflector including a reflector dish and a backing structure. The reflector dish has a reflecting surface and a back surface. The backing structure is arranged in a pattern on the back surface of the reflector dish for supporting and stiffening the reflector dish. The backing structure includes a first backing structure skin and a second backing structure skin and a backing structure core there between. The core is substantially thicker than each skin. The backing structure is arranged such that the first backing structure skin is faced against the back surface of the reflector dish. Also, a method of manufacturing a reflector.

Abstract: A tool assembly including a male tool including an inner shape tool including a bag having a connection connectable to a depressurization source for providing a vacuum in the bag such that beads therein form a body of firm cohesion providing the inner shape tool rigid. The male tool further includes a flexible, hollow curing support arranged around the rigid inner shape tool, the inner shape tool is arranged to be removable from the flexible, hollow curing support by rupturing the vacuum.

Abstract: The present invention relates to a method of manufacturing a composite structure (3) comprising a plurality of sheets (1, 2, 5) and a radius filler (6), wherein the radius filler is adapted to fill a gap (4) at least partially formed by the sheets of the composite structure. The radius filler comprises a plastic material with a first curing temperature (T1) and the sheets comprise a plastic material with a second curing temperature (T2). The method includes the steps of arranging the sheets in a desired shape, applying the radius filler material into the gap, exposing the sheets and the radius filler material to the first temperature (T1), whereby the material of the radius filler cures, and exposing the sheets and the radius filler to the second temperature (T2), which exceeds the first temperature (T1), whereby the material of the sheets cures. The invention also relates to a radius filler (6) for filling gaps (4) between sheets (1, 2, 5) of a composite structure (3).

Abstract: A method and device for shaping of an article of composite material. The method includes arranging a blank of composite material on a top surface of a forming tool. A portion of the blank is arranged to protrude outside the top surface of the tool. At least one support is arranged in contact with an underside of the protruding portion of the blank. An air-tight foil is arranged over the arrangement. The air-tight foil is forced towards the blank. The support is lowered until the blank is shaped over the tool. The support is stopped and/or removed. The device includes a tool including a top surface and side surface for shaping at least one blank of composite material into an article having a predetermined profile; and a air-tight foil. The device further includes at least one support arranged to be in supporting contact with the underside of the protruding part of the blank.

Abstract: A method and an apparatus for manufacturing of a curved elongated structural element of composite material. The curved elongated structural element includes a first elongated portion and a second elongated portion in an angled relation. A substantially flat blank of composite material including a first and second elongated edge is provided. The blank is folded over a first portion forming surface and a second portion forming surface of a forming tool's flexible tool body for forming the first elongated portion and the second elongated portion. The forming tool's tool body is bent such that its bending moment center prevails essentially adjacent the first portion forming surface.

Abstract: A method and an apparatus for manufacture of an elongated beam profile element including a recess configured to accommodate a support element. The method includes forming the blank into the web portion with at least one first protrusion formed to extend across the web portion and to protrude outward from the web portion's outer surface; and into the first flange portion with at least one second protrusion formed to extend across the first flange portion and to protrude inward from the first flange portion's inner surface, wherein this second protrusion merges into the first protrusion and constitutes the recess for accommodating the support element under a wing.

Abstract: A method and an apparatus for manufacturing of a profile element including a web portion, a first and second flange portion, which extend from the web portion and are disposed essentially opposite each other. The method includes folding a blank of composite material about a first and second flange forming surface of a forming tool. The method includes setting at least one flange forming surface of a forming tool a distance from another flange forming surface greater than a desired distance between inner surfaces of the flange portions of a finished profile element. The folded blank is cured and a gradual decrease of the distance between the flange forming surfaces is simultaneously controlled. The cured profile element is removed from the forming tool.

Abstract: A method for producing an object of composite material comprising the steps of: placing one or several prepregs on a plane surface, forming a fibre stack; lifting over the fibre stack to a moulding tool; downforming the fibre stack; curing the downformed fibre stack; where the method also comprises the step of: orienting the fibre directions so that all fibres, when the fibre stack is lifted over to the moulding tool, will cross an edge of the moulding tool only once.

Abstract: The present invention relates to a reflector for a reflector antenna. The reflector includes a reflective surface in the form of a first skin, wherein the first skin is adherent to a core that is substantially thicker than the first skin. A portion of the core not adherent to the first skin is adherent to a second skin in such a way that the core is enclosed by the first and second skin; thus forming a sandwich construction. The core of the reflector has a thickness that varies in accordance with a given pattern so that a stiffening structure is formed in the reflector. The present invention also relates to a method of forming such a reflector.

Abstract: The invention relates to a method of manufacturing an integral article comprising a fiber-reinforced composite material. An inner tool body (12) of a cellular plastic material is provided, onto which an airtight sheet (14) of a flexible material is applied so as to fully encompass and seal the tool body (12). A plurality of layers (16) of fiber-reinforced composite material are then applied onto the outer surface of the airtight sheet (14), and an airtight vacuum bag (18) is in turn applied onto the outer layer of the composite material (16). The vacuum bag (18) is evacuated and the layers (16) of composite material compressed. The composite material is heat treated so as to cure the same. The vacuum bag (18) is then removed from the thus formed article. To form a hollow integral tank, the formed article is provided with a hole (22), and a solvent is poured therein to dissolve the cellular plastic material.

Abstract: A method for producing an article of composite material comprising the steps of: providing a moulding tool of male type; placing one or several prepregs on the moulding tool, forming a fibre stack; placing a dry layer, e.g. fabric, externally on the fibre stack, forming a fibre stack having a dry surface; providing a moulding tool of female type; overturning or tilting the stack having a dry surface from the male tool to the female tool. The method may further comprise the step of arranging said dry fibre layer so that this comprises the edge of the fibre stack. The dry layer may be made of a metal net or other suitable metal structures, or be made of glass fibre fabric or another similar glass fibre structure, or a combination of glass fibre and metal. The fact that metal is an electrically conducting material and that glass fibre is an electrical isolator may be exploited, particularly when producing aircraft components.

Abstract: The present invention relates to a method for the fabrication of a former for manufacture of composite articles. The method is characterized by the following steps: forming a wetted water-soluble fiber composite on a master tool such that the fiber composite material lies against a surface area of the master tool, allowing the water-soluble fiber composite to dry on the master tool and removing the dry water-soluble fiber composite from the master tool, wherein the dry fiber composite forms the walls of the thus fabricated former.

Abstract: Method for manufacturing an elongate stiffening element (12) and a rigid shell structure (10) integrated with at least one elongate stiffening element (12). The method includes the steps of providing a preformed, form-stable reinforcement member (16), which has a hat profile with two inwardly directed, opposing flange portions (20), covering the reinforcement member with a curable composite material to form an external hat profile having outwardly directed flanges (26), and integrating this assembly with either a curable or preformed shell structure (10) of composite material.

Abstract: The present invention relates to a stiffening element (1) and a method for manufacturing of a stiffening element (1) of composite material, which stiffening element (1) is provided for attachment to a curved shell surface (9). A substantial flat blank (29) of composite material comprising a first (13) and a second (15) essentially parallel elongated edge is provided for forming in the web (3) of the stiffening element (1) at least one rounded bulge (19) having a conical form tapering from the first edge (13) to a first folding line (17). Thereby is achieved a curved flange (5), which first folding line (17) essentially merges with an apex of the rounded bulge (19).

Abstract: The present invention relates to a method for the manufacture of a composite article comprising a composite plate (1) and at least one fitting (4). The method is characterized by the steps of arranging at least one former on said composite plate (1), arranging at least one fitting (4) on said composite plate (1), producing a lay-up by applying a composite material layer (9) least partly covering an external surface of the former and of the fitting, and curing the layup in a curing process. After curing, said composite material layer (9) forms the walls of a stiffener and at least partly encloses the fitting so as to support it in a predetermined position.

Abstract: Automatic tape laying (ATL-) apparatus for laying tape (1) containing fibre onto a surface (7) to form a composite article, which comprises means (2) to divide the tape into a plurality of inter-connected or separate, substantially longitudinal strips (3) before the tape is laid onto the surface (7).

Abstract: This invention concerns a method for fabricating a curved beam from fiber composite material. A flat fiber composite laminate (2) comprising a plurality of layers and at least two different fiber directions is formed. The fiber composite laminate (2) is disposed in contact with a male tool (1) comprised of a first flange (1a), a second flange (1c) and an intermediate web (1b), which male tool (1) is curved in its longitudinal direction with a radius of curvature R in such a way that the first flange (1a) has a shorter longitudinal extent than the second flange (1c). The fiber composite laminate (2) is brought into contact with and secured to the first flange (1a) of the male tool (1).

Abstract: The present invention relates to a reflector for a reflector antenna. The reflector includes a reflective surface in the form of a first skin, wherein the first skin is adherent to a core that is substantially thicker than the first skin. A portion of the core not adherent to the first skin is adherent to a second skin in such a way that the core is enclosed by the first and second skin; thus forming a sandwich construction. The core of the reflector has a thickness that varies in accordance with a given pattern so that a stiffening structure is formed in the reflector. The present invention also relates to a method of forming such a reflector.

Abstract: The invention concerns a reflector and a satellite antenna system comprising such a reflector. In the satellite antenna system, microwave radiation from one or more feed horns (5) is emitted at the reflector (1), which comprises first and second reflector elements (2, 3). Upon reflection of the radiation from the reflector elements (2, 3), a distinct beam shape for the reflected microwave energy is generated. The reflector elements (2, 3) are disposed at a fixed distance from one another so that radiation that passes the first reflector element (2) strikes the second element. The first reflector element (2) comprises a lattice structure aimed toward the feed horn, which lattice structure consists of plates (8) of electrically conductive material, wherein the distance between the plates and the depth of said plates are adapted for reflection of polarization parallel to the plates.

Abstract: The present invention relates to a method for the fabrication of a former for manufacture of composite articles. The method is characterized by the following steps: forming a wetted water-soluble fiber composite on a master tool such that the fiber composite material lies against a surface area of the master tool, allowing the water-soluble fiber composite to dry on the master tool and removing the dry water-soluble fiber composite from the master tool, wherein the dry fiber composite forms the walls of the thus fabricated former.