Abstract: Methods and systems for manufacturing fiber-reinforced resin parts are disclosed herein. In one embodiment, a method for manufacturing a fiber-reinforced resin part includes positioning a plurality of fibers on a mold surface of a female tool, and covering the fibers with a sealing layer. The method further includes pressing a portion of the covered fibers against an interior transition region (e.g., an internal radius) of the mold surface. While the portion of covered fibers is pressed against the interior transition region, air is removed from between the sealing layer and the mold surface to draw at least a partial vacuum between the sealing layer and the mold surface.

Abstract: An apparatus for tensioning a preform may include a mandrel to receive a preform. The mandrel may have a first mandrel end and a second mandrel end. The preform may have a first preform end and a second preform end. The apparatus may include an anchoring groove disposed at the first mandrel end, and an anchoring device being configured and located to urge the first preform end towards the anchoring groove to secure the first preform end therebetween. The apparatus may include a tensioning groove disposed between the first mandrel end and the second mandrel end, and a tensioning device being configured and located to urge at least a portion of the preform into the tensioning groove.

Abstract: An apparatus to prepare a preform for fabrication includes a mandrel, anchoring groove, anchoring device, tensioning groove, and tensioning device. The mandrel receives the preform. The mandrel has a first mandrel end and a second mandrel end. The preform has a first preform end and a second preform end. The anchoring groove is disposed at the first mandrel end. The anchoring device is configured and located to urge the first preform end towards the anchoring groove to secure the first preform end therebetween. The tensioning groove is disposed between the first mandrel end and the second mandrel end. The tensioning device is configured and located to urge a portion of the preform into the tensioning groove.

Abstract: An apparatus for tensioning a preform may include a mandrel to receive a preform. The mandrel may have a first mandrel end and a second mandrel end. The preform may have a first preform end and a second preform end. The apparatus may include an anchoring groove disposed at the first mandrel end, and an anchoring device being configured and located to urge the first preform end towards the anchoring groove to secure the first preform end therebetween. The apparatus may include a tensioning groove disposed between the first mandrel end and the second mandrel end, and a tensioning device being configured and located to urge at least a portion of the preform into the tensioning groove.

Abstract: Methods and systems for manufacturing fiber-reinforced resin parts are disclosed herein. In one embodiment, a method for manufacturing a fiber-reinforced resin part includes positioning a plurality of fibers on a mold surface of a female tool, and covering the fibers with a sealing layer. The method further includes pressing a portion of the covered fibers against an interior transition region (e.g., an internal radius) of the mold surface. While the portion of covered fibers is pressed against the interior transition region, air is removed from between the sealing layer and the mold surface to draw at least a partial vacuum between the sealing layer and the mold surface.

Abstract: Methods and systems for manufacturing fiber-reinforced resin parts are disclosed herein. In one embodiment, a method for manufacturing a fiber-reinforced resin part includes positioning a plurality of fibers on a mold surface of a female tool, and covering the fibers with a sealing layer. The method further includes pressing a portion of the covered fibers against an interior transition region (e.g., an internal radius) of the mold surface. While the portion of covered fibers is pressed against the interior transition region, air is removed from between the sealing layer and the mold surface to draw at least a partial vacuum between the sealing layer and the mold surface.

Abstract: An apparatus to prepare a preform for fabrication includes a mandrel, anchoring groove, anchoring device, tensioning groove, and tensioning device. The mandrel receives the preform. The mandrel has a first mandrel end and a second mandrel end. The preform has a first preform end and a second preform end. The anchoring groove is disposed at the first mandrel end. The anchoring device is configured and located to urge the first preform end towards the anchoring groove to secure the first preform end therebetween. The tensioning groove is disposed between the first mandrel end and the second mandrel end. The tensioning device is configured and located to urge a portion of the preform into the tensioning groove.

Abstract: A wind tunnel blade (30) connected to a base (32) and held in position by a two-piece cuff (34). The wind tunnel blade (30) is formed in a resin transfer molding process in which central, fore, and aft foam core sections (70, 72, 74) are placed together to form the wind tunnel blade (30). Radius fillers (120) are used to fill the gaps between the outer edge of the foam core sections. The radius fillers (120) used in the wind tunnel blade (30) are formed by a braided sleeve (122) surrounding a number of unidirectional tows (124). A tip (68) is formed separately from the rest of the wind tunnel blade (30) and is glued to the top thereof. Stacked layers of braided fibers (100) are used to reinforce the central core section (70).

Abstract: A wind tunnel blade (30) connected to a base (32) and held in position by a two-piece cuff (34). The wind tunnel blade (30) is formed in a resin transfer molding process in which central, fore, and aft foam core sections (70, 72, 74) are placed together to form the wind tunnel blade (30). Radius fillers (120) are used to fill the gaps between the outer edge of the foam core sections. The radius fillers (120) used in the wind tunnel blade (30) are formed by a braided sleeve (122) surrounding a number of unidirectional tows (124). A tip (68) is formed separately from the rest of the wind tunnel blade (30) and is glued to the top thereof. Stacked layers of braided fibers (100) are used to reinforce the central core section (70).

Abstract: A method for forming a plurality of composite parts via resin transfer molding in a single molding cycle. The method includes the steps of using a mold having first and second mold members that cooperate to house a plurality of shims and placing a plurality of preform workpiece into the mold cavity such that at least one of the shims is disposed between each of an adjacent pair of the preform workpieces. A liquid resin is then injected into the mold cavity and subsequently cured to thereby form a cured workpiece matrix that is composed of a plurality of semi-finished composite parts and at least one shim separating the plurality of semi-finished composite parts from one another.

Abstract: A wind tunnel blade (30) connected to a base (32) and held in position by a two-piece cuff (34). The wind tunnel blade (30) is formed in a resin transfer molding process in which central, fore, and aft foam core sections (70, 72, 74) are placed together to form the wind tunnel blade (30). Radius fillers (120) are used to fill the gaps between the outer edge of the foam core sections. The radius fillers (120) used in the wind tunnel blade (30) are formed by a braided sleeve (122) surrounding a number of unidirectional tows (124). A tip (68) is formed separately from the rest of the wind tunnel blade (30) and is glued to the top thereof. Stacked layers of braided fibers (100) are used to reinforce the central core section (70).

Abstract: A liquid molding pressure control apparatus is provided that includes a housing and a piston assembly movably disposed within the housing. The piston assembly includes a shaft and first and second pistons engaged with the shaft. The housing is configured to receive a pressurized fluid adjacent the first piston and to receive a starting material adjacent the second piston. The first and second pistons are sized such that the starting material received within the housing exits the housing at a pressure greater than the pressure of the pressurized fluid received within the housing. Accordingly, the liquid molding control apparatus may be used to increase the pressure within the mold cavity after mold cavity has been provided with the starting material. Alternatively, the liquid molding control apparatus may be used to substantially maintain pressure within a mold cavity after the mold cavity has been provided with the starting material.

Abstract: A wind tunnel blade (30) connected to a base (32) and held in position by a two-piece cuff (34). The wind tunnel blade (30) is formed in a resin transfer molding process in which central, fore, and alt foam core sections (70, 72, 74) are placed together to form the wind tunnel blade (30). Radius fillers (120) are used to fill the gaps between the outer edge of the foam core sections. The radius fillers (120) used in the wind tunnel blade (30) are formed by a braided sleeve (122) surrounding a number of unidirectional tows (124). A tip (68) is formed separately from the rest of the wind tunnel blade (30) and is glued to the top thereof. Stacked layers of braided fibers (100) are used to reinforce the central core section (70).

Abstract: A wind tunnel blade (30) connected to a base (32) and held in position by a two-piece cuff (34). The wind tunnel blade (30) is formed in a resin transfer molding process in which central, fore, and aft foam core sections (70, 72, 74) are placed together to form the wind tunnel blade (30). Radius fillers (120) are used to fill the gaps between the outer edge of the foam core sections. The radius fillers (120) used in the wind tunnel blade (30) are formed by a braided sleeve (122) surrounding a number of unidirectional tows (124). A tip (68) is formed separately from the rest of the wind tunnel blade (30) and is glued to the top thereof. Stacked layers of braided fibers (100) are used to reinforce the central core section (70).

Abstract: A method for forming a plurality of composite parts via resin transfer molding in a single molding cycle. The method includes the steps of using a mold having first and second mold members that cooperate to house a plurality of shims and placing a plurality of preform workpieces into the mold cavity such that at least one of the shims is disposed between each of an adjacent pair of the preform workpieces. A liquid resin is then injected into the mold cavity and subsequently cured to thereby form a cured workpiece matrix that is composed of a plurality of semi-finished composite parts and at least one shim separating the plurality of semi-finished composite parts from one another.

Abstract: The present invention relates to a seal pin indexed precisely in a resin transfer molding die to assure the desired resin-to-fiber ratio in the mold part, and, thereby, to produce reliably and consistently a part of minimum weight with adequate strength. The index/resin seal pin of the present invention for RTM mold dies is novel in that it provides the seal (via replaceable O-rings) on the threaded stem of the pin to prevent low viscosity resin from invading the threads, bolts pins, or other elements of the internal mandrel. The pin allows the entire inner mandrel to be enclosed and sealed within the mold cavity, simplifying the sealing system. The invention also relates to a method for using the seal pin in a resin transfer molding process.

Abstract: The present invention relates to an index/seal pin indexed precisely in a resin transfer molding die to assure the desired resin-to-fiber ratio in the mold part, and, thereby, to produce reliably and consistently a part of minimum weight with adequate strength. The index/seal pin seals via replaceable O-rings on the threaded stem of the pin to prevent low viscosity resin from exiting a mold cavity and invading the threads, bolts, pins, or other elements of the internal mandrel. The pin also assures accurate positioning of a mandrel in the die cavity while it allows the entire inner mandrel to be enclosed and sealed within the mold cavity, simplifying the sealing system.

Abstract: The present invention relates to a seal pin indexed precisely in a resin transfer molding die to assure the desired resin-to-fiber ratio in the mold part, and, thereby, to produce reliably and consistently a part of minimum weight with adequate strength. The index/resin seal pin of the present invention for RTM mold dies is novel in that it provides the seal (via replaceable O-rings) on the threaded stem of the pin to prevent low viscosity resin from invading the threads, bolts pins, or other elements of the internal mandrel. The pin allows the entire inner mandrel to be enclosed and sealed within the mold cavity, simplifying the sealing system. The invention also relates to a method for using the seal pin in a resin transfer molding process.

Abstract: The present invention relates to a seal pin indexed precisely in a resin transfer molding die to assure the desired resin-to-fiber ratio in the mold part, and, thereby, to produce reliably and consistently a part of minimum weight with adequate strength. The index/resin seal pin of the present invention for RTM mold dies is novel in that it provides the seal (via replaceable O-rings) on the threaded stem of the pin to prevent low viscosity resin from invading the threads, bolts pins, or other elements of the internal mandrel. The pin allows the entire inner mandrel to be enclosed and sealed within the mold cavity, simplifying the sealing system. The invention also relates to a method for using the seal pin in a resin transfer molding process.

Abstract: A wind tunnel blade (30) connected to a base (32) and held in position by a two-piece cuff (34). The wind tunnel blade (30) is formed in a resin transfer molding process in which central, fore, and aft foam core sections (70, 72, 74) are placed together to form the wind tunnel blade (30). Radius fillers (120) are used to fill the gaps between the outer edge of the foam core sections. The radius fillers (120) used in the wind tunnel blade (30) are formed by a braided sleeve (122) surrounding a number of unidirectional tows (124). A tip (68) is formed separately from the rest of the wind tunnel blade (30) and is glued to the top thereof Stacked layers of braided fibers (100) are used to reinforce the central core section (70).