Joining A Plurality Of Superposed Fibrous Or Textile Layers Patents (Class 264/258)
  • Publication number: 20140183784
    Abstract: A method of fabricating a reinforced thermoplastic composite part comprises moving a laminate of reinforcing fibers embedded in a thermoplastic matrix for sequential operations through a heating station and then a forming station. The heating station is used to soften the thermoplastic matrix in a portion of the laminate while the forming station is used to impart a geometry to a portion of the laminate whose thermoplastic matrix had just been softened. The softening and the forming are performed simultaneously on different portions of the laminate.
    Type: Application
    Filed: January 2, 2013
    Publication date: July 3, 2014
    Applicant: THE BOEING COMPANY
    Inventor: The Boeing Company
  • Publication number: 20140183785
    Abstract: A method of fabricating an element (25) out of composite material, the element comprising three arms (22, 23, 24) arranged in a triangle. The method comprises the operations of: fabricating a three-dimensionally woven preform from reinforcing fibers and including through slots defining two arms (22, 23) and two half-arms that are all parallel and contiguous in pairs, each arm (22, 23) having one end whereby it is connected to a half-arm and another end whereby it is connected to the other arm (22, 23); shaping the preform by deploying it and by uniting its two half-arms in order to give it a triangle configuration; securing together the half-arms by stitching with reinforcing fibers; and injecting resin into the preform and polymerizing the resin.
    Type: Application
    Filed: July 31, 2012
    Publication date: July 3, 2014
    Applicant: MESSIER-BUGATTI-DOWTY
    Inventors: Richard Masson, Gildas Garnier
  • Patent number: 8765042
    Abstract: In accordance with the method, an inside layer of a fuselage section skin made from first fibers is placed on a manufacturing surface, the first fibers being placed in one or more first fiber directions. On the inside layer, a stiffening structure is formed from stiffening fibers, the stiffening fibers being placed in one or more stiffening fiber directions. An outside layer of the fuselage section skin, comprising fourth fibers, is placed on the stiffening structure formed from stiffening fibers, the fourth fibers being placed in one or more fourth fiber directions. The stiffening structure is designed and developed in such a way that the fuselage section does not require an additional stiffening structure, is connected with the fuselage section skin, and comprises the inside layer, the stiffening structure, and the outside layer; in particular, an additional stiffening structure in the form of stringers and frames is not required.
    Type: Grant
    Filed: June 7, 2011
    Date of Patent: July 1, 2014
    Assignee: Airbus Operations GmbH
    Inventors: Holger Frauen, Robert Alexander Goehlich
  • Patent number: 8753469
    Abstract: A method of vacuum-assisted RTM includes disposing a resin distribution medium on one surface of a reinforcing-fiber substrate, covering the whole with a bag material, reducing the pressure inside the bag material, and injecting a resin into the resin distribution medium to distribute the resin substantially in in-plane directions and then impregnate the resin into the reinforcing-fiber substrate in the thickness direction.
    Type: Grant
    Filed: March 19, 2008
    Date of Patent: June 17, 2014
    Assignees: Toray Industries, Inc., Mitsubishi Heavy Industries, Ltd.
    Inventors: Shigeru Nishiyama, Fumihito Takeda, Hiroshi Odani, Masumi Mizobata
  • Publication number: 20140159274
    Abstract: A fiber reinforced part is formed from a compression molded thermoplastic resin reinforced with individual fibers of differing lengths randomly oriented substantially throughout the part.
    Type: Application
    Filed: February 18, 2014
    Publication date: June 12, 2014
    Applicant: The Boeing Company
    Inventors: David E. Gideon, Edward M. Fisher, JR.
  • Publication number: 20140151925
    Abstract: A method for producing a closed-section portion of an aircraft wherein a strain gauge is glued on a first face of a flat tape that, in turn, is fastened on a face of a tool comprising a rigid elongated body covered by an extensible sack. The tool supporting the tape is arranged in a cavity of an aircraft structure. A vacuum is then created to obtain the expansion of the vacuum sack and perform the pressure gluing of the tape onto a wall of said cavity. The tool is subsequently extracted from the cavity. Upon conclusion of these operations, the tape is integrally fastened onto a wall of the cavity so that any deformation applied to this wall is transmitted to said strain gauge.
    Type: Application
    Filed: June 6, 2013
    Publication date: June 5, 2014
    Inventors: Sabato Inserra Imparato, Giuseppe Lauria, Sergio Recchia, Alberto Russolillo, Carlo Arnone, Vincenzo De Vita, Antonio Fiore
  • Publication number: 20140150635
    Abstract: The present invention discloses a method of producing and application for a projectile resistant matrix that allows for manufacture of low weight projectile resistant armor trauma shields without metal or ceramic plates using projectile resistant textiles encapsulated in a composite matrix through use of injection molding process or spray-on technique as constituents of the projectile resistant trauma shield without metal or ceramic plates of the present invention.
    Type: Application
    Filed: June 27, 2013
    Publication date: June 5, 2014
    Inventor: Alan R. Sporn
  • Patent number: 8741198
    Abstract: A process for producing a fiber reinforced resin which comprises placing at least a reinforcing fiber substrate in a cavity of a mold, injecting a resin into the cavity, and curing the resin, characterized in that a substrate for forming a skin layer, and a resin distribution medium, which is located between the substrate for forming the skin layer and the reinforcing fiber substrate and in which the ratio of the coefficient of impregnation thereof to that of the substrate for forming the skin layer is 1.5-10, are disposed on at least one surface of the reinforcing fiber substrate via an interlayer having a cover factor of 90%-100% and comprising at least one woven fabric. The process diminishes pinhole generation in the skin layer in RTM, and can reduce the necessity of a repair step in, e.g., a painting step as a later step, thereby improving productivity.
    Type: Grant
    Filed: March 1, 2007
    Date of Patent: June 3, 2014
    Assignee: Toray Industries, Inc.
    Inventors: Toshihide Sekido, Hidehiro Takemoto, Seiji Tsuji, Shintaro Tanaka
  • Publication number: 20140147619
    Abstract: The present invention relates to a composite article 801, wherein the article has a longitudinal direction L and a transversal direction T, the article 80 comprises a stack of plies wherein one ply is a bottom ply and one ply is a top ply, most of or all of the plies comprise fibres, and the article comprises a plurality of plies having fibres substantially in the orthogonal direction 810 to the longitudinal direction L of the article 801 and the stack further comprises a plurality of plies having fibres substantially in the same direction 811 as the longitudinally direction L of the article 801 and/or a plurality of plies having fibres in the diagonal direction (812, 813, 815, 816, 817, 818) of the longitudinal direction (L) of the article (801), wherein at least one of the ply/plies having fibres substantially in the orthogonal direction 810 to the longitudinal direction L of the article 801 comprise fibres that are stiffer than the fibres in the other plies which have less stiff fibres.
    Type: Application
    Filed: January 21, 2011
    Publication date: May 29, 2014
    Applicant: SAAB AB
    Inventors: Tommy Grankaell, Per Hallander, Anders Lundberg, Tonny Nyman, Bjoern Weidmann, Mikael Petersson
  • Patent number: 8734925
    Abstract: Composite pre-forms are molded at high pressure to form composite parts that can be used in place of metal-based high performance parts, such as the outlet guide vanes found in turbofan jet engines. The composite pre-forms include two different fiber orientations that are co-molded in a resin matrix at high pressures to provide composite outlet guide vanes and other high performance parts. Chambers within the composite part are optionally formed during molding of the pre-form at high pressures.
    Type: Grant
    Filed: October 19, 2011
    Date of Patent: May 27, 2014
    Assignee: Hexcel Corporation
    Inventors: Matthew Kweder, Bruno Boursier
  • Patent number: 8734605
    Abstract: A composite component, such as an aerofoil component for a gas turbine engine, comprises a body and a platform which are formed from respective body and platform preforms. The body preform includes fibers which are directed laterally of the preform, forming a cavity in the end of the preform. The platform preform includes a projection constituting a deltoid filler which is received in the cavity. The projection includes a 3D woven structure of reinforcement fibers so that the cavity is occupied by fibers to give the platform a generally uniform volume fraction. A further platform preform fits over the body preform so that the lateral fibers are sandwiched between the platform preforms.
    Type: Grant
    Filed: November 30, 2009
    Date of Patent: May 27, 2014
    Assignee: Rolls-Royce PLC
    Inventor: Neil R. Harrison
  • Publication number: 20140138873
    Abstract: A method for manufacturing rigid panels made of a composite material requires a caul sheet having a smooth surface that is formed with a plurality of grooves. A first layer of the composite material is laid on the caul sheet, and is cut to create flaps that extend into the respective grooves. Strips of composite material are then placed along the edges of the groove to extend and overlap each other in the groove. Next, a unidirectional ply is placed along the length of the groove, and this combination is then covered with a second layer of the composite material. Together, the combination of the first and second layers, the strips and the unidirectional ply are co-cured to create a rigid panel with integral stiffening members.
    Type: Application
    Filed: January 24, 2014
    Publication date: May 22, 2014
    Applicant: Spectrum Aeronautical, LLC
    Inventors: Larry J. Ashton, Michael G. Allman, Troy L. White, Benko S. Ta'ala
  • Patent number: 8728265
    Abstract: An apparatus and method of manufacturing a skeg protector to cover a motorboat skeg to prevent damage to the skeg and to the propellers. The SkegProtector™ apparatus is made of a composite of non-stainless steel woven material of high material strength and durability, such as carbon fiber, Kevlar®, fiberglass, titanium, and polyethylene fiber. It is affixed over the skeg using marine grade underwater adhesive, and without installing bolts or other mechanical means to secure it. Methods of manufacture comprise the use of curing using a heated platen press on aluminum molds encasing multiple layers (7) of woven material and a mandrel.
    Type: Grant
    Filed: October 5, 2011
    Date of Patent: May 20, 2014
    Inventor: Courtney T. Harris
  • Patent number: 8721830
    Abstract: A method for manufacturing a structural part including at least two wings extending in intersecting planes made of thermoplastic fiber-reinforced composite material including at least two plies of continuous fibers. The fibers extend from one wing to another. The method includes cutting the at least two plies in a fabric and/or a tape of fibers pre-impregnated with a thermoplastic resin; assembling the plies to create a preform; and compacting the preform to a final shape of the part by subjecting the preform to a defined cycle of temperature and pressure. A toolset can implement the method described above. Such a toolset includes a rigid punch and die such that closing the tool creates a sealed chamber in a shape of the part between the punch and the die.
    Type: Grant
    Filed: February 24, 2010
    Date of Patent: May 13, 2014
    Assignee: Airbus Operations S.A.S.
    Inventors: Didier Kurtz, Florian Chotard
  • Publication number: 20140124977
    Abstract: A composite structural element and a method for making same are provided. The element includes a polymer foam core and at least one fibrous layer adhered to the polymer foam core by epoxy. Nano-particles are suspended in the epoxy prior to curing; preferably they are mixed with the hardener before it is mixed with the resin. The polymer foam core is preferably an exothermic foam such as polyurethane, and heat generated by the exothermic foam cures the epoxy, thereby causing the fibrous layer to adhere to the foam core. The nano-particles may be made from at least one of carbon, a ceramic, tungsten, a carbide, titanium, zircon, aluminum, silver, or boron. When carbon nano-particles are used, the strength of the composite is greatly increased, and the curing time of the heat-curable epoxy is significantly reduced. Ceramic nano-particles can be used to increase penetration resistance and provide increased ballistic protection.
    Type: Application
    Filed: July 15, 2013
    Publication date: May 8, 2014
    Inventor: Michael J. Merkel
  • Patent number: 8715556
    Abstract: A gas turbine engine blade for aircraft which has a 3-dimensional blade surface shape twisted around a center line at an angle of 45 degrees or more and 70 degrees or less, wherein the aforementioned blade is provided with multiple composite material prepregs which contain reinforced fiber and which are integrally molded after being laminated in the thickness direction, and the aforementioned reinforced fiber runs continuously without interruption within each layer of the aforementioned composite material prepregs.
    Type: Grant
    Filed: March 27, 2009
    Date of Patent: May 6, 2014
    Assignees: IHI Corporation, IHI Aerospace Co., Ltd.
    Inventors: Tsutomu Murakami, Hideo Morita, Takahiro Ogi, Ikuo Okumura, Katsuyoshi Moriya
  • Patent number: 8715310
    Abstract: A non-compliant fiber-reinforced medical balloon comprises a first fiber layer and a second fiber layer embedded in a continuous matrix of thermally-weldable polymer material defining a barrel wall, cone walls and neck walls. The fibers of the first fiber layer run substantially parallel to one another and substantially parallel to the longitudinal axis. The fibers of the first fiber layer have a pattern of different lengths and are divisible into a first group and a second group based on length.
    Type: Grant
    Filed: July 31, 2012
    Date of Patent: May 6, 2014
    Assignee: Bard Peripheral Vascular, Inc.
    Inventors: Lanny R. Pepper, Charles J. Cox, William F. Davies, Jr.
  • Patent number: 8715561
    Abstract: A method of assembling and shaping a laminate panel. An intermediate member is mounted on a lay-up table and a lay-up is assembling by laying a series of plies onto the intermediate member on the lay-up table. The intermediate member and the lay-up are then removed from the lay-up table and placed them on a shaped surface. The lay-up is then forced against the shaped surface, via the intermediate member, in a manner that modifies the shape of the lay-up to form a shaped laminate panel. Finally the shaped laminate panel is removed from the intermediate member. The lay-up table can thus support the flexible intermediate member during assembly, and can be relatively flat to enable the lay-up to assembled by an automated process.
    Type: Grant
    Filed: August 28, 2009
    Date of Patent: May 6, 2014
    Assignee: Airbus Operations Limited
    Inventors: Andrew Levers, Gary Wiles
  • Publication number: 20140120332
    Abstract: A process for forming a composite structure includes the steps of: providing a preform having a plurality of layers; applying a tackifier to each of the layers of the preform; and infusing the preform with a resin. The tackifier may be catalyzed or uncatalyzed, thermoset or thermoplastic resin. The tackifier has a strain capability greater than the strain of the resin which infuses the preform.
    Type: Application
    Filed: October 26, 2012
    Publication date: May 1, 2014
    Applicant: UNITED TECHNOLOGIES CORPORATION
    Inventors: Joseph Jalowka, Charles R. Watson, Cristal Chan
  • Patent number: 8709576
    Abstract: The disclosed embodiments concern a curved structural part composed of a composite material with reinforced, continuous fibers whose cross section includes at least two wings, with said fibers extending from one wing to the other, with said structural part having a variation in the width of its section parallel to the local radius of curvature. The structural element that results from assembling the parts in the disclosed embodiments therefore has local widening of the section at the connections between the parts constituting a structural element, such as an aircraft fuselage frame, and widening at the connection with the floor profiles, if such a profile is used to make an aircraft fuselage structure. The disclosed embodiments also concern a process for manufacturing such a part, as well as a device for advantageously implementing such a process.
    Type: Grant
    Filed: November 19, 2009
    Date of Patent: April 29, 2014
    Assignee: Airbus Operations (SAS)
    Inventors: Vanessa Kubryk, Nathalie Hellard-Lambic
  • Patent number: 8696849
    Abstract: A novel reinforcement system for maximizing tensile strength and modulus of elasticity per ply for composite systems has one or more pockets with a first pocket edge, a second pocket edge, a pocket front surface, and a pocket rear surface. The pocket front surface and the pocket rear surface each have a pocket cross-stitch that perpendicularly traverses the pocket. The pocket traverses the fabric parallel and adjacent to the first fabric edge and the second fabric edge in a warp, or 0 degree, or x-axis direction. The pockets contain one or more fiber tows with a plurality of filaments in a stack.
    Type: Grant
    Filed: December 21, 2011
    Date of Patent: April 15, 2014
    Inventor: James J. Butler
  • Patent number: 8696965
    Abstract: Systems and methods for the fabrication of prepregs possessing enhanced ability for the removal of gases from within prepregs and prepreg layups prior to and/or during at least a portion of consolidation and cure process to form composite structures are disclosed. In certain embodiments, perforations of selected configurations may be introduced into the prepregs prior to, during, and after layup. The perforations provide routes for gases trapped within and between the perforated prepregs and prepreg lay-ups to escape during consolidation and cure process, reducing the residual porosity within the resulting composite. For example, composites having residual porosities less than 10 vol. %, on the basis of the volume of the composite, may be achieved in this manner.
    Type: Grant
    Filed: October 16, 2009
    Date of Patent: April 15, 2014
    Assignee: Cytec Technology Corp.
    Inventors: Christopher Lee Bongiovanni, Jack Douglas Boyd
  • Patent number: 8691137
    Abstract: A device changes the shape of a die used to compression mold a part. The device includes a sleeve placed between the die and a charge to be molded. The sleeve has an inner face generally conforming to a face of the die, and a outer face for molding a part.
    Type: Grant
    Filed: March 4, 2009
    Date of Patent: April 8, 2014
    Assignee: The Boeing Company
    Inventors: Charles R. Prebil, James R. Fox, Alexander M. Rubin, Randall D. Wilkerson
  • Patent number: 8691037
    Abstract: A method for fabricating a one-piece composite fuselage section that minimizes out-of-plane fiber distortion. This is accomplished by fabricating a mandrel having a coefficient of thermal expansion in the hoopwise direction that is sufficiently greater than that of the laid-up composite ply assembly. As a result of this differential in the coefficients of thermal expansion in the hoopwise direction, the laid-up composite ply assembly is stretched circumferentially as the mandrel expands radially during cure, thereby eliminating or reducing out-of-plane fiber distortion. At the same time, the mandrel and part being fabricated should have substantially the same coefficient of thermal expansion in the lengthwise direction. As the outer surface of the mandrel increases in circumference, the circumferentially oriented reinforcing fibers of the inner plies are stretched, while the circumferentially oriented reinforcing fibers of the outer plies do not reduce in circumference and thus do not form waves or wrinkles.
    Type: Grant
    Filed: December 14, 2006
    Date of Patent: April 8, 2014
    Assignee: The Boeing Company
    Inventors: William H. Ingram, Jr., Kenneth M. Dull, Robert Biornstad
  • Patent number: 8685302
    Abstract: Monolithic acoustically-treated composite structures and methods for fabricating the same are provided. A monolithic acoustically-treated composite structure comprises an internal frame assembly comprising a unitary composite frame structure and at least one acoustic panel assembly. The unitary composite frame structure defines a shape of the monolithic acoustically-treated composite structure to be fabricated. A composite overlay covers the internal frame assembly. The method for fabricating the monolithic acoustically-treated composite structure comprises forming the unitary composite frame structure, including the at least one acoustic panel in the unitary composite frame structure, and covering the internal frame assembly with the composite overlay.
    Type: Grant
    Filed: February 20, 2012
    Date of Patent: April 1, 2014
    Assignee: Honeywell International Inc.
    Inventors: Adam Kowal, Jeff M. Hein, David E. Wilcox
  • Patent number: 8685297
    Abstract: With a method for the manufacture of fiber-composite components, more particularly of fan blades for aircraft engines, dry fiber mats are superimposed in a lay-up mold, correctly positioned and fixed with locating pins and subsequently sewn in the mold. Metallic indicators are provided on at least one mat. The preformed entity of fiber mats is whipped at its edges with thermoplastic material and subsequently smoothed by application of heat. Remaining fiber residues are cut off. The blank thus available is infiltrated with synthetic resin in an infiltration mold or a sheathing remaining on the component. The fiber mats are checked for correct positioning by non-destructive inspection procedures. The fiber-composite component thus formed conforms to high quality requirements.
    Type: Grant
    Filed: November 13, 2007
    Date of Patent: April 1, 2014
    Assignee: Rolls-Royce Deutschland Ltd & Co KG
    Inventor: Karl Schreiber
  • Patent number: 8678417
    Abstract: The present invention relates to a universal frame for electric bikes and human powered bicycles, the frame body of the universal frame is consisted of a top tube, a down tube, a seat tube, two seat stays and two chain stays, wherein a holder is welded on the junction of the down tube, the seat tube and the chain stays, the holder is used to fasten on a bottom bracket shell with different specifications according to usage requirements. By the composition of the above elements, the present invention may be provided to assemble the main-shaft-chain wheel set of electric bikes or human powered bicycles, to thereby simplify the process, reduce the amount of inventories and achieve the convenience of universal interchangeability.
    Type: Grant
    Filed: September 26, 2012
    Date of Patent: March 25, 2014
    Assignee: Vulcan Sports Co., Ltd.
    Inventor: Chin Shu Chang
  • Publication number: 20140080376
    Abstract: A polymer matrix composites is formed from a preform layup from a plurality of fibers and is optionally tackified on its surface with a resin. The preform layup is placed in a vacuum bag and resin is flowed into the bag to infuse the layup to form a resin filled layup, then heated to increase the viscosity of the resin. The vacuum bag is vented to remove residual resin and/or entrapped gas, applying pressure to the preform layup in the bag to consolidate the layup to the target fiber volume, and the resin is cured.
    Type: Application
    Filed: September 20, 2012
    Publication date: March 20, 2014
    Applicant: United Technologies Corporation
    Inventor: Joseph Jalowka
  • Publication number: 20140077413
    Abstract: An apparatus and method for shaping an airfoil. A prepreg assembly is positioned relative to a part in a plurality of parts for a tool for the airfoil using a positioning section for a frame. The positioning section is configured to move relative to the tool and a base of the frame and move a number of parts in the plurality of parts for the tool relative to each other. A number of sections in the prepreg assembly are heated. A force is applied to the number of sections in the prepreg assembly that have been heated to conform to the tool to cause the number of sections in the prepreg assembly that have been heated to conform to the tool with a shape for a component of the airfoil.
    Type: Application
    Filed: November 20, 2013
    Publication date: March 20, 2014
    Applicant: The Boeing Company
    Inventor: Raymond Neil Henderson
  • Publication number: 20140069269
    Abstract: Provided is an anti-ballistic protective assembly including a plurality of layers of anti-ballistic material including at least two types of anti-ballistic materials, and an enclosure which is at least partially injection molded over the plurality of layers of anti-ballistic material and retains the plurality of layers of anti-ballistic material in a mutually compressed operative orientation.
    Type: Application
    Filed: March 7, 2012
    Publication date: March 13, 2014
    Applicant: BULLET PLATE LTD.
    Inventor: Oded Penn
  • Patent number: 8668858
    Abstract: A method for manufacturing rigid panels made of a composite material requires a caul sheet having a smooth surface that is formed with a plurality of grooves. A first layer of the composite material is laid on the caul sheet, and is cut to create flaps that extend into the respective grooves. Strips of composite material are then placed along the edges of the groove to extend and overlap each other in the groove. Next, a unidirectional ply is placed along the length of the groove, and this combination is then covered with a second layer of the composite material. Together, the combination of the first and second layers, the strips and the unidirectional ply are co-cured to create a rigid panel with integral stiffening members.
    Type: Grant
    Filed: September 14, 2007
    Date of Patent: March 11, 2014
    Assignee: Spectrum Aeronautical, LLC
    Inventors: Larry J. Ashton, Michael G. Allman, Troy L. White, Benko S. Ta'ala
  • Patent number: 8668864
    Abstract: Processes for fabricating polymer composite materials that contain a polymer matrix, reinforcement fabrics, and particles of a filler material. The processes include spraying the particles of the filler material on at least two articles that each comprise at least one of the reinforcement fabrics to form particle-laden articles. The particle-laden articles are stacked to form a stacked structure, and a resin present within the stacked structure is then cured to form a laminate polymer composite material. The process can be employed in the fabrication of at least a portion of an aircraft engine nacelle, for example, the inlet lip of a fan nacelle.
    Type: Grant
    Filed: May 31, 2011
    Date of Patent: March 11, 2014
    Assignee: MRA Systems Inc.
    Inventors: Mahendra Maheshwari, Xiaomei Fang
  • Patent number: 8663526
    Abstract: This relates to a method, a device and a curved molded member made of composite material. From at least one composite strip (24) formed of at least two tapes (3, 4, 5) made of unidirectional reinforcing fibers, pre-impregnated with resin and pre-compacted one with the other, the strip is applied longitudinally on a silicone flexible mandrel (13), by compaction under vacuum to confer the specific shape of the mandrel to it, the resulting strip (24) is deposited on a heated metal tool (31) having a curve that complements the shape of the mandrel and forming the core (32) of a pressure and temperature application mold (26), the flexible mandrel is removed then the mold is brought to pressure and temperature for polymerization, and the member is demolded after cooling.
    Type: Grant
    Filed: March 5, 2009
    Date of Patent: March 4, 2014
    Assignee: Airbus
    Inventors: Gilles Duqueine, Jerome Aubry
  • Patent number: 8661644
    Abstract: A tool is used to form a joint between a composite dome and a surrounding composite skirt. The tool includes a tool shell on which composite plies may be laid up to form the skirt and a spacer connected with the shell for filling a gap between the dome and the skirt.
    Type: Grant
    Filed: October 6, 2010
    Date of Patent: March 4, 2014
    Assignee: The Boeing Company
    Inventors: Michael Leslie Hand, Douglas A. McCarville, Jennifer S. Noel
  • Patent number: 8652380
    Abstract: A method of manufacturing a rim for a bicycle wheel includes wrapping plys of fibers in a resin matrix around a mandrel; curing the plys to form the rim; and reducing a size of the mandrel to allow the mandrel to be removed from the rim.
    Type: Grant
    Filed: September 21, 2011
    Date of Patent: February 18, 2014
    Assignee: Reynolds Cycling LLC
    Inventors: Paul Lew, Richard A. Steinke
  • Patent number: 8647548
    Abstract: In an embodiment of the disclosure, there is provided a method to reduce porosity in a composite structure. The method adds an additive to a resin material to form an additive-resin mixture. The method combines the additive-resin mixture with reinforcement fibers to form a composite prepreg material, and in turn, a composite structure. The method heat cures the composite structure in a heating apparatus under a vacuum device at the resin cure temperature, heats the composite structure to an increased temperature above the additive phase transition temperature, and maintains the increased temperature for a time period sufficient. The method reduces the increased temperature back down to the resin cure temperature to allow the additive gas to undergo a phase transition to a condense phase, resulting in a substantially reduced vacuum pressure, resulting in a reduction in a porosity of the composite structure.
    Type: Grant
    Filed: August 31, 2012
    Date of Patent: February 11, 2014
    Assignee: The Boeing Company
    Inventor: Keith Daniel Humfeld
  • Publication number: 20140035195
    Abstract: A device for producing fiber preforms includes a plurality of unwind stations, a plurality of grippers and at least one first molding tool. Each gripper is movable on a path between a maximum position and a pick-up position. The pick-up position is provided at a thread transfer point and is closer to the unwind station than the maximum position. The first molding tool has a draping position in the region of the connecting lines between the maximum position and the thread transfer points, and a starting position outside the connecting lines. A thread tension control for the threads or rovings is provided.
    Type: Application
    Filed: October 8, 2013
    Publication date: February 6, 2014
    Applicant: Voith Patent GmbH
    Inventors: Marco Göttinger, Michael Kaiser
  • Publication number: 20140033949
    Abstract: An integrated self-supporting and deformation-resistant modular driver's cabin structure for mounting to the front end of a rail vehicle body and for providing a driver space and a windshield opening, is composed of a composite sandwich structure with a single, common, continuous outer skin layer, a single, common, continuous inner skin layer and an internal structure wholly covered with and bonded to the inner and outer skin layers, the internal structure comprising a plurality of core elements. The driver's cabin structure comprises at least: side pillars each having a lower end and an upper end, and an undercarriage structure at the lower end of each of the side pillars. The fibre-reinforced sandwich located in the side pillars is provided with several layers of fibres oriented to provide a high bending stiffness. The fibre-reinforced sandwich of the undercarriage structure is such to transfer static and crash loads without flexural buckling.
    Type: Application
    Filed: September 19, 2011
    Publication date: February 6, 2014
    Applicant: Bombardier Transportation GmbH
    Inventors: Jan Prockat, Conor O'neill, Joseph Carruthers, Mark Robinson
  • Patent number: 8641952
    Abstract: A method of fabricating components (23) based on fiber-reinforced plastics material, in particular with the help of a wrapped mold core (10), includes the following steps: a) fabricating the mold core (10); b) wrapping the mold core (10) with a wrapper (14) that withstands resin; c) applying fiber semi-finished products (16) and introducing resin to create the plastics component (23); and d) hardening the plastics component (23) under the effect of temperature; which method is improved by the fact that, under all circumstances, and during hardening in step d), substantial pressure equilibrium is established across the fiber semi-finished product (16, 20) between ambient pressure (pu) and the pressure (pk) inside the core. A device is also described.
    Type: Grant
    Filed: July 20, 2009
    Date of Patent: February 4, 2014
    Assignee: Eurocopter Deutschland GmbH
    Inventors: Tom Kretschmer, Steffen Kunze, Christian Wellhausen
  • Publication number: 20140026974
    Abstract: A method for manufacturing a nacelle air intake lip including a plurality of components includes the following steps. The first step is positioning, inside a mold, two components within a set of fibrous layers encompassing all or part of the components so that a preform is formed. Next step is performing impregnation of the obtained preform to obtain molding of the nacelle air intake lip.
    Type: Application
    Filed: July 29, 2013
    Publication date: January 30, 2014
    Applicant: AIRCELLE
    Inventors: Bertrand DESJOYEAUX, Olivier Hubier
  • Patent number: 8636936
    Abstract: A method for fabricating a laminated composite body including a metal foil and a plurality of fiber plies. The method includes perforating a sheet of metal foil, stacking the perforated metal foil sheet and the plurality of fiber plies in face to face relation in a predetermined order and orientation, and infusing resin into the stacked sheet and plies so that resin flows through the perforations in the metal foil sheet and intersperses between the plurality of fiber plies to form the laminated composite body.
    Type: Grant
    Filed: January 9, 2006
    Date of Patent: January 28, 2014
    Assignee: The Boeing Company
    Inventors: Andrew E. Modin, Robert D. Hawkins, Robert G. Albers, Jack A. Woods
  • Publication number: 20140023515
    Abstract: Method of manufacturing a fibre-reinforced composite moulding, the method comrisinci the steps of: (a) disposing at least one layer of fibrous reinforcing material within a mould; (b) disDosing at least one pre-preg layer adjacent to the fibrous reinforcing material, the pre-preg layer comprising fibrous reinforcement at least partially impregnated with uncured first resin material, to form a laminar assembly of the at least one layer of fibrous reinforcing material and the at least one pre-preg layer within the mould; (c) applying a vacuum to the assembly; (d) infusing a flowable uncured second resin material, under the vacuum, into the at least one layer of fibrous reinforcing material: and (e) curing the first and second resin materials at least partially simultaneously to form the fibre-reinforced composite moulding which comprises at least one first structural portion formed from the fibrous reinforcement and the cured first resin material bonded to at least one second structural portion formed from the
    Type: Application
    Filed: September 27, 2013
    Publication date: January 23, 2014
    Applicant: Gurit (UK) Ltd.
    Inventor: Daniel Thomas JONES
  • Patent number: 8632710
    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.
    Type: Grant
    Filed: August 16, 2006
    Date of Patent: January 21, 2014
    Assignee: SAAB AB
    Inventors: Mikael Petersson, Björn Weidmann, Max Krogager, Ingemar Turesson
  • Patent number: 8632330
    Abstract: Tools for manufacturing composite parts and methods for using such tools are disclosed herein. A method in accordance with one aspect of the invention includes manufacturing a fiber-reinforced resin part from a plurality of fibers positioned on a tool having a female mold surface. The mold surface can include a first side region, a second side region, an interior region between the first and second side regions, and transition regions between the first and second side regions and the interior region. The method includes positioning a compaction tool over the mold surface. The compaction tool includes a first pressing device and a second pressing device carrying the first pressing device. The method further includes pressing a first portion of the fibers against the transition regions with the first pressing device without generally compacting the portions of the fibers outboard of the transition regions.
    Type: Grant
    Filed: November 23, 2009
    Date of Patent: January 21, 2014
    Assignee: The Boeing Company
    Inventors: Darrell D. Jones, Joseph D. Brennan, Mark W. King, Kurtis S. Willden, George D. Hempstead
  • Patent number: 8632653
    Abstract: A method of manufacturing curved composite structural elements can include fabricating a web ply in a flat curve over a removable substrate and laying up the ply on a curved web surface of a manufacturing tool. The method also can include laying up a diagonal ply with fibers oriented at +/?45° from the centerline of the web surface. The method further can include cutting a unidirectional composite tape into segments and laying up the tape segments to form a cross ply with a fiber orientation normal to the centerline of the web surface. One or both edges of the diagonal and cross plies may be folded over one or two sides of the manufacturing tool to form one or two flange surfaces. Additionally, a cap ply can be laid up on one or both flange surfaces using composite tape. The structural element layup can then be inspected and any excess composite material can be trimmed away.
    Type: Grant
    Filed: May 3, 2005
    Date of Patent: January 21, 2014
    Assignee: The Boeing Company
    Inventors: Todd A. Brown, Stephen Douglas Friddell, Christopher G. Harris, Andrew E. Modin
  • Patent number: 8632708
    Abstract: A method for making a ladder rail includes the steps of using a central reinforcement to carry structural resin and maintain distribution of structural resin through an impregnation process, wherein the central reinforcement is fed to a curing die at a rate of greater than 5 ft/min. There is the step of forming the rail.
    Type: Grant
    Filed: July 27, 2007
    Date of Patent: January 21, 2014
    Assignee: Werner Co.
    Inventors: Richard M. Kelly, James Vincent Gauchel, Allison Stright Clapper
  • Patent number: 8623252
    Abstract: A process of manufacturing a fibrous article includes submerging a fiber substrate in a bath of first thermoplastic resin to impregnate the fiber substrate with the first thermoplastic resin; heating the fiber substrate until the fiber substrate becomes a thick continuous fiber substrate; cutting the thick continuous fiber substrate into units; stacking the fiber substrate units; pressing and heating the stacked fibrous structure units until a stacked fibrous structure is formed; heating a mold; conveying the stacked fibrous structure to the mold to melt; cooling the mold to shape the molten fibrous structure into a half-finished article; removing the half-finished article out of the mold; eliminating burrs and sharp edges of the half-finished article; conveying the half-finished article to the mold; and uniformly applying a molten second thermoplastic resin on an inner surface of the half-finished article by injection molding to produce the finished fibrous article.
    Type: Grant
    Filed: January 9, 2009
    Date of Patent: January 7, 2014
    Assignee: Catcher Technology Co., Ltd.
    Inventors: Ma Shui-Yuan, Ling-Ling Cheng
  • Patent number: 8623263
    Abstract: A process for curing a porous muffler preform defined by a plurality of glass fibers and a heat-curing thermoset or thermoplastic materials applied to the plurality of glass fibers is disclosed herein. The process includes the step of enclosing the muffler preform in a chamber. The process also includes the step of surrounding the muffler preform with steam. The process also includes the step of causing steam to enter the muffler preform from multiple directions.
    Type: Grant
    Filed: September 21, 2009
    Date of Patent: January 7, 2014
    Assignee: OCV Intellectual Capital, LLC
    Inventors: Norman T. Huff, Janakikodandaram Karra
  • Patent number: 8617442
    Abstract: A process for the bonding of a fiber-reinforced material to an injection-molding material and an article produced by the process. The process improves the bond between a fiber-reinforced starting material and a material applied by injection. A further plastics material is inserted under pressure into a fiber-reinforced plastics material. This results in interlock bonding between the further plastics material and the fibers of the fiber-reinforced plastics material. This type of bonding is substantially more stable than known bonding.
    Type: Grant
    Filed: June 14, 2010
    Date of Patent: December 31, 2013
    Assignee: Lanxess Deutschland GmbH
    Inventor: Ulrich Dajek
  • Publication number: 20130344266
    Abstract: Stiffened thin-walled natural fibre composite product having first fibre yarns (A), each first fibre having a first thickness, and second fibre yarns (B) having a second thickness larger than the first thickness. At least one side of said product is even. Applications for a seat post; a bicycle saddle; a bicycle frame; a bicycle handle bar; a baseball bat; a piece of furniture; a paddle; or a sheet for automotive applications.
    Type: Application
    Filed: November 16, 2011
    Publication date: December 26, 2013
    Applicant: BCOMP SA
    Inventors: Christian Fischer, Julien Rion