Abstract: A bonding preparation patch for application to a resin treated surface is provided. The patch includes a strip having first and second portions, each of which has corresponding first and second sides. The strip is formed of resin porous material and is foldable such that the respective first sides of the first and second portions face each other. The patch further includes a resin barrier interposable between corresponding portions of the respective first sides and a tape including at least one adhesive side, which is securable relative to the first portion and disposable in contact with the second side of the second portion.

Abstract: A bonding preparation patch for application to a resin treated surface is provided. The patch includes a strip having first and second portions, each of which has corresponding first and second sides. The strip is formed of resin porous material and is foldable such that the respective first sides of the first and second portions face each other. The patch further includes a resin barrier interposable between corresponding portions of the respective first sides and a tape including at least one adhesive side, which is securable relative to the first portion and disposable in contact with the second side of the second portion.

Abstract: A fiber orientation verification system includes a sensor and an indicator to identify the fiber orientation within each sequentially laid composite material layer. The indicator projects visible indicator lines upon the lay-up surface which are indicative of a desired orientation for the composite material layer. The sensor and the indicator communicate with a computer module which contains a database including a detailed sequence to assure that each layer is proper placed. The operator is thereby provided with an exact location to lay-up each composite material layer and the proper fiber orientation of that layer. Continued verification is thus provided to the operator.

Abstract: A fiber orientation verification system includes a sensor and an indicator to identify the fiber orientation within each sequentially laid composite material layer. The indicator projects visible indicator lines upon the lay-up surface which are indicative of a desired orientation for the composite material layer. The sensor and the indicator communicate with a computer module which contains a database including a detailed sequence to assure that each layer is proper placed. The operator is thereby provided with an exact location to lay-up each composite material layer and the proper fiber orientation of that layer. Continued verification is thus provided to the operator.

Abstract: A transfer device for picking up and placing resin preimpregnated composite plies. The transfer device includes a movable transfer head with a plurality of transfer feet movably mounted within it. Each transfer foot includes a support cage with a plurality of spaced posts extending between upper and lower ends. A mounting plate is located on the support cage. A pickup foot extends from the lower end of the support cage and has a channel formed through it which communicates with an opening in the lower end of the support cage. The pickup foot includes a tip end adapted to contact the resin preimpregnated composite ply. A valve is mounted within the support cage and includes a valve member located adjacent to the opening in the lower end of the support cage. The valve member is movable between a closed position and an open position. A spring surrounds at least a portion of the periphery of the transfer foot and biases the transfer foot into the transfer head.

Abstract: A method for manufacture of a fiber reinforced composite spar for a helicopter rotor blade including upper and lower sidewall regions and forward and aft conic regions. Constant width crossplies and unidirectional plies are stacked and arranged to form crossply and unidirectional laminates. The composite spar is manufactured via a vacuum forming technique which includes forming the composite laminates directly over an inflatable mandrel assembly. Regarding the latter method, a spar forming apparatus is used to position and manipulate the mandrel assembly as composite laminates are laid. The spar forming apparatus includes first and second pedestal supports being suitably configured so as to facilitate formation of the butt joints in the conic regions of the composite spar.

Abstract: A process handling resin preimpregnated fabric plies that assures release of the plies from surfaces. The process includes applying pressure to a substantially dry side of a resin impregnated fabric ply with a surface, thereby facilitating release of the ply from the surface.

Abstract: A main controller (55) causes a vision controller (36) to determine the exact location of plies (24) for a composite article in response to images from video cameras (35). The main controller then causes a robot controller (40) to direct a robot (42-46) to pick up the plies and move to a neutral position. The main controller causes the vision controller to determine that the plies were in fact picked up. If so, the main controller causes the robot controller to direct the robot to move the plies to the mold while the vision controller looks for the next ply to be picked up, in overlapped fashion. Failure to properly locate the plies and failure to verify that the plies were picked up causes an automatic retry to locate the plies or verify ply pick up.

Abstract: An integrated, automated composite material manufacturing system for pre-cure processing of preimpregnated composite materials, and particularly, for one-sided preimpregnated composite materials.

Abstract: A bi-functional transfer foot that is structurally configured and operative to provide automated handling of preimpregnated composite materials. The transfer foot includes a valve member having a knock-off stem movably mounted in a housing, a solenoid valve and fluid line interconnection to vacuum and pressure sources, and a control subsystem for regulating the operation of the transfer foot. The transfer foot is bi-functional for "ON" and "OFF" operation. A control signal issued by the control subsystem turns the transfer foot "ON" wherein vacuum forces causes a first displacement of the valve member within the housing to provide a vacuum force for engaging and retaining the tacky surface of preimpregnated composite plies.