Joining A Plurality Of Superposed Fibrous Or Textile Layers Patents (Class 264/258)
  • Patent number: 10391684
    Abstract: Cauls and methods of using cauls to produce composite articles are provided. The caul transitions from a rigid state to an elastomeric state and from an elastomeric state to a rigid state in response to a stimulus and has a reinforcement density of from 100 kg/m3 to 500 kg/m3. Methods of using cauls to produce composite articles involve positioning one or more fiber layers between a caul and a cure mold surface when the caul is in a rigid state. The fiber layers, caul, and cure mold surface may be covered with a sealed barrier and a pressure gradient may be applied. Before, after, or before and after performing the vacuum the fiber layers may be impregnated with resin. The fiber layers may be cured, which may provide a stimulus to transition the caul from a rigid to an elastomeric state, and the composite article is produced.
    Type: Grant
    Filed: November 30, 2016
    Date of Patent: August 27, 2019
    Assignee: Spintech, LLC
    Inventors: Thomas W. Margraf, Jr., Matthew C. Everhart, David E. Havens, Robert V. Graziano, Craig S. Jennings
  • Patent number: 10358206
    Abstract: A self-destruction device adapted to be installed in a propeller blade, the self-destruction device including a detector adapted to detect a release of the propeller blade, a warning mechanism adapted to send a release alarm in the event of the detector detecting release of the propeller blade, and a destruction mechanism adapted to destroy the propeller blade in the event of receiving a release alarm from the warning mechanism. An engine and an aircraft are also provided.
    Type: Grant
    Filed: December 18, 2015
    Date of Patent: July 23, 2019
    Assignees: Airbus Operations, S.L., Airbus Operations (S.A.S.)
    Inventors: Javier Toral Vázquez, Diego Folch Cortes, Esteban Martino González, Pablo Goya Abaurrea, Vasillis Votsios, Michel Fouinnetau, Sylvain Roumegas
  • Patent number: 10245793
    Abstract: For forming profile elements, in particular trapezoidal or ?-shaped profile elements, from a multilayer stacking of pre-impregnated fibers, the stacking is moved in feed direction with feed speed by sets of conveyor belts which engage with the upper and lower surfaces of the lateral edge sections of the stacking and hold the edge sections in a starting plane. The sets of conveyor belts are arranged so that the distance between the sets engaging with opposite edge sections decreases in feed direction. To conduct the forming step a middle portion of the stacking is moved over a ramp upwardly inclined in feed direction with respect to the starting plane.
    Type: Grant
    Filed: August 13, 2015
    Date of Patent: April 2, 2019
    Assignee: Airbus Operations GmbH
    Inventors: Tassilo Witte, Hannes Winter
  • Patent number: 10213994
    Abstract: In one aspect, a method for manufacturing a spar cap for a wind turbine rotor blade may generally include stacking a plurality of plates together to form a plate assembly, wherein each of the plates is formed from a fiber-reinforced composite including a plurality of fibers surrounded by a thermoplastic resin material. The method may also include positioning the plate assembly relative to a mold defining a mold surface, wherein the mold surface is shaped so as to correspond to at least one blade parameter of the wind turbine rotor blade. In addition, the method may include applying pressure to the plate assembly via the mold such that at least a portion of the plate assembly conforms to the shape of the mold surface.
    Type: Grant
    Filed: September 23, 2015
    Date of Patent: February 26, 2019
    Assignee: General Electric Company
    Inventors: James Robert Tobin, Christopher Daniel Caruso, Aaron A. Yarbrough, Daniel Alan Hynum
  • Patent number: 10213954
    Abstract: A method includes the step placing composite laminate material onto a three dimensional forming tool with an external surface and at least four junctures associated with the external surface. Each juncture is positioned between two adjacent planar surfaces in which each of the two adjacent surfaces extend in a different plane, the junctures converge and each juncture defines a line of direction. The three dimensional forming tool arranged in a two dimensional pattern, has the lines of direction and the two adjacent planar surfaces positioned on opposing sides of each of the at least four junctures are all positioned in a common plane. The line of direction of each of the at least four junctures in the two dimensional pattern converge to a common point. At least one line of direction is not in alignment beyond the common point with another line of direction. Tool apparatus is also provided.
    Type: Grant
    Filed: February 19, 2016
    Date of Patent: February 26, 2019
    Assignee: THE BOEING COMPANY
    Inventor: Stanley Warren Stawski
  • Patent number: 10195769
    Abstract: The object of the present invention is to provide a gasket forming mold with a structure in which curling of the reversing section of the gasket molding does not occur easily. To achieve said object, the forming mold for integrally forming an endless shaped gasket has forming grooves as cavities in the parting surfaces of the forming mold and the forming grooves have a reversing section in a part thereof. The reversing section has two linear portions and the ends of the two linear portions are connected by an arc-shaped curved section. The two linear portions are arranged at literally-symmetrical positions and are arranged so that a distance therebetween is enlarged little by little from one end toward the other. The ends where said distance is enlarged are connected by the circular arc-shaped curved section.
    Type: Grant
    Filed: October 3, 2014
    Date of Patent: February 5, 2019
    Assignee: NOK Corporation
    Inventors: Nobuyuki Umezaki, Hideto Nameki
  • Patent number: 10124568
    Abstract: A method of manufacturing a curved profile from a rectilinear preform of pre-impregnated fiber plies. The method includes stacking plies on a deformable mandrel and winding the deformable mandrel and the stacked plies on a bending tool along a rotation axis, the profile comprising a stack of N plies. At least one first section of the profile is arranged along a plane perpendicular to the axis of rotation and at least one second section is arranged in a plane parallel to the axis. The method includes the steps of stacking the N plies of fibers on the deformable mandrel, bending in a single step the N plies sandwiched between the deformable mandrel and the bending tool and polymerizing the bent N plies. The curved profile comprises M plies with fibers oriented at A° relative to a longitudinal direction and M+/?5% plies with fibers oriented at ?A°.
    Type: Grant
    Filed: March 11, 2013
    Date of Patent: November 13, 2018
    Assignee: Airbus Operations SAS
    Inventor: Denis De Mattia
  • Patent number: 10076452
    Abstract: There is provided a tampon pledget that includes one or more enhanced features that result in the pledget exhibiting increased bypass leakage prevention. These enhanced features may include, but are not limited to, geometry, absorption, and any combinations thereof. There is also provided one or more methods for constructing a tampon pledget having increased bypass leakage protection.
    Type: Grant
    Filed: December 17, 2015
    Date of Patent: September 18, 2018
    Assignee: Edgewell Personal Care Brands, LLC.
    Inventors: Robert Jorgensen, Keith Edgett
  • Patent number: 10035300
    Abstract: A system for manufacturing a stiffened composite panel may include a stiffener tooling assembly, a caul plate, and a rotatable strongback. The stiffener tooling assembly may include stiffener tooling configured to support a plurality of composite stiffeners. The caul plate may have a layup surface for laying up a composite skin. The strongback may be releasably coupled to the caul plate. The system may include a plurality of hinges each having a fixed hinge portion and a movable hinge portion. The movable hinge portion may be coupled to the strongback for rotation thereof between an open position and a closed position for engagement of the caul plate with the stiffener tooling assembly.
    Type: Grant
    Filed: June 23, 2015
    Date of Patent: July 31, 2018
    Assignee: The Boeing Company
    Inventors: Joe Encinosa, Andrew Barwick, Robert Bick
  • Patent number: 10035588
    Abstract: An aircraft wing tip device may include a unitized, monolithic leading edge torque box that may be formed of polymer matrix fiber-reinforced material. The leading edge torque box may include a skin that may define a continuous, uninterrupted outer mold line surface extending aftwardly from a winglet leading edge by a distance of at least approximately 60 percent of a local chord length. The leading edge torque box may further include at least one internal component extending between opposing inner surfaces of the skin and being integrally formed therewith.
    Type: Grant
    Filed: August 27, 2015
    Date of Patent: July 31, 2018
    Assignee: The Boeing Company
    Inventors: Darrell D. Campbell, Jr., Brett I. Lyons
  • Patent number: 10010456
    Abstract: The present invention relates to an intravaginal tampon for feminine hygiene. In particular, it relates to methods for producing such a tampon having relatively deep, penetrating grooves in which adjacent penetrating jaws pass through the same tampon press space during manufacture and to an apparatus useful in making such a tampon as well as the tampons made therewith.
    Type: Grant
    Filed: October 7, 2015
    Date of Patent: July 3, 2018
    Assignee: Johnson & Johnson GmbH
    Inventors: David L. Kimball, Tony C. Ng, Tara Zedayko
  • Patent number: 9950503
    Abstract: A jig for fixing laminated materials, a system for manufacturing bonded laminated materials, and a method of manufacturing bonded laminated materials are provided at a good yield factor and to efficiently manufacture the bonded laminated materials that are pressed and bonded after being laminated without a misalignment of the membranes or deformation of the laminated materials or any deficiency in bonding at the interface. The bonded laminated materials are manufactured by storing materials made of membranes (W) in a housing space (S) formed by a first sheet-shaped member (12), a second sheet-shaped member (22), and a sealing member (30), exhausting the housing space (S) to sandwich the laminated materials (W) between the first and second sheet-shaped members (12, 22) to fix them, and pressing and bonding them by hot-pressing rollers (51) and cold-pressing rollers (52) of a machine (50) for manufacturing the bonded laminated materials while they are fixed.
    Type: Grant
    Filed: January 5, 2012
    Date of Patent: April 24, 2018
    Assignee: SINTOKOGIO, LTD.
    Inventors: Masahiko Nagasaka, Shogo Nakajima, Takayuki Nozawa, Osamu Sugino, Ikuto Mishima
  • Patent number: 9934885
    Abstract: A gas turbine engine 10 is provided with electrical harness rafts 200 comprising electrical conductors embedded in a rigid composite material. The rafts 200 are used to transport electrical signals (which may be, for example power and/or control signals) around a gas turbine engine. Rafts 200 may be connected together and to other components using flexible cables, that may help to accommodate relative movement of the rafts 200, for example through vibration. The rafts 200 are lighter, more compact, and more convenient to handle than conventional electrical harnesses. The rafts 200 may provide a convenient and secure mounting surface for other components/systems of a gas turbine engine, such as EECs and/or fluid pipes.
    Type: Grant
    Filed: December 17, 2012
    Date of Patent: April 3, 2018
    Assignee: ROLLS-ROYCE plc
    Inventors: Paul Broughton, Robin Charles Kennea
  • Patent number: 9849931
    Abstract: A method for forming a bicycle frame assembly having a number of elongate tubes is disclosed. A two part mold can be used to form a hollow finish part as part of the assembly. The assembly includes a passage that is defined by the elongate member, a partition, and a bridge. The partition isolates the passage from an interior volume of the elongate tube. The bridge extends in a direction normal to an elongate direction of the passage and defines an inlet and an outlet of the passage. The inlet, outlet, and bridge are generally flush with an exterior surface of the elongate tube and provide a passage that cooperates with a flexible connector, such as a cable tie, for securing supplemental structures, such as brake and shift control cables, to the elongate tube of the bicycle frame assembly.
    Type: Grant
    Filed: July 29, 2015
    Date of Patent: December 26, 2017
    Assignee: Trek Bicycle Corporation
    Inventor: James Colegrove
  • Patent number: 9623641
    Abstract: A method and apparatus for reinforcing an end portion of a deformable tool configured for use in forming a composite object. An insert may be placed within a hollow portion of the end portion of the deformable tool in which the insert substantially conforms to a cross-sectional shape and a size of the hollow portion of the end portion of the deformable tool. A side of the end portion of the deformable tool may be reinforced by the insert located within the hollow portion of the end portion of the deformable tool during a curing process used to form the composite object.
    Type: Grant
    Filed: September 24, 2013
    Date of Patent: April 18, 2017
    Assignee: THE BOEING COMPANY
    Inventors: Michael R. Chapman, Khanh M. Pham
  • Patent number: 9604417
    Abstract: A contoured composite part is made by assembling a preform charge, including aligning a plurality of plies along a preselected contour. The assembled aligned preform charge is then placed in a forming tool, where the charge is formed and cured.
    Type: Grant
    Filed: April 5, 2011
    Date of Patent: March 28, 2017
    Assignee: THE BOEING COMPANY
    Inventor: Andrew E. Modin
  • Patent number: 9545780
    Abstract: A method for producing a part made of a composite material, including a skin and at least one stiffener made of strips, which are in turn made of one or more plies of fibers impregnated with a non-polymerized resin. The method includes the steps of: producing a preform of the part by pulling the strips through a die for shaping and positioning the skin and the stiffeners, a polymerization core being provided between a first strip and a second strip prior to the passage thereof through the die; and pressing the resulting preform in a hot press for a duration dt while applying a pressure P and at a temperature T for polymerizing the resin of the strips in the hot press over a pressing length L that is shorter than the length of the panel.
    Type: Grant
    Filed: October 11, 2012
    Date of Patent: January 17, 2017
    Assignee: Airbus Operations (SAS)
    Inventors: Philippe Blot, Matthieu Kneveller
  • Patent number: 9505188
    Abstract: A method of fabricating a wind turbine blade tubular spar, wherein the tubular spar extends along a designated axis, is made of reinforced polymer material having fibers arranged in at least two directions, and a polymer matrix incorporating the fibers, and has two caps and two webs; the method including the steps of: molding and cross-linking at least part of a cap or web in composite material; molding and cross-linking an L-shaped structure, which has two opposite parallel flanges, and at least partly incorporates the previously molded, cross-linked cap or web of composite material; repeating the above steps to mold and cross-link a further L-shaped structure; and joining the two cross-linked, L-shaped structures, with the flanges positioned facing in pairs.
    Type: Grant
    Filed: September 30, 2011
    Date of Patent: November 29, 2016
    Assignee: WINDFIN B.V.
    Inventors: Matteo Casazza, Matteo Verdesca, Amedeo Sabbadin, Philip Baby
  • Patent number: 9463840
    Abstract: A bicycle component with reinforced structure and a manufacturing method thereof are disclosed. The bicycle component includes a hollow main body and a foam material. The main body is manufactured by stacking plural carbon fiber prepreg layers and provided with a force bearing area. The foam material is disposed on the force bearing area and wrapped by the carbon fiber prepreg layers. Therefore, the present invention improves the structural strength of the bicycle component, lightens the weight of a bicycle made of the bicycle components, and provides a greater controllability of the bicycle.
    Type: Grant
    Filed: April 24, 2015
    Date of Patent: October 11, 2016
    Inventor: Louis Liu
  • Patent number: 9403302
    Abstract: A fabrication method and a fabrication device capable of fabricating medium-scale mass production parts. The method of fabricating a composite material hollow part includes: holding a tool on a frame using a holding section that maintains a gap between the tool and the frame, placing a prepreg on the tool, covering the tool and the prepreg using a highly stretchable sheet, securing the highly stretchable sheet and the frame with a securing jig so that tension is applied to the highly stretchable sheet from the top portion of the prepreg where the highly stretchable sheet contacts the prepreg at the highly stretchable sheet and the outer periphery of both the tool and the prepreg to the edges of the highly stretchable sheet, thereby forming an enclosed space that houses the tool and the prepreg, and subsequently evacuating the inside of the enclosed space to wrap the prepreg around the tool.
    Type: Grant
    Filed: March 28, 2012
    Date of Patent: August 2, 2016
    Assignee: MITSUBISHI HEAVY INDUSTRIES, LTD.
    Inventors: Hidetaka Hattori, Hideki Horizono, Tadashi Yazaki, Naoaki Fujiwara
  • Patent number: 9370903
    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: Grant
    Filed: July 31, 2012
    Date of Patent: June 21, 2016
    Assignee: MESSIER-BUGATTI-DOWTY
    Inventors: Richard Masson, Gildas Garnier
  • Patent number: 9284010
    Abstract: An inverted tube bike frame with bottle opener gusset system is a bicycle frame with the top tube and down tube having a heightened profile with concave sidewalls and a bottle opener gusset strengthening the joint between the seat tube and the top tube. The top tube has a downwardly curved design for added mechanical strength. Other tube-members of the frame have an elongated elliptical cross-section for increased strength and impact damage resistance. The wheel base is wider than that of a standard bicycle adding to forward movement stability and rider comfort. The design of the frame provides added strength and increased frame life with rugged service.
    Type: Grant
    Filed: January 14, 2015
    Date of Patent: March 15, 2016
    Inventor: Scott Kump
  • Patent number: 9278511
    Abstract: A method for producing a curved section piece from a rectilinear preform of preimpregnated fiber layers includes stacking layers on a deformable mandrel and winding the mandrel and bending the stacked layers on a bending tool on a rotation axis in a single phase and polymerizing the bent layers. The section piece includes a stack of N layers, at least a first portion of which is placed in a plane perpendicular to the rotation axis (X) and at least one second portion parallel to the axis (X) including at least one layer of fibers oriented at 0° along the length of the perform. The N fiber layers are stacked on the mandrel. A neutral fiber is placed on a portion of the mandrel closer to the rotation axis (X) than the last layer of fibers oriented at 0° stacked on the 0second portion parallel to the rotation axis (X).
    Type: Grant
    Filed: June 12, 2013
    Date of Patent: March 8, 2016
    Assignee: Airbus Operations SAS
    Inventor: Denis De Mattia
  • Patent number: 9212596
    Abstract: A spherical annular seal member 35 for use in an exhaust pipe joint has a spherical annular base member 33 which is defined by a cylindrical inner surface 29 forming a through hole 28, a partially convex spherical sliding surface 39, and annular end faces 31 and 32 on large- and small-diameter sides of the partially convex spherical sliding surface 39.
    Type: Grant
    Filed: December 18, 2013
    Date of Patent: December 15, 2015
    Assignee: Oiles Corporation
    Inventor: Hiroaki Wada
  • Patent number: 9206901
    Abstract: A spherical annular seal member 35 for use in an exhaust pipe joint includes: a spherical annular base member 33 defined by a cylindrical inner surface 29, a partially convex spherical surface 30, and large- and small-diameter side annular end faces 31 and 32 of the partially convex spherical surface 30; and an outer layer 34 formed integrally on the partially convex spherical surface 30 of the spherical annular base member 33.
    Type: Grant
    Filed: November 19, 2013
    Date of Patent: December 8, 2015
    Assignee: Oiles Corporation
    Inventors: Kouhei Kurose, Toshihiko Shimura, Osamu Miyashita
  • Patent number: 9132589
    Abstract: A method for producing a curved profile from a rectilinear preform of preimpregnated fiber webs, including stacking webs on the deformable mandrel and winding the deformable mandrel and the stacked webs on a bending tool along an axis of rotation (X), the profile including a stack of N webs, at least one first part of the profile being positioned in a plane perpendicular to the axis of rotation (X) and at least one second part parallel to the axis (X) whereof a face can be in contact with the bending tool. The method includes stacking the N fiber webs on the deformable mandrel, generating a heat gradient between the face and the rest of the preform that is hotter than the face, bending, in a single phase, the N webs inserted between the deformable mandrel and the bending tool, and polymerizing the N bent webs.
    Type: Grant
    Filed: April 22, 2013
    Date of Patent: September 15, 2015
    Assignee: AIRBUS OPERATIONS SAS
    Inventor: Denis De Mattia
  • Patent number: 9120518
    Abstract: A seat post for a frame, the seat post comprising, a tubular section having a circumference; the tubular section including one or more slots; and the one or more slots extending through a portion of the circumference of the tubular section.
    Type: Grant
    Filed: June 25, 2012
    Date of Patent: September 1, 2015
    Inventor: Lars Janssen
  • Patent number: 9120250
    Abstract: A structure such as a containment case (2) for a gas turbine engine (1) comprises an annular housing (3) made of composite material. A sleeve-like flange unit (4) is fitted onto an end of the housing (3) and is mechanically joined thereto by a first portion (31, 32, 33) of the composite material of the housing which projects into a recess (411) of the flange unit (4). This reduces or eliminates the need to use mechanical fasteners to connect the housing (3) to the flange unit (4).
    Type: Grant
    Filed: October 6, 2011
    Date of Patent: September 1, 2015
    Assignee: GKN Aerospace Services Limited
    Inventor: Gary Wiles
  • Patent number: 9056428
    Abstract: A method having the following steps: feeding a plastic material in the area of an inner surface of the mold, conforming the material to the inner surface of the mold, feeding a tubular film into the mold so that the material is positioned between an outer surface of the tubular film and the mold, expanding the tubular film using pressure and/or a vacuum, applying a pressure above atmospheric pressure and/or heating the mold so that the material is partly or completely melted and is adapted to conform to an inner contour of the mold and an outer contour of the expanded tubular film. The tubular film is shaped before it is fed into the mold. The invention further relates to a tubular film (1) and a method for manufacturing the same.
    Type: Grant
    Filed: September 29, 2009
    Date of Patent: June 16, 2015
    Assignee: Airbus Helicopters Deutschland GmbH
    Inventor: Sven Meyer-Noack
  • Patent number: 9050769
    Abstract: A pre-form CMC cavity and method of forming pre-form CMC cavity for a ceramic matrix component includes providing a mandrel, applying a base ply to the mandrel, laying-up at least one CMC ply on the base ply, removing the mandrel, and densifying the base ply and the at least one CMC ply. The remaining densified base ply and at least one CMC ply form a ceramic matrix component having a desired geometry and a cavity formed therein. Also provided is a method of forming a CMC component.
    Type: Grant
    Filed: April 13, 2012
    Date of Patent: June 9, 2015
    Assignee: General Electric Company
    Inventors: Philip Harold Monaghan, John McConnell Delvaux, Glenn Curtis Taxacher
  • Publication number: 20150145182
    Abstract: A method of press moulding a moulding material to form a moulded part of fibre-reinforced resin matrix composite material, the method comprising the steps of: i. providing a mould tool having a lower mould part and an upper mould part, the upper mould part having a first moulding surface for moulding a first moulded surface of the moulded part and the lower mould part having a second moulding surface for moulding a second moulded surface of the moulded part; ii. providing a multilaminar panel of moulding material comprising at least one layer of fibres and at least one layer of resin, the multilaminar panel having first and second opposite major surfaces, a surface resin layer of the multilaminar panel being at or adjacent to the first major surface and a dry fibre layer of the multilaminar panel forming the second major surface; iii.
    Type: Application
    Filed: May 30, 2013
    Publication date: May 28, 2015
    Applicant: Gurit (UK) Ltd.
    Inventors: Daniel Thomas Jones, Stephen Patrick Main, Martin James Starkey, Peter Jennings, Gregory Aratoon
  • Publication number: 20150145159
    Abstract: A method of press moulding a moulding material to form a vehicle body panel of fibre-reinforced resin matrix composite material, the vehicle body panel having a front A-surface and a rear B-surface, the method comprising the steps of: i. providing a heated mould tool having a lower mould part and an upper mould part, the upper mould part having a first moulding surface for moulding a front A-surface of the vehicle body panel and the lower mould part having a second moulding surface for moulding a rear B-surface of the vehicle body panel; ii. providing a multilaminar panel of moulding material comprising at least one layer of fibres and at least one layer of resin, the multilaminar panel having first and second opposite major surfaces, a surface resin layer of the multilaminar panel being at or adjacent to the first major surface; iii. locating the moulding material in the mould tool; iv. closing the mould tool to define a substantially closed mould cavity containing the moulding material; v.
    Type: Application
    Filed: May 30, 2013
    Publication date: May 28, 2015
    Inventors: Daniel Thomas Jones, Stephen Patrick Main, Martin James Starkey, Peter Jennings, Gregory Aratoon
  • Publication number: 20150145160
    Abstract: A method of press moulding a moulding material to form a moulded part of fibre-reinforced resin matrix composite material, the method comprising the steps of: i. providing a mould tool having a lower mould part and an upper mould part, the upper mould part having a first moulding surface for moulding a first moulded surface of the moulded part and the lower mould part having a second moulding surface for moulding a second moulded surface of the moulded part; ii. providing a multilaminar panel of moulding material comprising at least one layer of dry fibres and at least one layer of resin, the multilaminar panel having first and second opposite major surfaces; iii. locating the moulding material in the mould tool; iv.
    Type: Application
    Filed: May 30, 2013
    Publication date: May 28, 2015
    Applicant: Gurit (UK) Ltd.
    Inventors: Daniel Thomas Jones, Stephen Patrick Main, Martin James Starkey, Peter Jennings, Gregory Aratoon
  • Publication number: 20150130105
    Abstract: A method of making a sandwich-type, compression-molded, composite component having improved surface appearance is provided. Reinforced thermoplastic skins, first and second sheets of thermoplastic adhesive and a cellulose-based core of a blank or stack of sandwich materials are heated to a softening temperature of the thermoplastics. The heated blank or stack is allowed to cool in the mold cavity until inner surfaces of the skins are bonded to top and bottom surfaces of the core by the sheets to seal core cavities. Air in the sealed cavities urges softened portions of the sheets and portions of the core inwardly towards the cavities of the core as the air in the cavities cools to inhibit debossing and improve surface appearance of a first outer surface of the blank or stack.
    Type: Application
    Filed: January 23, 2015
    Publication date: May 14, 2015
    Inventors: Darius J. Preisler, Christopher A. Heikkila
  • Publication number: 20150130109
    Abstract: A method for producing a textile preform includes manufacturing a multi-layer fiber fabric, which includes a first flange portion and a web portion connected to the first flange portion, deforming a first fiber layer of the first flange portion with respect to the web portion, such that the first fiber layer is at a first flange portion angle to the web portion, a web height of the web portion being set in a variable manner during the deformation of the first fiber layer, and depositing a unidirectional fiber fabric only on the deformed first fiber layer of the first flange portion.
    Type: Application
    Filed: October 10, 2014
    Publication date: May 14, 2015
    Inventors: Tassilo Witte, Alexander Gillessen, Jan Huelnhagen
  • Patent number: 9023265
    Abstract: Tools for forming a corrugated structure from a pliable blank include a plurality of forming blocks that laterally move relative to each other, a compaction mechanism configured to selectively conform the pliable blank to the forming blocks, and a block translating mechanism configured to reconfigure the tool from a pre-formed configuration to a post-formed configuration, in which the forming blocks are positioned closer together than when the tool is in the pre-formed configuration. Associated systems, methods, and apparatuses also are disclosed herein.
    Type: Grant
    Filed: January 28, 2013
    Date of Patent: May 5, 2015
    Assignee: The Boeing Company
    Inventors: Daniel M. Rotter, Brian G. Robins, Kurtis S. Willden, Stephen Lee Metschan, Brad Andrew Coxon, Stephen Keith Kirchmeier, Joseph D. Anderson
  • Patent number: 9011748
    Abstract: A die for producing pressed, fiber-reinforced plastic components, as well as a method for producing the plastic component, and the plastic component itself. The plastic components comprising at least two structural parts which overlap one another a pressing direction such that the die comprises at least one upper die portion formed with a pressing unit for applying a pressing force in the pressing direction, and at least one lower die portion which cooperates with the upper die portion to form a cavity in which the plastic component is formed. A die insert is fitted in the die and can move by and with the upper die portion and is designed to transmit the pressing force to the at least one structural part of the plastic component which is overlapped by the other structural part of the plastic component in the pressing direction.
    Type: Grant
    Filed: May 22, 2012
    Date of Patent: April 21, 2015
    Assignee: ZF Friedrichshafen AG
    Inventors: Thomas Eifflaender, Daniel Wolf, Jens Heimann
  • Patent number: 9005382
    Abstract: A method for forming a ceramic matrix composite (CMC) component for gas turbine engines. The method contemplates replacing a plurality of plies with insert material. The insert material can be partially cured or pre-cured and applied in place of a plurality of small plies or it may be inserted into cavities of a component in the form of a paste or a ply. The insert material is isotropic, being formed of a combination of matrix material and chopped fibers, tow, cut plies or combinations thereof. The use of the insert material allows for features such as thin edges (650) with thicknesses of less than about 0.030 inches and small radii such as found in corners (680, 710). The CMC components of the present invention replace small ply inserts cut to size to fit into areas of contour change or thickness change, and replace the small ply inserts with a fabricated single piece discontinuously reinforced composite insert, resulting in fewer defects, such as wrinkles, and better dimensional control.
    Type: Grant
    Filed: September 4, 2009
    Date of Patent: April 14, 2015
    Assignee: General Electric Company
    Inventors: James Dale Steibel, Douglas Melton Carper, Suresh Subramanian, Stephen Mark Whiteker
  • Patent number: 8999216
    Abstract: A method of manufacturing a component by molding is provided. A mold has a mold surface representing a negative image of the component. The mold has openings in the mold surface. Flow channels extending from the openings in the mold surface and are connectable to a suction device. Further, the mold has a periphery delimiting the mold surface. A bag is fixed to the periphery of the mold. The bag is inflated to a pressure level above ambient pressure. The pressure is released from the bag while sucking the bag to the mold surface using the suction device. Fabrics are layered onto the bag while the bag is kept sucked to the mold surface. Resin is introduced into the fabrics and then the resin is cured.
    Type: Grant
    Filed: March 11, 2013
    Date of Patent: April 7, 2015
    Assignee: Siemens Aktiengesellschaft
    Inventors: Soeren Oemann Lind, Finn Daugaard Madsen, Jason Stege
  • Publication number: 20150090524
    Abstract: The present disclosure is related to a method for producing a cellular panel which includes a cellular structure sandwiched between first and second stiff skins. The method includes the following steps: preparing at least two blocks of cellular material; disposing the two blocks on a base ply of dry fabric, while maintaining a space between the two blocks; folding the base ply around the two blocks so as to envelop the two blocks; filling in the space with a reinforcing ply; covering the base ply with a covering ply, on a side where the reinforcing ply has been introduced; injecting resin to an assembly obtained in the previous step; and curing the assembly.
    Type: Application
    Filed: December 11, 2014
    Publication date: April 2, 2015
    Inventors: Didier LERETOUR, Alain ROUSSEL, Xavier DUPONT
  • Patent number: 8992813
    Abstract: A component made of at least one thermoformable material, having a first layer made of a first material, a second layer made of a second material, and a third layer made of the first material. The three layers form a sheet, which is formed to various shapes, depending upon the part that is to be created. The sheet may be formed to produce the bumper of an automobile, a door panel for an automobile, a flotation device, such as a pontoon for a pontoon boat, or the like. The first and third layers are SMC, and the second layer, or “core,” is disposed between the first and third layers, allowing the strength of the first and third layers to be used more efficiently, compared to a sheet having only the first and third layers, and no core.
    Type: Grant
    Filed: December 20, 2010
    Date of Patent: March 31, 2015
    Assignee: Magna International Inc.
    Inventors: Jeffrey R. Robbins, Jeremy Alan Panasiewicz, Louis Dodyk
  • Patent number: 8980152
    Abstract: A method of manufacturing a wing structure includes laying a plurality of layers of preimpregnated material on a first mould half and on a second mold half so as to form a first fresh skin and a second fresh skin of the wing structure. A plurality of layers of preimpregnated material are laid in succession on a shaped apparatus to form a fresh leading edge skin of the wing structure. Fresh spars of preimpregnated material are formed. A wedgelike body of expanded plastics material is formed, this body being designed to be interposed between the first and second skins at the trailing edge of the wing structure. The fresh spars are positioned in a coordinated way on the first fresh skin, removable support members also positioned next to the spars. The second mold half is turned over on to the first mold half so as to position the second fresh skin on the spars and the supports, to produce a fresh wing structure. The fresh wing structure is subjected to a polymerization cycle, using a vacuum bag.
    Type: Grant
    Filed: June 30, 2008
    Date of Patent: March 17, 2015
    Assignee: Alenia Aeronautica S.p.A.
    Inventors: Vincenzo De Vita, Sabato Inserra Imparato, Giovanni Lanfranco, Nicola Miani, Giovanni Sagnella, Massimo Riccio
  • Patent number: 8973871
    Abstract: There is provided a box structure for carrying load having upper and lower composite integrated sandwich panels. The panels have facesheets sandwiching one or more core portions and adjacent dense packs oriented in an axial direction. The box structure further has a plurality of spars. Each spar has a web and web attachments and has a spar length in the axial direction. The plurality of spars are connected to the panels with the web attachments located at the dense packs. The facesheets are configured to carry primarily torsion and pressure loads in shear and no significant axial loads. The dense packs are configured to carry all significant box bending in axial tension and compression loads.
    Type: Grant
    Filed: January 26, 2013
    Date of Patent: March 10, 2015
    Assignee: The Boeing Company
    Inventors: Jeffery L. Marcoe, Paul S. Nordman, Stephen T. Brown, William G. Roeseler, Terry K. Isomura, Willard N. Westre
  • Patent number: 8968617
    Abstract: A resin flow-controlling apparatus for infusing composite reinforcement material with resin. The resin flow-controlling apparatus may have at least one viscosity valve to speed, slow, allow, or deny resin flow through the viscosity valve to the composite reinforcement material depending on the temperature of the viscosity valve. The viscosity valve may fluidly couple a resin reservoir with an enclosed chamber in which the composite reinforcement material resides. The viscosity valve may be thermally coupled with heating and/or cooling elements selectively variable between at least two different temperatures to affect viscosity of the resin and control resin flow from the resin reservoir into the composite reinforcement material. A vacuum port at an opposite end of the composite reinforcement material from the viscosity valve may fluidly couple with the enclosed chamber and a vacuum source may pull atmosphere and/or resin from the enclosed chamber and/or the resin reservoir.
    Type: Grant
    Filed: November 12, 2012
    Date of Patent: March 3, 2015
    Assignee: Spirit AeroSystems, Inc.
    Inventors: Mark A. Wadsworth, Adrienne M. Strohmeyer, Khai Nguyen
  • Publication number: 20150056430
    Abstract: This method includes the arrangement of a first sheet (22A) of porous material on a first face (18) of a base layer and of a second sheet (22B) of porous material of a second face (20) of the base layer before a heating step. Each sheet (22A, 22B) of porous material has a thickness of less than that of the formed layer (16). The sheets (22A, 22B) of porous material confine between them the molten polymeric material derived from the heat fusible polymer fibers during the heating step. The sheets (22A, 22B) of porous material are bound to the formed layer (16) after the step for building up the formed layer (16), in order to make up a first composite body (12A).
    Type: Application
    Filed: March 5, 2013
    Publication date: February 26, 2015
    Inventors: Stève Jeunesse, Valérie Marcel
  • Publication number: 20150048539
    Abstract: A xylylenediamine-based polyamide resin/fiber composite material and molding are provided that do not exhibit a decline in properties under high temperatures and high humidities, and that exhibit a high elastic modulus and present little warping, and exhibit better recycle characteristics, a better moldability, and a better productivity than for thermosetting resins. The polyamide resin-type composite material comprises a fibrous material (B) impregnated with a polyamide resin (A) wherein at least 50 mole % of diamine structural units derived from xylylenediamine, and having a number-average molecular weight (Mn) of 6,000 to 30,000, and containing a component of a molecular weight of not more than 1,000 at 0.5 to 5 mass %.
    Type: Application
    Filed: October 30, 2014
    Publication date: February 19, 2015
    Applicant: Mitsubishi Gas Chemical Company, Inc.
    Inventor: Jun MITADERA
  • Publication number: 20150040749
    Abstract: A method of making a ballistic resistant composite material having improved resistance to high energy rifle bullets and the like. The method comprises providing at least one fibrous layer comprising a network of high tenacity aramid fibers. The fibrous layer is coated with a thermoplastic polyurethane resin. The coated fibrous layer is molded at a pressure of at least about 1,500 psi (10.3 MPa). Preferably, a plurality of fibrous layers are employed, each of which is formed from to unidirectionally oriented aramid fibers in a thermoplastic polyurethane resin matrix. Adjacent fibrous layers are preferably oriented at 90° with respect to each other.
    Type: Application
    Filed: March 14, 2014
    Publication date: February 12, 2015
    Applicant: HONEYWELL INTERNATIONAL INC.
    Inventors: ASHOK BHATNAGAR, LORI L. WAGNER, DAVID A. HURST, BRIAN D. ARVIDSON
  • Publication number: 20150030803
    Abstract: A composite laminate has a pattern of holes therein. The holes are formed by laying down plies of unidirectional pre-preg material having varying fiber orientations. The tows are spaced apart and located to form holes through the laminate.
    Type: Application
    Filed: July 29, 2013
    Publication date: January 29, 2015
    Applicant: THE BOEING COMPANY
    Inventors: Geoffrey Allen Butler, Brice A. Johnson, Jessica R. Hughes, Justin Honshune Lan
  • Publication number: 20150028520
    Abstract: A method for making a female member of a hook-and-loop fastener includes the steps of: (a) bonding together a base layer and a surface layer, that is formed from a fiber material and that is superimposed on the base layer, by applying heat to the surface layer so that fibers of the surface layer are curled; and (b) immediately after step (a), subjecting the surface layer to a rapid cooling treatment so as to set the curled fibers of the surface layer.
    Type: Application
    Filed: March 21, 2014
    Publication date: January 29, 2015
    Applicant: KANG NA HSIUNG ENTERPRISE CO., LTD.
    Inventors: Jung-Chi Tai, Ho-Hsi Yang, Chien-Chung Su
  • Publication number: 20150031818
    Abstract: A method of manufacturing a moulded article and a moulding material suitable therefor comprising the steps of providing a moulding material comprising a fibrous reinforcement material, a first resin material and a second resin material, the first resin material being at least partially processed; providing the moulding material in relation to a mould to form a moulding; and processing the moulding to form the moulded article by providing energy input to the moulding. The energy input for processing the moulding to form the moulded article is less than the energy input required for processing the moulded article from a moulding.
    Type: Application
    Filed: May 17, 2012
    Publication date: January 29, 2015
    Applicant: HEXCEL HOLDING GMBH
    Inventors: Johannes Moser, Uwe Karner, Pascal Perrillat-Collomb