Joining A Plurality Of Superposed Fibrous Or Textile Layers Patents (Class 264/258)
  • Publication number: 20130137340
    Abstract: There is provided an underwire for a brassiere. In a first embodiment, the underwire is made of two or more different materials. In a second embodiment, one end of the underwire is tapered. A method of manufacturing the underwire and a mold for manufacturing the underwire are also provided.
    Type: Application
    Filed: November 29, 2011
    Publication date: May 30, 2013
    Inventor: Zhenqiang Liu
  • Patent number: 8449709
    Abstract: Fiber reinforced composite structures having curved stepped surfaces are fabricated by laying up plies of fiber reinforced material over a tool having a stepped tool feature. The plies are rotated about a fixed axis as they are laid up to substantially form a fixed axis rosette pattern. The plies are angularly oriented such that at least certain of the plies have fiber orientations other than 0, +45, ?45 and 90 degrees. Potential bridging of the fibers over the stepped tool features is reduced or eliminated by cutting slits in the plies in the area of the stepped features, so that the plies can be fully compacted.
    Type: Grant
    Filed: May 25, 2007
    Date of Patent: May 28, 2013
    Assignee: The Boeing Company
    Inventors: Andrew E. Modin, Jack A. Woods, Robert D. Hawkins
  • Publication number: 20130130846
    Abstract: A composite sporting implement, such as a ball bat or bat barrel, is formed with layers of continuous structural fibers embedded in a binder material having a high melting point. Such a binder does not undergo a chemical conversion process during forming of the ball bat. The layers are shaped into a preform and placed in a mold. Heat and pressure are applied to bring the binder to its melting point and to cause the binder material to flow between adjacent layers. The mold is then cooled below the binder's melting point to solidify the composite structure. A composite sporting implement formed in this manner exhibits excellent shear strength, toughness, and damping qualities.
    Type: Application
    Filed: November 22, 2011
    Publication date: May 23, 2013
    Inventor: William B. Giannetti
  • Patent number: 8444900
    Abstract: A method and system for fabricating a geometrically versatile composite lattice support structure having a seamless three-dimensional configuration. The lattice support structure is created by forming two or more cross supports, such as helical, longitudinal, circumferential and/or lateral cross supports, which intersect to form a plurality of multi-layered nodes. The lattice support structure may be designed without any protrusions extending outward from the overall geometry, thus enabling efficient tooling, and thus enabling ease of mass production. The lattice support structure may comprise a completely circumferentially closed geometry, such as a cylinder, ellipse, airfoil, etc. The method for fabricating the lattice support structure comprises laying up a fiber material, in the presence of resin, within rigid channels of a rigid mold, thus creating a green, uncured three-dimensional geometry of unconsolidated cross supports and multi-layered nodes where these intersect.
    Type: Grant
    Filed: August 17, 2009
    Date of Patent: May 21, 2013
    Assignee: Sigma-Tek, LLC
    Inventors: Erich A. Wilson, Michael D. Kipp, Michael D. Ridges
  • Patent number: 8444792
    Abstract: Method of manufacturing aerogenerator blades that avoids or reduces some formation deficiencies existing in the traditional methods of manufacturing aerogenerator blades. The method comprises: positioning at least one support plate (2) on a plug (3) corresponding to a predetermined shape of at least a portion of the blade; removably fixing the support plate (2) to the plug (3); stacking a plurality of layers (1) of at least one material over the support plate (2); stitching the plurality of layers (1) to the support plate (2); displacing the plurality of layers (1) stitched to the support plate (2) into a mold (4), the mold (4) having a shape corresponding to the counter shape of the plug (3).
    Type: Grant
    Filed: February 26, 2009
    Date of Patent: May 21, 2013
    Assignee: Tecsis Tecnologia E Sistemas Avançados Ltda
    Inventor: Leo Ossanai
  • Patent number: 8425824
    Abstract: An object of the present invention is to provide a process for producing a mixture of a two-liquid mixing type curable resin, which process is hard to generate curing unevenness, can be carried out with low energy consumption, and is suited for mixing even with a disposable static mixer. The present invention provides a process for producing a mixture of a two-liquid mixing type curable resin by mixing the constituents of the resin, wherein mixing operations of the constituents are performed multiple times and a non-mixing time is provided between at least one of the mixing operations and another one of the mixing operations subsequent thereto.
    Type: Grant
    Filed: July 9, 2007
    Date of Patent: April 23, 2013
    Assignee: Asahi Kasei Chemicals Corporation
    Inventors: Yuzuru Ishibashi, Akihiro Watanabe
  • Publication number: 20130095282
    Abstract: A laminated base material includes a lamination and integration of prepreg base materials each of which includes many reinforcing fibers arranged substantially in one direction and a matrix resin adhered to the reinforcing fibers, wherein at least one of the laminated prepreg base materials is formed with a prepreg base material having, throughout its whole surface, many incisions each extending in a direction crossing the reinforcing fibers, substantially all of the reinforcing fibers divided by incisions, and wherein a length L of each of reinforcing fiber segments formed by the incisions is 10 to 100 mm, a thickness H of the prepreg base material is 30 to 300 ?m, and a fiber volume content Vf of the reinforcing fibers is 45 to 65% and arranging directions of the reinforcing fibers between one and another laminated prepreg base materials have at least two directions different each other.
    Type: Application
    Filed: December 7, 2012
    Publication date: April 18, 2013
    Applicant: TORAY INDUSTRIES, INC.
    Inventor: Toray Industries, Inc.
  • Patent number: 8419883
    Abstract: A fiber reinforced core panel is formed from strips of plastics foam helically wound with layers of rovings to form webs which may extend in a wave pattern or may intersect transverse webs. Hollow tubes may replace foam strips. Axial rovings cooperate with overlying helically wound rovings to form a beam or a column. Wound roving patterns may vary along strips for structural efficiency. Wound strips may alternate with spaced strips, and spacers between the strips enhance web buckling strength. Continuously wound rovings between spaced strips permit folding to form panels with reinforced edges. Continuously wound strips are helically wrapped to form annular structures, and composite panels may combine both thermoset and thermoplastic resins. Continuously wound strips or strip sections may be continuously fed either longitudinally or laterally into molding apparatus which may receive skin materials to form reinforced composite panels.
    Type: Grant
    Filed: November 8, 2007
    Date of Patent: April 16, 2013
    Assignee: Milliken & Company
    Inventors: Stephen W. Day, G. Scott Campbell, Danny E. Tilton, Frederick Stoll, Michael Sheppard, Robin Banerjee
  • Patent number: 8409396
    Abstract: A connection between composites with non-compatible properties and a method of preparing of such connections are provided. The composites comprise first and second type fibers, respectively, as well as resin. The connection comprises a transition zone between the composites having a layered structure. The transition zone may optionally comprise a transition member and the transition member may optionally be integrated with one or more of the composites. Examples of non-compatible properties where the present connection will be appreciated are great differences in stiffness, e.g. Young's modulus, or in coefficient of thermal expansion.
    Type: Grant
    Filed: March 4, 2009
    Date of Patent: April 2, 2013
    Assignee: Vestas Wind Systems A/S
    Inventors: Anton Bech, Frank A. Hoelgaard Hahn
  • Patent number: 8398910
    Abstract: A method for manufacturing a fiber-composite component with a cladding field and a primary component for reinforcing the fiber-composite component includes the steps of: applying a prepreg semifinished product to a mold to form the cladding field, where in the prepreg semifinished product fibers extend in some sections in a curved manner according to an assumed flow force path in the cladding field of the component to be manufactured; curing the prepreg semifinished product; applying layers of a semifinished textile product to the cured prepreg semifinished product to form the primary component; impregnating the semifinished textile product with matrix material; and curing the assembly comprising pre-cured prepreg semifinished product and semifinished textile product; a fiber-composite component with at least one structural component and a skin section connected to said structural component with a recess as well as a fiber-composite fuselage component of an aircraft with a shell component with at least one re
    Type: Grant
    Filed: February 9, 2009
    Date of Patent: March 19, 2013
    Assignee: Airbus Operations GmbH
    Inventors: Wolfgang Kastner, Thomas Grauerholz
  • Publication number: 20130064675
    Abstract: The invention concerns a wind power installation rotor blade. The rotor blade has a rotor blade root, a rotor blade tip, a rotor blade leading edge and a rotor blade trailing edge. The rotor blade further has a pressure side and a suction side as well as at least one web at least partially between the suction and pressure sides. The rotor blade has a longitudinal direction between the rotor blade root and the rotor blade tip. The web is of a wave-shaped configuration in the longitudinal direction of the rotor blade.
    Type: Application
    Filed: March 9, 2011
    Publication date: March 14, 2013
    Applicant: WOBBEN PROPERTIES GMBH
    Inventor: Klaus-Peter Jaquemotte
  • Patent number: 8394310
    Abstract: An inflatable compaction tool for consolidating a composite material inside a faceted hollow or tubular mold for a composite part is made from an elastic material. The compaction tool includes relatively flat wall segments conjoined by corner segments that define a sealed chamber. The wall segments curve away from the mold surface toward the midpoint of each wall segment, so that as a pressurized fluid is introduced into the compaction tool, a component of the force exerted on the tool interior surface is transmitted through the wall segments toward the corner segments. Thus, during initial inflation, the corner segments are forced toward the corner regions of the mold before the wall segments contact the composite material, firmly compressing the composite material into the corner regions of the mold before the friction of the wall segments against the composite material inhibits expansion of the corner segments into the mold corner regions.
    Type: Grant
    Filed: October 15, 2010
    Date of Patent: March 12, 2013
    Assignee: The Boeing Company
    Inventors: Steven F. Hanson, Amitabh Vyas
  • Publication number: 20130056900
    Abstract: A leaf spring for a motor vehicle is made from a fiber composite component including individual fibers in form of at least two textile layers stacked on top of each other and a matrix made of a duroplastic or thermoplastic resin surrounding the fibers. The resin is hardened in a mold tool by applying pressure and heat. The stacked textile layers are formed inside a mold tool and fixed by a dry binder applied to at least one of the textile layers to form a dry preform. A fiber composite blank is stamped from the preform and subsequently infiltrated with the resin in a RTM cavity and hardened. The binder applied in dry form may only be arranged in certain areas of the textile layers.
    Type: Application
    Filed: February 27, 2012
    Publication date: March 7, 2013
    Applicant: Benteler SGL GmbH & Co. KG
    Inventor: Ulrich Müller
  • Patent number: 8388787
    Abstract: The invention relates to a method of making a composite sheet. A plurality of layers is first assembled, each layer being comprised of an untreated, unidirectional array of strands. The assembled layers are then placed adjacent one another to form an assembled sheet, with adjacent layers being in a non-parallel orientation, and without any of the layers having been treated with a matrix or binding component. The assembled sheet is then impregnated with a matrix component, which comprises a binding component and may also comprise a radiation-absorbing component.
    Type: Grant
    Filed: July 13, 2010
    Date of Patent: March 5, 2013
    Assignee: Gentex Corporation
    Inventors: Ramesh Kaushal, Leonard Peter Frieder, John LaJesse, Amit Chatterjee
  • Publication number: 20130052443
    Abstract: A method of manufacturing an interior substrate material, e.g., for an automobile includes impregnating a sheet-shaped, nonwoven mat material, which consists of glass fibers, with a urethane-yielding liquid, and heating the mat material impregnated with the urethane-yielding liquid to foam and heat cure the urethane-yielding liquid in the mat material, thereby producing the interior substrate material.
    Type: Application
    Filed: August 8, 2012
    Publication date: February 28, 2013
    Applicant: NAKAGAWA SANGYO CO., LTD.
    Inventor: Noriaki Nakagawa
  • Publication number: 20130039775
    Abstract: The present invention concerns a process for the production of a wind power installation rotor blade. To permit more economical manufacture at high quality the following steps are provided: providing at least one mold, placing a layered fiber composite having at least one core in the mold, wherein the core has a top side with first channel portions and an underside with second channel portions, and connecting portions between the first and second channel portions, and feeding resin, in particular through the first and/or second channel portions, until the layered fiber composite is adequately saturated.
    Type: Application
    Filed: February 18, 2011
    Publication date: February 14, 2013
    Applicant: WOBBEN PROPERTIES GMBH
    Inventors: Sven Muschke, Johannes Kannenberg
  • Patent number: 8372327
    Abstract: A composite fabrication apparatus which may include a first tooling die and a second tooling die movable with respect to each other; a temperature control system having induction coils disposed in thermal contact with the first tooling die and the second tooling die; a first die susceptor provided on the first tooling die and a second die susceptor provided on the second tooling die and connected to the induction coils; and a cooling system disposed in thermal contact with the first tooling die and the second tooling die. A resin transfer system delivers resin from a resin source to the tooling dies to allow resin transfer molding. A composite fabrication method is also disclosed.
    Type: Grant
    Filed: September 21, 2007
    Date of Patent: February 12, 2013
    Assignee: The Boeing Company
    Inventors: Marc R. Matsen, Kim E. Peterson
  • Patent number: 8366981
    Abstract: A composite structure is provided. The structure includes at least one ply of preimpregnated material formed into a curved elongated member of continuous fibers onto a mandrel. The fibers have a select orientation. The curved elongated member has a length and a cross-sectional geometry that varies along the length.
    Type: Grant
    Filed: September 15, 2010
    Date of Patent: February 5, 2013
    Assignee: Alliant Techsystems Inc.
    Inventors: Vernon M. Benson, Jason K. Slack, Todd A. Rosevear, James L. Harvey, Mark Roman, Timothy Olschewski
  • Publication number: 20130029089
    Abstract: Polymer articles are often reinforced by addition of fibers which may be assembled into a structured reinforcement such as a woven mat or sheet and the mat or sheet serves as the reinforcement. Such woven fiber-reinforced polymer composite articles may exhibit undesirable variations in surface height which mimic the geometry of the underlying reinforcements, a phenomenon known as print through. By forming, on the surface of the article, a relatively thin, layer of a compatible polymer incorporating closely-spaced, short, carbon nanotubes more or less uniformly dispersed throughout the layer and oriented normal to the article surface, print through may be reduced or eliminated. Methods for fabricating such an article are detailed.
    Type: Application
    Filed: July 27, 2011
    Publication date: January 31, 2013
    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
    Inventor: Hamid G. Kia
  • Patent number: 8357323
    Abstract: A stitching geometry and method for selective interlaminar reinforcement of a CMC wall (20A). The CMC wall is formed of ceramic fiber layers (22) individually infused with a ceramic matrix, stacked, and at least partially cured. A row of holes is formed in the wall, and a ceramic fiber thread (25) is infused with a wet ceramic matrix and passed through the holes to form stitches (28, 30, 31). The stitches are then cured, causing them to shrink more than any remaining wall shrinkage, thus tensioning the stitches and compressing the wall laminae together. The stitches may have through-wall portions (30, 31) that are angled differently in different wall areas as a function of interlaminar shear over interlaminar tension, optimizing wall reinforcement locally depending on magnitude and direction of shear. Alternate rows of stitches (54, 56) may have offsets in a stitch direction (34) and/or different through-wall angles (A1, A2).
    Type: Grant
    Filed: July 16, 2008
    Date of Patent: January 22, 2013
    Assignee: Siemens Energy, Inc.
    Inventors: Jay A. Morrison, Jay E. Lane
  • Publication number: 20120328887
    Abstract: A method for fabricating an insulated flame retardant panel includes the provision of a mixture of rice hulls and adhesive adhered to one or more skins of the panel with pressure in which the adhesive is either a urethane adhesive or a sodium silicate adhesive that is set by applying pressure, with the rice hulls providing an R value comparable to that associated with expanded polystyrene foam or urethane foam but with significantly improved structural properties and without involving environmentally unfriendly processes.
    Type: Application
    Filed: June 24, 2011
    Publication date: December 27, 2012
    Inventors: Dale Ryan, David Gauthier
  • Patent number: 8337192
    Abstract: A method and apparatus for manufacturing composite components. A tool is present for use in manufacturing composite components. The tool comprises an encapsulation layer having a shape, an insulation layer on the encapsulation layer, and an isolation layer on the insulation layer. The isolation layer has an outer surface capable of contacting a composite material laid up on the outer surface. The insulation layer is capable of insulating the encapsulation layer from heat applied to the composite material. The encapsulation layer is capable of maintaining a shape with the composite material laid up on the isolation layer during a curing process to form a composite component from the composite material.
    Type: Grant
    Filed: January 30, 2008
    Date of Patent: December 25, 2012
    Assignee: The Boeing Company
    Inventor: John M. Griffith
  • Patent number: 8337740
    Abstract: A complex-shaped, three-dimensional fiber reinforced composite structure may be formed by using counteracting pressures applied to a structural lay-up of wetted fibers. The wetted fibers are arranged on pressurizable members and may be configured to include internal structural features, such as shear webs. A reinforcement stiffener may be located adjacent to at least one of the pressurizable members and the wetted fibers that form the internal structural feature. The reinforcement stiffener includes a modulus of elasticity that is substantially higher than a modulus of elasticity of the resin used to wet the fibers. In one embodiment, the reinforcement stiffener may be received in a pocket of one of the pressurizable members and may include a releasing agent that permits removal of the stiffener after the composite structure has been pressurized and cured.
    Type: Grant
    Filed: September 23, 2009
    Date of Patent: December 25, 2012
    Inventor: William L. Rodman
  • Publication number: 20120321480
    Abstract: A plurality of fibre layers is stacked to form a fibre insertion extending in a longitudinal direction of the shell part to be manufactured, whereby a core element having a tapered edge section is arranged along the fibre insertion. The fibre layers are stacked so that the tapered edge section of the core element is wedged into the fibre insertion. The core element is composed by a first and a second core part that are arranged along each other. The first core part forms at least part of the tapered edge section of the core element. The surface of the first core part has a higher permeability to liquid polymer than that of the surface of the second core part so that, during infusion, liquid polymer penetrates the surface of the first core part more readily than it penetrates the surface of the second core part.
    Type: Application
    Filed: June 15, 2012
    Publication date: December 20, 2012
    Applicant: LM WIND POWER A/S
    Inventor: Hanumantha Jois Guru Prasad
  • Patent number: 8333858
    Abstract: A fabrication method of forming curved thermoplastic composite laminate parts with tailored and varying thickness in a continuous process. Automated equipment or hand lay-up are used to collate parts or components into a multi-layer stack. Each stack contains all plies, including ply build-up areas, tacked in the proper location to maintain orientation and location. Ply consolidation tooling contains all necessary part features and is coordinated to the customized multiple ply stacks to form a single integrated thermoplastic composite laminate potentially having areas of differing thickness from the multiple ply stacks.
    Type: Grant
    Filed: October 20, 2006
    Date of Patent: December 18, 2012
    Assignee: The Boeing Company
    Inventors: Alexander M. Rubin, James R. Fox, Randall D. Wilkerson
  • Publication number: 20120315433
    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: Application
    Filed: May 22, 2012
    Publication date: December 13, 2012
    Applicant: ZF FRIEDRICHSHAFEN AG
    Inventors: Thomas EIFFLAENDER, Daniel WOLF, Jens HEIMANN
  • Publication number: 20120315455
    Abstract: A method for manufacturing a preform and a preform manufactured by the method includes a plurality of substrates to which a binder has been affixed laminated to form a laminate and a forming die is used to form the laminate, thereby manufacturing a preform which is a precursor in resin transfer molding (RTM) of fiber reinforced plastic (FRP). During the manufacturing the laminate is pressed into a predetermined shape by the forming die, the binder is melted by directly heating the binder of the substrates in the laminate being pressed or both and is cooled thereafter to solidify the binder, and the substrates are adhered between layers thereof to retain the formed shape of the preform.
    Type: Application
    Filed: December 16, 2010
    Publication date: December 13, 2012
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Masaaki Yamasaki, Toyokazu Hino, Seiji Tsuji
  • Patent number: 8329085
    Abstract: A method of manufacturing a panel made of a composite material using a tool having a support on which a lay-up is performed, the lay-up producing a stack of plies of fiber prepregs, followed by consolidating the stack aiming to obtain the panel using a compacting plate arranged above the stack. The method is implemented such that a first set of polyimide films partially covering each other is located in contact with the stack of plies, between the latter and the compacting plate.
    Type: Grant
    Filed: September 13, 2007
    Date of Patent: December 11, 2012
    Assignee: Airbus Operations SAS
    Inventors: Didier Kurtz, Stephane Pauchet, David Bouvet, Marc Challet
  • Patent number: 8329084
    Abstract: The invention relates to a process for the manufacture of a shaped part comprising the steps of—forming a stack by stacking (2) or more sheets comprising mono-layers of unidirectional anti-ballistic fibers and a binder followed by placing the stack in a mould, clamping the stack in the mould with a control member closing the mould—consolidating the stack under temperature and pressure into a curved shaped part. The invention furthermore relates to products obtainable with said process, which are very suitable for use in anti-ballistic applications and include e.g. helmets, curved panels, cones and domes.
    Type: Grant
    Filed: March 21, 2007
    Date of Patent: December 11, 2012
    Assignee: DSM IP Assets B.V.
    Inventors: Jean H. M. Beugels, William A. C. Roovers, Martin A. Es,Van, Roelof Marissen, Hen Hoefnagels
  • Patent number: 8327738
    Abstract: A composite transmission housing includes resin transfer molding or vacuum assisted resin transfer molding manufacturing processes combined with discontinuous fiber preforms. The preforms are assembled in a prepared injection and cure mold with additional details and fillers. The preforms are constructed such that the preforms are assembled into the mold in a specific order to assure proper arrangement. Using a combination of vacuum and pressure, a resin is injected into the mold to completely infuse the assembled preforms. At completion, the mold is heated to the resin cure temperature and held at this temperature for sufficient time to insure complete cure.
    Type: Grant
    Filed: November 7, 2003
    Date of Patent: December 11, 2012
    Assignee: Sikorsky Aircraft Corporation
    Inventors: Geoffrey Clive Robert Davis, Thomas Arthur Carstensen, Stephen Carter Varanay
  • Patent number: 8329077
    Abstract: The present invention relates to a jig for the manufacture, by means of injection and curing processes, of preforms of composite material frames for aircraft fuselages by using the RTM (resin transfer molding) technology. Two preforms are thus manufactured, one with a C shaped section and another with a L shaped section, together with the preforms of the stabilization ribs for stabilizing the web of the frames and the preform of the roving or staple fiber to cover the gap between the C shaped preform and the L shaped preform. Theses preforms are previously manufactured by any known process for manufacturing preforms. According to a second aspect, the present invention relates to a method of manufacturing composite material load frames for aircraft.
    Type: Grant
    Filed: November 8, 2010
    Date of Patent: December 11, 2012
    Assignee: Airbus Operations S.L.
    Inventors: Jesús Manuel Martín Martín, Ignacio José Márquez López
  • Publication number: 20120308782
    Abstract: A process for producing a molded fiber-reinforced resin by an RTM method includes disposing a molding precursor in a molding cavity of a mold; closing the mold in which the molding precursor is disposed; injecting a heated and pressurized resin into the molding cavity of the mold closed; solidifying the resin injected into the molding cavity; opening the mold after the resin has been solidified; and taking out the molded fiber-reinforced resin from the mold opened.
    Type: Application
    Filed: August 13, 2012
    Publication date: December 6, 2012
    Applicant: TORAY INDUSTRIES, INC.
    Inventors: Masaaki Yamasaki, Toshihide Sekido, Hidehiro Takemoto
  • Publication number: 20120299216
    Abstract: An adhesive adapted to enable spray delivery and seamless polymerization during epoxy resin vacuum infusion techniques.
    Type: Application
    Filed: July 1, 2011
    Publication date: November 29, 2012
    Applicant: WESTECH AEROSOL CORPORATION
    Inventors: David W. Carnahan, Robert R. Yuodelis, James C. Manlove
  • Patent number: 8318067
    Abstract: A resin transfer molding process for an article incorporating a protective insert of polymer material such as polyether ether ketone (PEEK). A piece of PEEK material is cut and thermoformed to the required shape and then placed in position in a mold. A bead of elastomer material is formed around the edge of the insert to seal it against an internal wall of the mold in order to prevent resin tracking between the mold and insert faces during subsequent injection into the mold.
    Type: Grant
    Filed: February 17, 2009
    Date of Patent: November 27, 2012
    Assignee: Rolls-Royce PLC
    Inventors: Quinten J. Northfield, Robert Lewin
  • Patent number: 8303887
    Abstract: A tool for the infusion of a resin into a preform made of fiber material includes a mould which can be closed around the preform and in the body of which at least one inlet duct is formed to allow resin to be injected into the mould so that the resin can be infused into the preform. At least one reservoir which can contain the resin, is also formed in the body of the mould and is connected to the at least one inlet duct. The mould can be inserted in an autoclave and the reservoir is configured to permit the transfer of the resin from the reservoir to the inlet duct under the effect of the temperature and of the pressure that are produced in the autoclave, thus allowing the resin to be injected into the mould.
    Type: Grant
    Filed: October 29, 2008
    Date of Patent: November 6, 2012
    Assignee: Alenia Aeronautica S.p.A.
    Inventors: Vincenzo De Vita, Francesco Beneventi, Marco Raffone
  • Patent number: 8303757
    Abstract: An apparatus to prepare a preform for fabrication includes a mandrel, anchoring groove, anchoring device, tensioning groove, and tensioning device. The mandrel receives the preform. The mandrel has a first mandrel end and a second mandrel end. The preform has a first preform end and a second preform end. The anchoring groove is disposed at the first mandrel end. The anchoring device is configured and located to urge the first preform end towards the anchoring groove to secure the first preform end therebetween. The tensioning groove is disposed between the first mandrel end and the second mandrel end. The tensioning device is configured and located to urge a portion of the preform into the tensioning groove.
    Type: Grant
    Filed: December 4, 2006
    Date of Patent: November 6, 2012
    Assignee: The Boeing Company
    Inventors: Michael L. Glain, David J. Kehrl, Andrew E. Modin, Scott A. Harris, Robert A. Coleman, Andrew Head, Steven C. Stenard, Thomas R. Cundiff, Joo Hyun Han, Timothy D. Aquino
  • Publication number: 20120277706
    Abstract: Absorbent members and methods of making the same are disclosed. In one embodiment, the absorbent member is a unitary absorbent fibrous web having a density profile through its thickness. In one embodiment, the density profile is relatively centered through the thickness of the web and the maximum density of the web is located between about 35% and about 65% of the distance through the thickness of the web. In one embodiment, the method involves subjecting a precursor web to at least one cycle (or pass) through a mechanical deformation process. Typically, the method involves subjecting the precursor web to multiples cycles (or passes) through a mechanical deformation process.
    Type: Application
    Filed: April 26, 2011
    Publication date: November 1, 2012
    Inventors: Luigi Marinelli, Kirk Wallace Lake, Jill Marlene Orr, John Brian Strube, Keith Robert Priessman, Carmine Cimini, Mario Dipilla
  • Publication number: 20120261856
    Abstract: A matched mold curing apparatus defining a molding cavity has two sets of layers of curable, fiber-reinforced, thermosetting composite material laminated on a lower forming tool and upper forming tool. Closed-cell foam core segments are provided and placed adjacent to each other on the layers. The core segments are oversized with respect to the nominal size determined by the molding cavity in the closed condition, minus the thickness of the layers of composite material. A controlled temperature is applied firstly to allow plastic deformation of the core segments, but without closing completely the matched mold. The temperature and pressure are then applied to cause complete closure of the matched mold and curing of the laminated layers.
    Type: Application
    Filed: April 10, 2012
    Publication date: October 18, 2012
    Applicant: ALENIA AERMACCHI S.p.A
    Inventor: Ruggero Pitzolu
  • Patent number: 8287790
    Abstract: A method for manufacturing a hollow load-bearing beam structure of fiber-reinforced composite material. The method includes preparing a first lay-up of a first plurality of layers, and a second lay-up of a second plurality of layers. The first and second lay-ups are positioned on different sides of a mandrel and formed to a beam structure by bending the lay-ups against the mandrel, such that the side edges of the respective layers of the first and second lay-ups are arranged as offset butt joints in the circumferential direction of the formed beam structure.
    Type: Grant
    Filed: October 9, 2008
    Date of Patent: October 16, 2012
    Assignee: SAAB AB
    Inventors: Anders Westerdahl, Ingemar Turesson, Jan-Erik Lindbäck, Mats Folkesson
  • Patent number: 8285407
    Abstract: A computer implemented method, apparatus, and computer usable program code for providing ply lay-up data for a composite part. A designation of a location is received for the composite part in a three dimensional object from a requester. A three dimensional model is opened in which the composite part is located. The ply lay-up data is extracted for a section within the composite part within the three dimensional model to form extracted ply lay-up data for the section. An output file is created containing a drawing of the composite part overlaid with a grid containing the section with the ply lay-up data identifying a ply stacking sequence, an orientation of each ply in the ply stacking sequence, and a material for the each ply in the ply stacking sequence. The output file is returned to the requester.
    Type: Grant
    Filed: August 15, 2008
    Date of Patent: October 9, 2012
    Assignee: The Boeing Company
    Inventors: Jamie A. Kessel, Phillip J. Fisher, Paul J. Shirron, Donald M. Mullins
  • Publication number: 20120248284
    Abstract: The present invention relates to a supporting structure (200) for a nacelle of a jet engine, in particular provided with a thrust reverser device, including at least one base body (201) made of a composite material, characterised in that the base body has a transverse section which is essentially open and provided with at least one reinforcement means.
    Type: Application
    Filed: December 9, 2010
    Publication date: October 4, 2012
    Applicant: AIRCELLE
    Inventors: Alexandre Bellanger, Florent Bouillon, Laurent Dubois
  • Publication number: 20120244323
    Abstract: Components are produced by injecting a thermoplastic melt into a mold, wherein a flat blank of two or more fiber woven or non-crimp fiber fabrics connected at one or both sides thereof with a randomly oriented fiber layer and impregnated with a thermoplastic is heated to above the softening temperature of the thermoplastic, the thus expanded porous blank is laid out adjacent to one of the two inner walls of the mold, the mold is closed, compressing the blank, reopened to a desired width, and thermoplastic melt is injected into the porous core.
    Type: Application
    Filed: August 17, 2010
    Publication date: September 27, 2012
    Applicant: QUADRANT PLASTIC COMPOSITES AG
    Inventor: Harri Dittmar
  • Publication number: 20120234538
    Abstract: Herein disclosed is a frac ball comprising three orthogonal axes x, y, and z; wherein the frac ball has approximately equal strength in each direction of the three axes x, y, and z. In an embodiment, the frac ball comprises a resin. In an embodiment, the frac ball comprises glass fibers or carbon fibers or both. In an embodiment, the frac ball comprises an equal amount of glass fibers in each direction of the x, y, and z axes. In an embodiment, the frac ball comprises glass fibers in the x and y axes and carbon fibers in the z axis. In an embodiment, the frac ball comprises no interlaminar layers. In an embodiment, the frac ball has different diameters. Also disclosed herein are methods of making and using such frac balls.
    Type: Application
    Filed: December 15, 2011
    Publication date: September 20, 2012
    Applicant: General Plastics & Composites, LP
    Inventors: Tracy Martin, Jesus Ignacío Chavez
  • Publication number: 20120238198
    Abstract: A filter element (1), for example a cabin filter for a motor vehicle, includes a pleated fold pack (2), a plastic frame (4) that is molded at least in part to the fold pack (2) supporting pleat profiles (3), and a plastic foam seal (7) that is foamed at least in part onto the plastic frame (4). In a method for producing a corresponding filter element (1), a plastic frame (4) is generated at least in part around a fold pack (2) in a first injection molding process, and subsequently a plastic foam seal (7) is generated at least in part on the plastic frame (4) in a second injection molding process.
    Type: Application
    Filed: May 31, 2012
    Publication date: September 20, 2012
    Applicant: MANN+HUMMEL GMBH
    Inventor: Anton RABANTER
  • Patent number: 8268107
    Abstract: Techniques and apparatus for providing a fly away caul plate are disclosed. In an embodiment, a method for curing a composite structure includes placing a pre-cured caul plate proximate an uncured composite lay-up, the lay-up may or may not include one or more stiffeners extending substantially perpendicular to the lay-up surface, the caul plate including an aperture for receiving the at least one stiffener. A force may be exerted against the caul plate to engage the composite lay-up. Heat and/or pressure may be applied to the composite lay-up to cure the stiffener panel and co-bond the caul plate to the composite lay-up.
    Type: Grant
    Filed: September 21, 2007
    Date of Patent: September 18, 2012
    Assignee: The Boeing Company
    Inventors: Thomas A. Albertson, Karl R. Bernetich, Robert J. Freeman
  • Patent number: 8262979
    Abstract: In accordance with certain embodiments of the present disclosure, a process of forming a prosthetic device is provided. The process includes forming a dispersion of polymeric particles, a fiberizing polymer, and a solvent, the dispersion having a viscosity of at least about 50,000 cPs. A tubular frame is positioned over a tubular polymeric structure. Nanofibers from the dispersion are electrospun onto the tubular frame to form a prosthetic device. The prosthetic device is heated.
    Type: Grant
    Filed: August 9, 2010
    Date of Patent: September 11, 2012
    Assignee: Zeus Industrial Products, Inc.
    Inventors: Bruce L. Anneaux, Robert L. Ballard
  • Patent number: 8257542
    Abstract: A stack of 50 layers of a first pitch-base carbon fiber sheet is formed, two sets of stack each having two second pitch-base carbon fiber sheets stacked therein are fabricated. At this time, the second carbon fiber sheets have a thermal expansion coefficient larger than that of the first carbon fiber sheet. Next, the stack of the first carbon fiber sheet is then held between two sets of stack of the second carbon fiber sheets. The stack of the first and second carbon fiber sheets are then impregnated with an epoxy-base resin composition and the resin is solidified. As a result a prepreg composed of the first and second carbon fiber sheets and the resin component composed of the epoxy-base resin composition is obtained. Thereafter, interconnections and the like are then formed on the prepreg, to thereby complete a multilevel interconnection board.
    Type: Grant
    Filed: October 9, 2009
    Date of Patent: September 4, 2012
    Assignee: Fujitsu Limited
    Inventors: Keishiro Okamoto, Mamoru Kurashina, Tomoyuki Abe
  • Patent number: 8257640
    Abstract: In accordance with certain embodiments of the present disclosure, a process for forming a multilayered electrospun composite is provided. The process includes forming a dispersion of polymeric particles, a fiberizing polymer, and a solvent, the dispersion having a viscosity of at least about 50,000 cPs. Nanofibers from the dispersion are electrospun onto a first ePTFE layer. A second ePTFE layer is applied onto the nanofibers to form a composite structure. The composite structure is heated.
    Type: Grant
    Filed: August 9, 2010
    Date of Patent: September 4, 2012
    Assignee: Zeus Industrial Products, Inc.
    Inventors: Bruce L. Anneaux, Robert L. Ballard, David P. Garner
  • Patent number: 8257631
    Abstract: Machinable composite molds for use in molding composite structures. The mold includes a mold body having a tool surface that is shaped to provide the molded surface of the composite structure. The mold body is made up of at least one mold layer composed of a quasi-isotropic material composed of a plurality of randomly oriented fiber bundles or chips impregnated with a resin. The use of randomly oriented fiber chips allows post-cure machining of the mold body.
    Type: Grant
    Filed: May 30, 2011
    Date of Patent: September 4, 2012
    Assignee: Hexcel Corporation
    Inventor: Richard A. Callis
  • Patent number: 8252134
    Abstract: According to the invention, one or more thermoplastic sheets (NdT: “feuilles thermoplastique” in the original) (2) are applied on a flat or curved tool (13), and strips (NdT: “des bande” in the original) of a polymer are applied and pressed onto the sheets (2). They are maintained by suction pumps (8), the orifices (4) of which open into a closed volume or one substantially delimited by a sealing joint (3) and occupied by a draining fabric (7). The heating treatment concomitant to the deposition to harden or consolidate the prepreg softens the sheets (2), distorts them to the curvature of the tool (13) and incorporates them in the structure of the prepreg. Application to methods of draping parts with composite material.
    Type: Grant
    Filed: February 5, 2008
    Date of Patent: August 28, 2012
    Assignee: European Aeronautic Defence and Space Company-EADS France
    Inventor: Eric Soccard