Method for producing a three-dimensional fiber reinforced ring frame component

• US 20030222371A1
• Filed: 03/10/2003
• Published: 12/04/2003
• Est. Priority Date: 03/08/2002
• Status: Active Grant

• Current Assignee: Airbus Operations GmbH (Airbus SE), Institut Fuer Verbundwerkstoffe GmbH
• Original Assignee: Airbus Deutschland GmbH (Airbus SE), Institut Fuer Verbundwerkstoffe GmbH
• Inventors: Edelmann, Klaus, Weimer, Christian
• Granted Patent: US 7,014,806 B2
• Time in Patent Office: Days
• US Class Current: 264/103
• CPC Class Codes: B29C 70/222 the structure being shaped to form a three dimensional configuration
• CPC Class Codes: B29C 70/30 Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
• CPC Class Codes: B29C 70/543 Fixing the position or configuration of fibrous reinforcements before or during moulding for non-woven fabrics D04H3/08
• CPC Class Codes: B29L 2031/005 for making window frames windows B29L2031/778
• CPC Class Codes: B64C 1/1484 Windows B64C1/1492 takes precedence
• CPC Class Codes: D04C 1/06 Braid or lace serving particular purposes
• CPC Class Codes: D04H 1/4218 Glass fibres
• CPC Class Codes: D04H 1/4242 Carbon fibres
• CPC Class Codes: D04H 1/44 the fleeces or layers being consolidated by mechanical means, e.g. by rolling
• CPC Class Codes: D04H 13/00 Other non-woven fabrics
• CPC Class Codes: D10B 2505/02 Reinforcing materials; Prepregs
• CPC Class Codes: Y02T 50/40 Weight reduction

Abstract

A closed ring fiber reinforced frame structure is produced by first preparing a prepreg. A section of the prepreg is formed into a flange preferably after impregnation by folding the flange section along a folding line. The folding line is formed by securing a deformable or drapable fiber ribbon material, for example by sewing or stitching to a carrier substrate which is preferably also a fiber material. The sewing seam or stitching line becomes the folding line. The ribbon material is so secured to the carrier substrate that the fiber orientation of the ribbon material is uniformly distributed all around a ring component that is formed of the ribbon material on the substrate. The impregnated ring component with its substrate is then cured after the folding of the flange to complete the ring frame structure.

Claims

1. A method for producing a ring prepreg for a closed ring shaped fiber reinforced frame structure, said method comprising the following steps:

a) providing a carrier substrate (1),

b) securing, along a folding line ( ), a deformable fiber material (2) having a given fiber orientation, to said substrate (1) to form a ring component,

c) assuring with said securing that said given fiber orientation remains uniformly distributed all around said ring component, and

d) impregnating said ring component and said carrier substrate with a resin matrix material to form said ring prepreg.

2. The method of claim 1, further comprising using as said carrier substrate and as said fiber material a respective fiber woven or braided fabric.

3. The method of claim 1, further comprising using a fiber fabric circularly woven hose material at least for one of said carrier substrate and said fiber material forming said ring component and flattening said hose material into a ribbon.

4. The method of claim 1, further comprising using a flat sheet or web fiber structure for said carrier substrate (1).

5. The method of claim 1, further comprising using one of glass fiber material and carbon fiber material for said carrier substrate (1) and for said deformable fiber material (2).

6. The method of claim 1, further comprising cutting said carrier substrate (1) to such a size that said carrier substrate will define at least one dimension of said ring shaped fiber reinforced frame structure, when said ring prepreg is used for producing said ring shape fiber reinforced frame structure.

7. The method of claim 1, further comprising deforming, prior to said securing step, said deformable fiber material (2) into a ring shape and then performing said securing step.

8. The method of claim 1, further comprising performing said securing step by sewing or stitching said deformable fiber material (2) to said carrier substrate (1) along said folding line (7).

9. The method of claim 1, further comprising positioning said folding line (7) to extend in parallel between lateral edges of said deformable fiber material (2) for demarking a first radially inner section (2A) and a second radially outer section of said deformable fiber material (2).

10. The method of claim 1, further comprising stitching reinforcing patches (6) to one of said carrier substrate (1) and said deformable fiber material (2).

11. The method of claim 1, further comprising manually laminating said deformable fiber material (2) to said carrier substrate (1).

12. The method of claim 1, further comprising performing said impregnating step by a resin injection operation.

13. The method of claim 1, further comprising performing said impregnating step by a resin film infusion operation.

14. The method of claim 1, further comprising sewing or stitching an additional securing line (5) in parallel to said folding line (7) for securing said carrier substrate and said deformable fiber material (2) to each other along two lines.

15. A method for producing a ring shaped fiber reinforced frame structure having a rim, said method comprising the following steps:

a) forming a ring prepreg having a carrier substrate (1) and a deformable fiber material on said substrate,

b) securing, along a folding line (7), said deformable fiber material (2) having a given fiber orientation, to said substrate (1) to form a ring component,

c) assuring with said securing that said given fiber orientation remains uniformly distributed all around said ring component,

d) impregnating said ring component and including said carrier substrate with a resin matrix material to form said ring prepreg; and

e) folding a section of said deformable fiber material (2) along said folding line out of a plane defined by said carrier substrate (1) to form said rim, and curing said ring-prepreg to finish said ring shaped fiber reinforced frame structure.

16. The method of claim 15, further comprising performing said folding step so that said section of said deformable fiber material extends at an angle to said plane defined by said carrier substrate.

17. The method of claim 16, further comprising performing said folding step so that said section of said deformable fiber material extends at a right angle to said plane defined by said carrier substrate.

18. The method of claim 15, wherein said folding step is performed prior to said impregnating step.

19. The method of claim 15, further comprising securing two ends of said ring component to each other to close the ring component.

20. The method of claim 15, further comprising using a fiber ribbon material or flattened fiber hose material as said deformable fiber material (2).