Method For Fabricating A Curved Beam From Composite Material

• US 20060216480A1
• Filed: 12/01/2005
• Published: 09/28/2006
• Est. Priority Date: 12/06/2004
• Status: Active Grant

• Current Assignee: Saab AB
• Original Assignee: Saab AB
• Inventors: Petersson, Mikael, Rudqvist, Claes, Krogager, Max, Weidmann, Bjorn
• Granted Patent: US 7,670,525 B2
• Time in Patent Office: Days
• US Class Current: 428/174
• CPC Class Codes: B29C 70/32 on a rotating mould, former or core
• CPC Class Codes: B29C 70/38 Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns application heads for tyres B29D30/28
• CPC Class Codes: B29C 70/386 Automated tape laying [ATL]
• CPC Class Codes: B29C 70/541 Positioning reinforcements in a mould, e.g. using clamping means for the reinforcement positioning inserts in moulds B29C33/12; lay-up on a mould B29C70/30
• CPC Class Codes: Y02T 50/40 Weight reduction
• CPC Class Codes: Y10T 156/1036 Bending of one piece blank and joining edges to form article
• CPC Class Codes: Y10T 156/1043 Subsequent to assembly
• CPC Class Codes: Y10T 428/24124 Fibers
• CPC Class Codes: Y10T 428/24628 Nonplanar uniform thickness material

Abstract

This invention concerns a method for fabricating a curved beam from fiber composite material. A flat fiber composite laminate (2) comprising a plurality of layers and at least two different fiber directions is formed. The fiber composite laminate (2) is disposed in contact with a male tool (1) comprised of a first flange (1a), a second flange (1c) and an intermediate web (1b), which male tool (1) is curved in its longitudinal direction with a radius of curvature R in such a way that the first flange (1a) has a shorter longitudinal extent than the second flange (1c). The fiber composite laminate (2) is brought into contact with and secured to the first flange (1a) of the male tool (1). The male tool (1) and the fiber composite laminate (2) are then rotated relative to one another so that the fiber composite laminate (2) is brought into contact with the intermediate web (1b) of the male tool (1) in a first rotational movement, and brought into contact with the second flange (1c) of the male tool (1) in a second rotational movement. The fiber composite laminate (2) hardens on the male tool (1), and the finished beam is separated from the tool (1). The invention also relates to a beam of fiber composite material fabricated according to the method.

Claims

1. A method for fabricating a curved beam from fiber composite material, comprising the steps of:

forming a flat fiber composite laminate (2) comprised of a plurality of layers and at least two different fiber directions,

arranging the fiber composite laminate (2) against a male tool (1) comprised of a first flange (1a), a second flange (1c) and an intermediate web (1b), wherein the male tool (1) is curved in its longitudinal direction with a radius of curvature R in such a way that the first flange (1a) has a shorter longitudinal extent than the second flange (1c),

applying and securing the fiber composite laminate (2) to the first flange (1a) of the male tool (1),

rotating the male tool (1) and the fiber composite laminate (2) relative to one another so that the fiber composite laminate (2) is brought into contact with the intermediate web (1b) of the male tool (1) in a first rotational movement, and brought into contact with the second flange (1c) of the male tool (1) in a second rotational movement,

hardening the fiber composite laminate (2) on the male tool (1), and

separating the finished beam from the male tool (1).

2. A method according to claim 1, wherein the fiber composite laminate (2) is stretched over the intermediate web (1b) during the first rotational movement so that the fiber density per unit of area becomes lower in the portion of the fiber composite laminate (2) that is arranged in contact with the second flange (1c) than in the portion of the fiber composite laminate (2) that is arranged in contact with the first flange (1a).

3. A method according to claim 1, wherein the flat fiber composite laminate (2) is laid up in equipment for automatic tape lay-up.

4. A method according to claim 1, wherein the curved beam is shaped as a C-beam.

5. A method according to claim 1, wherein the curved beam is shaped as a Z-beam.

6. A method according to claim 1, wherein the curved beam is shaped in a hat shape.

7. A method according to claim 1, wherein the curved beam is shaped as an I-beam.

8. A beam of fiber composite material fabricated according to a method comprising the steps of:

forming a flat fiber composite laminate (2) comprised of a plurality of layers and at least two different fiber directions,

arranging the fiber composite laminate (2) against a male tool (1) comprised of a first flange (1a), a second flange (1c) and an intermediate web (1b), wherein the male tool (1) is curved in its longitudinal direction with a radius of curvature R in such a way that the first flange (1a) has a shorter longitudinal extent than the second flange (1c),

applying and securing the fiber composite laminate (2) to the first flange (1a) of the male tool (1),

rotating the male tool (1) and the fiber composite laminate (2) relative to one another so that the fiber composite laminate (2) is brought into contact with the intermediate web (1b) of the male tool (1) in a first rotational movement, and brought into contact with the second flange (1c) of the male tool (1) in a second rotational movement,

hardening the fiber composite laminate (2) on the male tool (1), and

separating the finished beam from the male tool (1).

9. A beam according to claim 8 that has a curve corresponding to a part of an airplane fuselage and is included in a support structure for said part of the airplane fuselage.