MANUFACTURING METHOD FOR TRUMPET SPAR AND OTHER CURVED OBJECTS

• US 20080048359A1
• Filed: 10/04/2006
• Published: 02/28/2008
• Est. Priority Date: 10/17/2005
• Status: Active Grant

• Current Assignee: Saab AB
• Original Assignee: Saab AB
• Inventors: Turesson, Ingemar, Westerdahl, Anders, Petersson, Mikael, Krogager, Max, Weidmann, Bjorn, Vaara, Jan
• Granted Patent: US 8,871,126 B2
• Time in Patent Office: Days
• US Class Current: 264/241
• 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 70/34 and shaping or impregnating by compression , i.e. combined with compressing after the lay-up operation
• CPC Class Codes: B29C 70/342 using isostatic pressure
• 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: B29D 99/0003 Producing profiled members, e.g. beams
• CPC Class Codes: B29L 2031/3085 Wings
• CPC Class Codes: B32B 27/04 as impregnant, bonding, or embedding substance not used
• CPC Class Codes: B32B 37/0015 to avoid warp or curl
• CPC Class Codes: B32B 38/1808 characterised by the laying up of the layers
• CPC Class Codes: B32B 38/1841 during laying up
• CPC Class Codes: B32B 38/1866 conforming the layers or laminate to a convex or concave profile
• CPC Class Codes: Y10T 156/1051 by folding
• CPC Class Codes: Y10T 156/1092 All laminae planar and face to face
• CPC Class Codes: Y10T 428/31504 Composite [nonstructural laminate]

Abstract

A method for producing an object of composite material comprising the steps of:

• • placing one or several prepregs on a plane surface, forming a fibre stack;
  • lifting over the fibre stack to a moulding tool;
  • downforming the fibre stack;
  • curing the downformed fibre stack; where the method also comprises the step of:
  • orienting the fibre directions so that all fibres, when the fibre stack is lifted over to the moulding tool, will cross an edge of the moulding tool only once.

Claims

1. A method for producing an object of composite material comprising the steps of:

providing a moulding tool;

placing one or several prepregs on the moulding tool, forming a fibre stack;

downforming the fibre stack;

curing the downformed fibre stack;

wherein said method further comprises the step of;

orienting the fibre directions of the prepregs in the fibre stack in such a way that none of the fibre directions of said prepregs occur parallel with a curve of said moulding tool.

2. A method according to claim 1, further comprising the step of orienting the fibre directions of the prepregs so that the difference between a critical fibre direction, i.e. the fibre direction being most parallel with the curve, and the curve, is such that a following downforming may be carried out in a simple manner by means of conventional downforming methods.

3. A method according to claim 1, further comprising the step of orienting the fibre directions of the prepregs so that the difference between some fibre direction in the stack and a curve of said tool is between zero and 90 degrees.

4. A method according to claim 2, further comprising the step of orienting the fibre directions of the prepregs so that the difference between some fibre direction in the stack and a curve of said tool is between 5 and 85 degrees.

5. A method according to claim 3, further comprising the step of orienting the fibre directions of the prepregs so that the difference between some fibre direction in the stack and a curve of said tool is between zero and 45 degrees, or between 5 and 40 degrees, or between 10 and 35 degrees.

6. A method according to claim 5, further comprising the step of orienting the fibre directions of the prepregs so that the difference between some fibre direction in the stack and a curve of said tool is between zero and 22.5 degrees, or between 5 and 17.5 degrees, or between 10 and 12.5 degrees.

7. A method for producing an object of composite material comprising the the steps of:

providing a moulding tool;

placing one or several prepregs on the moulding tool, forming a fibre stack;

downforming the fibre stack;

curing the downformed fibre stack;

wherein said method further comprises the step of;

choosing fibre directions for the prepregs to deviate from each direction that can be formed by binding two points on the edge 106 together, which points lack moulding tool in between.

8. A method for producing an object of composite material comprising the steps of:

placing one or several prepregs on a plane surface, forming a fibre stack;

lifting over the fibre stack to a moulding tool;

downforming the fibre stack;

curing the downformed fibre stack;

wherein the method further comprising the step of;

orienting the fibre directions so that all fibres, when the fibre stack is lifted over to the moulding tool, will cross an edge of the moulding tool only once.

9. An object manufactured by means of a method for producing an object of composite material comprising the steps of:

providing a moulding tool;

placing one or several prepregs on the moulding tool, forming a fibre stack;

downforming the fibre stack;

curing the downformed fibre stack;

wherein said method further comprises the step of;

orienting the fibre directions of the prepregs in the fibre stack in such a way that none of the fibre directions of said prepregs occur parallel with a curve of said moulding tool.

10. An object manufactured by means of a method for producing an object of composite material comprising the the steps of:

providing a moulding tool;

placing one or several prepregs on the moulding tool, forming a fibre stack;

downforming the fibre stack;

curing the downformed fibre stack;

wherein said method further comprises the step of;

choosing fibre directions for the prepregs to deviate from each direction that can be formed by binding two points on the edge 106 together, which points lack moulding tool in between.

11. An object manufactured by means of a method for producing an object of composite material comprising the steps of:

placing one or several prepregs on a plane surface, forming a fibre stack;

lifting over the fibre stack to a moulding tool;

downforming the fibre stack;

curing the downformed fibre stack;

wherein the method further comprising the step of;

orienting the fibre directions so that all fibres, when the fibre stack is lifted over to the moulding tool, will cross an edge of the moulding tool only once.