Method for making fibrous preforms for producing annular parts from a composite material

• US 6,009,605 A
• Filed: 05/22/1998
• Issued: 01/04/2000
• Est. Priority Date: 11/27/1995
• Status: Expired due to Term

• Current Assignee: Hexcel Fabrics SA (Hexcel Corporation), LEXVALL 8, Lexvall Co., Messier-Bugatti-Dowty
• Original Assignee: Societe Nationale D'Etude Et De Construction De Moteurs D'Aviation
• Inventors: Olry, Pierre, Bompard, Bruno, Aucagne, Jean, Coupe, Dominique
• Primary Examiner(s): Vanatta, Amy B.
• Application Number:
  US09/077,128
• Time in Patent Office: 592 Days
• Field of Search: 28/107, 28/109, 28/110, 28/143, 28/108, 28/111, 28/112, 28/113, 28/114, 28/115, 138/124, 138/129, 138/137, 138/141, 138/144
• US Class Current: 28/107
• CPC Class Codes: B29B 11/16 comprising fillers or reinforcement non-woven fabrics per se D04H1/00, D04H3/00
• CPC Class Codes: D04H 18/02 with needles
• CPC Class Codes: D04H 3/105 by needling needling machines D04H18/00
• CPC Class Codes: F16D 65/126 the material being of low mechanical strength, e.g. carbon, beryllium; Torque transmitting members therefor
• CPC Class Codes: F16D 69/023 Composite materials containing carbon and carbon fibres or fibres made of carbonizable material
• CPC Class Codes: F16D 69/026 containing fibres

Abstract

Fiber preforms for use in the manufacture of composite material annular ps are made by winding superposed layers of a strip of cloth (10) of spiral or helical shape comprising substantially helical warp threads and substantially radial weft threads. The mass per unit area of the warp of the helical cloth increases between its inside diameter and its outside diameter, and the layers of the strip of cloth are needled so as to be bonded together by fibers pulled from the yarn of the cloth, the increase in mass per unit area of the warp at least approximately compensating, in terms of density per unit volume of the preform, the decrease in density of the weft between the inside diameter and the outside diameter.

Claims

1. A method of making fiber preforms for manufacturing annular parts made of composite material, the method comprising:

providing a strip of spirally- or helically-shaped cloth having substantially helical warp yarns and substantially radial weft yarns, the mass per unit area of the warp of the helical cloth increasing from an inside diameter to an outside diameter an increase in mass per unit area of the warp at least approximately compensating, in terms of density per unit volume of the preform, a decrease in density of the weft from the inside diameter to the outside diameter;

winding superposed layers of the strip of spirally- or helically-shaped cloth; and

needling the layers of the strip of cloth to bond the layers together by fibers pulled from the yarns of the cloth.

2. A method according to claim 1, wherein in the step of providing the strip of cloth, the cloth is made up at least in part of yarn comprising parallel discontinuous fibers.

3. A method according to claim 2, wherein in the step of providing the strip of cloth, the cloth is constituted at least in part by yarn comprising parallel discontinuous fibers held together by a sacrificial covering yarn, and further comprising the step of eliminating the covering yarn prior to needling.

4. A method according to claim 2, wherein in the step of providing the strip of cloth, the cloth is constituted at least in part by yarn comprising discontinuous fibers held together by a small amount of twisting.

5. A method according to claim 1, wherein in the step of providing the strip of cloth, the size of the warp yarns increases from the inside diameter to the outside diameter.

6. A method according to claim 1, wherein in the step of providing the strip of cloth, the density of the warp yarns increases from the inside diameter to the outside diameter.

7. A method according to claim 1, wherein the needling step is performed with a density of needle strokes per unit area that is substantially constant over the entire surface of the layers of the strip of cloth.

8. A method according to claim 1, wherein the needling step is performed with a set of needles covering a sector extending over the entire width of the strip of cloth.

9. A method according to claim 1, wherein the needling step is performed to a substantially constant depth.

10. A method according to claim 1, wherein the needling step is performed progressively while the strip of cloth is being wound flat.

11. A method according to claim 1, wherein in the step of winding superposed layers of the strip, the strip of cloth is wound around an axis, building up superposed layers that are substantially perpendicular to said axis.

12. A method according to claim 1, wherein in the step of winding superposed layers of the strip, the strip of cloth is wound around an axis to form superposed layers that are frustoconical.

13. A method according to claim 1, wherein in the step of winding superposed layers of the strip, the strip of cloth is wound around a tube.

14. A method according to claim 1, further comprising storing the strip of cloth on a tray having a radial slot therein, and in the step of winding superposed layers, pulling the strip of cloth through the radial slot.

15. A method according to claim 1, further comprising storing the strip of cloth on a mandrel wound to form a stack of superposed frustoconical plies.

16. A method according to claim 15, further comprising taking the strip of cloth from the mandrel and winding the strip of cloth onto a turntable to form a preform made up of superposed frustoconical turns, with the strip of cloth being transferred by tangential contact between the stack of frustoconical plies on the mandrel and the preform that is being built up.

17. A method according to claim 1, wherein in the step of winding the superposed layers, the strip of cloth is wound flat and the step of needling is performed continuously while the strip of cloth is being wound so as to form a tube, and further comprising slicing the tube to provide preforms for manufacturing annular parts.

18. A method according to claim 1, comprising a step of making annular preforms for composite material brake disks.

19. A method according to claim 3, wherein:

in the step of providing the strip of cloth, the size of the warp yarns increases from the inside diameter to the outside diameter and the density of the warp yarns increases from the inside diameter to the outside diameter;

the needling step is performed with a density of needle strokes per unit area that is substantially constant over the entire surface of the layers of the strip of cloth;

the needling step is performed by means of a set of needles covering a sector extending over the entire width of the strip of cloth;

the needling step is performed to a substantially constant depth; and

the needling step is performed progressively while the strip of cloth is being wound flat.

20. A method according to claim 4, wherein:

in the step of providing the strip of cloth, the size of the warp yarns increases from the inside diameter to the outside diameter and the density of the warp yarns increases from the inside diameter to the outside diameter;

the needling step is performed with a density of needle strokes per unit area that is substantially constant over the entire surface of the layers of the strip of cloth;

the needling step is performed by means of a set of needles covering a sector extending over the entire width of the strip of cloth;

the needling step is performed to a substantially constant depth; and

the needling step is performed progressively while the strip of cloth is being wound flat.

21. A method according to claim 9, wherein in the step of winding the superposed layers:

the strip of cloth is wound around an axis, building up superposed layers that are substantially perpendicular to said axis;

the strip of cloth is wound around an axis to form superposed layers that are frustoconical;

the strip of cloth is wound around a tube; and

the strip of cloth is stored on a tray from which it is pulled through a radial slot.

22. A method according to claim 13, further comprising storing the strip of cloth on a mandrel wound to form a stack of superposed frustoconical plies.

23. A method according to claim 22, further comprising taking the strip of cloth from the mandrel and winding the strip onto a turntable to form a preform made up of superposed frustoconical turns, with the strip of cloth being transferred by tangential contact between the stack of frustoconical plies on the mandrel and the preform that is being built up.

24. A method according to claim 20, wherein in the step of winding the superposed layers, the strip of cloth is wound flat and the step of needling is performed continuously while the strip of cloth is being wound so as to form a tube, and further comprising slicing the tube to provide preforms for manufacturing annular parts.

25. A method according to claim 19, comprising a step of making annular preforms for composite material brake disks.

26. A method according to claim 20, comprising a step of making annular preforms for composite material brake disks.

27. A method according to claim 21, comprising a step of making annular preforms for composite material brake disks.

28. A method according to claim 22, comprising a step of making annular preforms for composite material brake disks.

29. A method according to claim 23, comprising a step of making annular preforms for composite material brake disks.