# US 10,369,756 B2 · Method of manufacturing a composite article > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,369,756 B2 - Document ID: US10369756B2 - Status: Granted - Kind: B2 - Application number: 14/834,925 - Filed: 2015-08-25 - Published: 2017-03-02 - Granted: 2019-08-06 - Earliest claimed: 2015-08-25 - Assignees: The Boeing Company - Applicants: The Boeing Company - Inventors: Karl R. Bernetich; James W. Kohlbrenner; Mark S. Wilenski - Web page: https://patentgrep.com/patent/US10369756B2 ## CPC - B29D 7/01: Films or sheets - B29C 70/44: using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding - B29C 70/546: {Measures for feeding or distributing the matrix material in the reinforcing structure} - B29C 70/547: {using channels or porous distribution layers incorporated in or associated with the product} - B29C 70/549: {Details of caul plates, e.g. materials or shape} - Y02T 50/40: Weight reduction - B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION ## Abstract A system for manufacturing a composite article may include a resin-wetting control layer configured to be placed in contact with a composite ply of a composite preform. The resin-wetting control layer may be configured complementary to a ply surface of the composite ply. ## Claims ### Claim 1 A method of manufacturing a composite article, comprising the steps of: complementarily mating a resin-wetting control layer with a side of a composite preform having a ply surface including a plurality of divots, the resin-wetting control layer including a surface texture comprising a plurality of nubs spaced apart from each other and configured complementary to the plurality of divots in the ply surface; and preventing resin and gases from entering a space in at least some of the divots respectively occupied by the plurality of nubs of the resin-wetting control layer during curing of the composite preform. ### Claim 2 (depends on 1) The method of claim 1, further including: at least partially filling at least some of the divots with the resin-wetting control layer. ### Claim 3 (depends on 1) The method of claim 1, wherein the step of complementarily mating the resin-wetting control layer with a side of a composite preform comprises: complementarily mating the resin-wetting control layer with an outermost ply of at least one of a tool side and a caul side of the composite preform having a plurality of divots; and the resin-wetting control layer being associated with at least one of a tool surface and a caul surface of a respective forming tool and caul plate. ### Claim 4 (depends on 1) The method of claim 1, wherein the step of complementarily mating the resin-wetting control layer with a side of a composite preform comprises: complementarily mating the resin-wetting control layer with an inner ply on a core side of the composite preform having a core; and the resin-wetting control layer being associated with at least one of opposing core surfaces. ### Claim 5 (depends on 1) The method of claim 1, further including: distributing resin throughout at least one of a tool side, a caul side, and a core side of the composite preform after at least partially filling the divots with the resin-wetting control layer. ### Claim 6 (depends on 1) The method of claim 1, wherein: the plurality of nubs are complementary to the ply surface of a woven fabric of the composite preform. ### Claim 7 (depends on 6) The method of claim 6, wherein the step of complementarily mating the resin-wetting control layer with a side of a composite preform comprises: positioning the nubs in alignment with the divots of the ply surface. ### Claim 8 (depends on 6) The method of claim 6, wherein: at least one of the nubs is sized and configured to fill at least 50 percent of a divot in the woven fabric. ### Claim 9 (depends on 1) The method of claim 1, wherein the resin-wetting control layer is a compliant layer being compliant along a through-the-thickness direction, the method further including: compressing the compliant layer against the ply surface; and at least partially filling at least some of the divots with localized portions of the compliant layer in response to compressing the compliant layer against the ply surface. ### Claim 10 (depends on 9) The method of claim 9, further including: infusing the composite preform with resin after compressing the compliant layer against the ply surface. ### Claim 11 (depends on 1) The method of claim 1, wherein: the composite preform is comprised of prepreg composite plies. ### Claim 12 (depends on 1) The method of claim 1, wherein: the resin-wetting control layer is integral with at least one of a tool surface of a forming tool, a caul surface of a caul plate, and a core surface of a core. ### Claim 13 (depends on 1) The method of claim 1, further including: forming an aircraft component. ### Claim 14 (depends on 9) The method of claim 9, wherein: the compliant layer comprises an elastomeric material. ### Claim 15 (depends on 14) The method of claim 14, wherein: the elastomeric material is chemically non-reactive with the resin. ### Claim 16 (depends on 14) The method of claim 14, wherein: the elastomeric material comprises a sheet of rubber, silicone, urethane, thermoplastic material, or thermosetting material. ### Claim 17 (depends on 9) The method of claim 9, wherein: the compliant layer has a layer thickness in a range of from 0.002 to 0.12 inch. ### Claim 18 (depends on 1) The method of claim 1, wherein: one or more of the nubs has a nub shape that is symmetrical about a central vertical axis along at least one direction of the nub. ### Claim 19 (depends on 1) The method of claim 1, wherein: one or more of the nubs has a nub shape that is non-symmetrical about a central vertical axis. ### Claim 20 (depends on 1) The method of claim 1, wherein: the nubs are formed at a nub spacing that is substantially equivalent to a divot spacing of the divots.