# US 10,479,049 B2 · Part made from composite material, comprising a reinforcement against delamination, and production method thereof

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- Number: US 10,479,049 B2
- Document ID: US10479049B2
- Status: Granted
- Kind: B2
- Application number: 15/974,714
- Filed: 2018-05-09
- Published: 2018-09-13
- Granted: 2019-11-19
- Earliest claimed: 2015-11-09
- Assignees: Safran Nacelles
- Applicants: Safran Nacelles
- Inventors: Arnaud Delehouze; Etienne Germain; Sébastien Louchard; Benjamin Provost
- Web page: https://patentgrep.com/patent/US10479049B2

## CPC

- B32B 5/06: characterised by a fibrous {or filamentary} layer {mechanically connected, e.g. by needling} to another layer, e.g. of fibres, of paper
- B29C 64/165: using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
- B29C 70/543: {Fixing the position or configuration of fibrous reinforcements before or during moulding (for non-woven fabrics D04H3/08)}
- B29D 99/0005: {Producing noodles, i.e. composite gap fillers, characterised by their construction}
- B32B 1/00: Layered products having a non-planar shape
- B32B 7/04: Interconnection of layers
- B32B 27/06: as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08)}
- B32B 27/12: next to a fibrous or filamentary layer
- B29C 65/564: {hidden in the joint, e.g. dowels or Z-pins (B29C65/603 takes precedence)}
- B29K 2307/04: Carbon
- B29L 2031/003: {having a profiled transverse cross-section}
- B29L 2031/3076: {Aircrafts (blades, propellers B29L2031/08)}
- B32B 2307/514: Oriented
- B32B 2307/54: Yield strength; Tensile strength
- B32B 2307/558: Impact strength, toughness
- B32B 2605/00: Vehicles
- B32B 2605/18: Aircraft
- Y10T 428/24174: including sheet or component perpendicular to plane of web or sheet
- Y10T 428/249923: Including interlaminar mechanical fastener
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- 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)
- B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

The present disclosure relates to a part made from composite material that includes a base and a T-shaped reinforcement. The T-shaped reinforcement includes a first L-shaped element having a first right-angled connection portion and a second L-shaped element having a second right-angled connection portion. The part further includes a plurality of needles, each connecting the base to the T-shaped reinforcement of the part, close to the connection portions and extending in multiple directions so as to oppose, in particular, the separation of the base from the T-shaped reinforcement.

## Claims

### Claim 1

A composite material workpiece comprising:
a soleplate;
a T-shaped reinforcement comprising a first L-shaped member and a second L-shaped member arranged back-to-back to form a T, wherein the first L-shaped member includes a first base and the second L-shaped member includes a second base, the first and second bases each extending on the soleplate, wherein the first L-shaped member includes a first rib and the second L-shaped member includes a second rib, the first and second ribs attached back-to-back to form a web, wherein the first L-shaped member includes a first connecting portion and the second L-shaped member includes a second connecting portion that connects said ribs on said first and second bases;
a plurality of needles connecting the soleplate on the T-shaped reinforcement in a vicinity of said first and second connecting portions, and extending in several directions through the soleplate and the T-shaped reinforcement; and
a core housed in a cavity delimited by a junction area between the soleplate, the first connecting portion, and the second connecting portion, wherein
the plurality of needles pass through said core,
at least one portion of the plurality of needles extends radially along a radius of curvature of the first connecting portion and the second connecting portion,
at least another portion of the plurality of needles extends in a direction of the first and second ribs, and
the plurality of needles extend in a star configuration by intersecting at a center of the core and said workpiece.

### Claim 2 (depends on 1)

The composite material workpiece according to claim 1, wherein the needles are formed by pultruded threads.

### Claim 3 (depends on 1)

The composite material workpiece according to claim 1, wherein the core is deformable to substantially match a shape of the L-shaped members.

### Claim 4 (depends on 1)

A manufacturing process of a composite material workpiece according to claim 1, the manufacturing process comprising:
one deposition step of the first L-shaped member and the second L-shaped member into a mold,
one deposition step of the core,
one deposition step of the soleplate which results in trapping the core, and
one compaction step of the workpiece which presses the L-shaped members, the soleplate and the core together, to penetrate the needles through the L-shaped members and the soleplate.

### Claim 5 (depends on 4)

The manufacturing process of a composite material workpiece according to claim 4, wherein the deposition step of the core comprises:
inserting the needles through the core then inserting the core into the cavity delimited by a junction area between the first connecting portion and the second connecting portion of said L-shaped members.

### Claim 6 (depends on 4)

The manufacturing process of a composite material workpiece according claim 4 further comprising:
a molding step of the workpiece which is carried out following the compaction step and which includes molding the workpiece and injecting resin into the workpiece.