# US 11,440,273 B2 · Method for forming 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 11,440,273 B2 - Document ID: US11440273B2 - Status: Granted - Kind: B2 - Application number: 16/367,350 - Filed: 2019-03-28 - Published: 2019-10-17 - Granted: 2022-09-13 - Earliest claimed: 2018-04-11 - Assignees: ROLLS-ROYCE plc - Applicants: ROLLS-ROYCE plc - Inventors: Vincent Gill - Web page: https://patentgrep.com/patent/US11440273B2 ## CPC - B29C 70/34: and shaping or impregnating by compression {, i.e. combined with compressing after the lay-up operation} - B29C 70/302: {Details of the edges of fibre composites, e.g. edge finishing or means to avoid delamination} - B29C 70/38: Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns {(application heads for tyres B29D30/28)} - B29C 70/443: {and impregnating by vacuum or injection} - B29C 70/545: {Perforating, cutting or machining during or after moulding} - B29D 99/0025: {Producing blades or the like, e.g. blades for turbines, propellers, or wings} - F01D 5/282: {Selecting composite materials, e.g. blades with reinforcing filaments} - B29C 70/24: oriented in at least three directions forming a three-dimensional [3D] structure - B29C 2793/0027: Cutting off - B29C 2793/0081: before shaping - B29C 2793/009: after shaping - B29K 2705/00: Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts - B29L 2031/08: Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers - F05D 2300/603: Composites; e.g. fibre-reinforced - 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) - F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D) - 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 - F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS ## Abstract A method of forming a composite article involves the steps of: providing a formed article, the formed article comprising a plurality of non-crimp fibre fabrics with each non-crimp fibre fabric comprising at least two dry-fibre layers; stabilising the plurality of non-crimp fibre fabrics; machining a surface of the formed article having exposed ply terminations to provide a smooth blended surface with chamfered plydrops; positioning the machined formed article in a second mould; infiltrating the second mould with a polymer matrix resin; and curing the machined formed article to form the composite article. ## Claims ### Claim 1 A method of forming a composite article, the method comprising the steps of: providing a formed article, the formed article comprising a plurality of non-crimp fibre fabrics with each non-crimp fibre fabric comprising at least two dry-fibre layers; stabilising the plurality of non-crimp fibre fabrics; arranging an insert at a first end of the plurality of non-crimp fibre fabrics such that at least a first plurality of non-crimp fibre fabrics are arranged directly adjacent to and contacting the insert; machining a surface of the formed article having exposed ply terminations to provide a smooth blended surface with chamfered plydrops; positioning the machined formed article in a second mould; infiltrating the second mould with a polymer matrix resin; and curing the machined formed article to form the composite article, wherein the step of infiltrating the machined preform article with a polymer matrix resin, comprises the additional previous step of applying a fibre fabric wrap layer to the machined formed article, the fibre fabric wrap layer extending over at least a part of the exterior surface of the machined formed article. ### Claim 2 (depends on 1) The method as claimed in claim 1, wherein the non-crimp fabric layers are multi-axial non-crimp fabric layers. ### Claim 3 (depends on 1) The method as claimed in claim 1, wherein the step of providing a formed article, comprises the steps of: providing a layup surface; sequentially positioning a plurality of non-crimp fibre fabrics onto the layup surface to form a first sub-section preform, and a second sub-section preform, each non-crimp fibre fabric being oriented in dependence on a geometry and load-carrying capability of the composite article; assembling the first sub-section preform and the second sub-section preform together to form a preformed article; positioning the preformed article in a first mould; and press-forming the preformed article in the first mould to create a formed article. ### Claim 4 (depends on 3) The method as claimed in claim 3, wherein the step of press-forming the preformed article in the first mould to consolidate the non-crimp fibre fabrics comprises the additional previous step of: lubricating the stack of non-crimp fibre fabrics with water. ### Claim 5 (depends on 3) The method as claimed in claim 3, wherein the step of sequentially positioning a plurality of non-crimp fibre fabrics onto the layup surface to form a sub-section preform, comprises the additional subsequent step of: applying a vacuum to the sub-section preform to debulk the plurality of non-crimp fibre fabrics. ### Claim 6 (depends on 3) The method as claimed in claim 3, wherein the step of assembling the first sub-section preform and the second sub-section preform together to form a preformed article comprises the additional subsequent step of: providing through-thickness reinforcement to the preformed article. ### Claim 7 (depends on 6) The method as claimed in claim 6, wherein the through-thickness reinforcement is provided by a technique selected from the group consisting of any of stitching, tufting, or pinning. ### Claim 8 (depends on 3) The method as claimed in claim 3, wherein the step of stabilising the plurality of non-crimp fibre fabrics, comprises the steps of: infiltrating the first mould with water; cooling the first mould to freeze the water; removing the formed article from the first mould; and the step of machining a surface of the formed article having exposed ply terminations to provide a smooth blended surface with chamfered plydrops, comprises the additional subsequent step of: heating the machined formed article to melt the residual ice. ### Claim 9 (depends on 3) The method as claimed in claim 3, wherein the step of stabilising the plurality of non-crimp fibre fabrics, comprises the steps of: applying a thermally activated binder to the plurality of non-crimp fibre fabrics; and the step of sequentially positioning a plurality of non-crimp fibre fabrics onto the layup surface to form a first sub-section preform, and a second sub-section preform, comprises the additional subsequent step of: heating the sub-section preform to thermally activate the thermally activated binder. ### Claim 10 (depends on 9) The method as claimed in claim 9, wherein the thermally activated binder is a thermally activated powder coating applied to the plurality of non-crimp fibre fabrics. ### Claim 11 (depends on 9) The method as claimed in claim 9, wherein the thermally activated binder is a thermally activated film interleaved between adjacent ones of the plurality of non-crimp fibre fabrics. ### Claim 12 (depends on 3) The method as claimed in claim 3, wherein the insert extends substantially perpendicularly to a longitudinal extent of each of the plurality of non-crimp fibre fabrics, wherein the plurality of non-crimp fibre fabrics includes at least one non-crimp fibre fabric arranged above the insert, and wherein a top surface of the insert is arranged adjacent to and contacts the at least one non-crimp fibre fabric arranged above the insert. ### Claim 13 (depends on 3) The method as claimed in claim 3, further comprising: prior to infiltrating the second mould with a polymer matrix resin, applying a vacuum to the second mould to remove any residual volatiles and to encourage the uptake of the polymer matrix resin. ### Claim 14 (depends on 3) The method as claimed in claim 3, wherein the step of sequentially positioning a plurality of non-crimp fibre fabrics onto the layup surface to form a sub-section preform, is performed by an automated fabric placement system.