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US 11,951,690 B2Granted
Method for processing massive fiber-composite preforms
AssigneeArris Composites Inc.
InventorsJ Scott Perkins, Bert D. Mannhalter, Riley Reese
Life of this patent
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Abstract
A method for processing massive fiber bundles includes massive fiber-bundle formation and massive materials handling, wherein plural small-diameter bundles are unified, while more or less preserving their legacy cross-sectional form. It also includes bending, such as to create non-linear preforms, and preform-charge fabrication. Embodiments of the invention operate to help preserve a desired fiber alignment throughout a part fabricated from relatively large-diameter fiber bundles.
Claims19
A method comprising:
- placing, in abutting relationship, plural small-diameter fiber bundles, wherein each of the small-diameter fiber bundles abuts at least one other of the small-diameter fiber bundles;
- heating the small-diameter fiber bundles to at least a heat deflection temperature of a resin within the small-diameter fiber bundles, but to less than a melting point of the resin;
- applying unification pressure to the small-diameter fiber bundles, thereby unifying the plural small-diameter fiber bundles into a single massive fiber bundle while substantially preserving a cross-sectional shape of each of the plural small-diameter fiber bundles;
- cooling the massive fiber bundle;
- and
- cutting the massive fiber bundle into a plurality of first portions by:
- (a) preheating a segment of one of the first portions of the massive fiber bundle to the heat deflection temperature;
- and
- (b) heating the preheated segment while bending the segment in a bending die, thereby forming a preform with a bend.
6 more elements
A method comprising:
- placing, in abutting relationship, plural small-diameter fiber bundles, wherein each of the small-diameter fiber bundles abuts at least one other of the small-diameter fiber bundles;
- heating the small-diameter fiber bundles to at least a heat deflection temperature of a resin within the small-diameter fiber bundles, but to less than a melting point of the resin;
- applying unification pressure to the small-diameter fiber bundles, thereby unifying the plural small-diameter fiber bundles into a single massive fiber bundle while substantially preserving a cross-sectional shape of each of the plural small-diameter fiber bundles;
- cooling the massive fiber bundle;
- cutting the massive fiber bundle into a plurality of first portions;
- placing two or more of the first portions in a fixture that organizes the first portions into a geometry of a part to be formed, or a geometry of a portion of the part;
- heating the first portions to the heat deflection temperature of the resin in the first portions;
- and
- applying pressure to the first portions, wherein the pressure is insufficient to fully consolidate the first portions.
6 more elements
A method comprising:
- placing, in abutting relationship, plural small-diameter fiber bundles, wherein each of the small-diameter fiber bundles abuts at least one other of the small-diameter fiber bundles;
- heating the small-diameter fiber bundles to at least a heat deflection temperature of a resin within the small-diameter fiber bundles, but to less than a melting point of the resin;
- applying unification pressure to the small-diameter fiber bundles, thereby unifying the plural small-diameter fiber bundles into a single massive fiber bundle while substantially preserving a cross-sectional shape of each of the plural small-diameter fiber bundles;
- cooling the massive fiber bundle;
- and
- crimping the massive fiber bundle at intervals enabling the massive fiber bundle to be folded back and forth onto itself.
3 more elements
A method comprising:
- placing, in abutting relationship, plural small-diameter fiber bundles, wherein each of the small-diameter fiber bundles abuts at least one other of the small-diameter fiber bundles;
- heating the small-diameter fiber bundles to at least a heat deflection temperature of a resin within the small-diameter fiber bundles, but to less than a melting point of the resin;
- applying unification pressure to the small-diameter fiber bundles, thereby unifying the plural small-diameter fiber bundles into a single massive fiber bundle while substantially preserving a cross-sectional shape of each of the plural small-diameter fiber bundles;
- bending and cutting the massive fiber bundle to form a plurality of preforms, at least some of which preforms include at least one bend;
- and
- cooling the plurality of preforms.
3 more elements
Dependencies are inferred from the claim text.