# US 11,999,079 B2 · Method for manufacturing a composite component > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,999,079 B2 - Document ID: US11999079B2 - Status: Granted - Kind: B2 - Application number: 17/662,270 - Filed: 2022-05-06 - Published: 2022-08-18 - Granted: 2024-06-04 - Earliest claimed: 2016-04-06 - Assignees: ROLLS-ROYCE plc - Applicants: Rolls-Royce PLC - Inventors: Giovanni Antonio Marengo - Web page: https://patentgrep.com/patent/US11999079B2 ## CPC - B29B 11/16: comprising fillers or reinforcement {(non-woven fabrics per se D04H1/00, D04H3/00)} - B29C 70/34: and shaping or impregnating by compression {, i.e. combined with compressing after the lay-up operation} - B29C 70/44: using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding - B29C 70/462: {Moulding structures having an axis of symmetry or at least one channel, e.g. tubular structures, frames} - B29C 70/541: {Positioning reinforcements in a mould, e.g. using clamping means for the reinforcement (positioning inserts in moulds B29C33/12; lay-up on a mould B29C70/30)} - B29C 70/56: Tensioning reinforcements before or during shaping - B29D 99/0025: {Producing blades or the like, e.g. blades for turbines, propellers, or wings} - F01D 25/243: {Flange connections; Bolting arrangements (F01D25/265 takes precedence)} - B29K 2105/06: containing reinforcements, fillers or inserts - B29L 2031/08: Blades for rotors, stators, fans, turbines or the like, e.g. screw propellers - B29L 2031/7504: {Turbines} - F05D 2220/32: in gas turbines - B29B: PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS - 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 There is disclosed a method of manufacturing a composite component comprising a main body and an integral flange, the method comprising applying fibre-reinforcement material on a tool having a main body portion and a flange-forming portion to provide a pre-form comprising a body region and a longitudinally adjacent flange region. The pre-form extends generally longitudinally between two longitudinal ends; and a trailing ply of the pre-form extends generally longitudinally between the longitudinal end closest to the flange region and an inner ply end located in the flange region or partway into the body region. Relative movement between the flange-forming portion and the main body portion causes sliding movement between the trailing ply and the flange-forming portion during a flange forming operation, thereby causing a tension force in at least the flange region of the pre-form of during forming of the flange. ## Claims ### Claim 1 A method of manufacturing a composite component comprising a main body and an integral flange, the method comprising: applying fibre-reinforcement material on a tool having a main body portion and a flange-forming portion to provide a pre-form comprising: a body region and a longitudinally adjacent flange region contiguous with the body region, the body region corresponding to the main body of the composite component and the flange region corresponding to the integral flange of the composite component; wherein the pre-form extends longitudinally between two longitudinal ends; and wherein a trailing ply of the pre-form extends longitudinally between the longitudinal end closest to the flange region and an opposing ply end, the trailing ply having an orientation substantially aligned with a longitudinal direction; causing relative movement between the flange-forming portion and the main body portion so that the flange region of the pre-form deforms to form the integral flange of the composite component; wherein the relative movement between the flange-forming portion and the main body portion causes sliding movement between the trailing ply and the flange-forming portion, thereby causing a tension force in at least the flange region of the pre-form during forming of the flange. ### Claim 2 (depends on 1) A method according to claim 1, wherein the opposing ply end of the trailing ply is coterminous with the opposing longitudinal end of the pre-form. ### Claim 3 (depends on 1) A method according to claim 1, wherein the fibre-reinforcement material is applied so that the trailing ply has an orientation perpendicular to a boundary between the body region and the flange region of the pre-form. ### Claim 4 (depends on 1) A method according to claim 1, wherein the fibre-reinforcement material is applied so that the trailing ply has an orientation perpendicular to a boundary between the main body portion and the flange-forming portion of the tool. ### Claim 5 (depends on 1) A method according to claim 1, wherein the flange region comprises a plurality of plies of fibre-reinforcement material arranged in ply layers, a base ply layer of which is a closest of the plurality of plies to the tool, and wherein the fibre-reinforcement material is applied so that the trailing ply at least partly forms the base ply layer. ### Claim 6 (depends on 1) A method according to claim 1, wherein the flange region comprises a plurality of plies of fibre-reinforcement material arranged in ply layers, and wherein the fibre-reinforcement material is applied so that the trailing ply at least partly forms an intermediate ply layer of the flange region or an outermost ply layer of the flange region which is farthest from the tool. ### Claim 7 (depends on 1) A method according to claim 1, wherein the flange region extends from the body region to an opposing outer end of the flange region, and wherein the trailing ply extends longitudinally from an inner ply end beyond the outer end of the flange region to the respective longitudinal end of the pre-form. ### Claim 8 (depends on 7) A method according to claim 7, wherein a thickness of the pre-form reduces beyond the outer end of the flange region. ### Claim 9 (depends on 7) A method according to claim 7, wherein the trailing ply extends longitudinally at least 20 mm beyond the outer end of the flange region. ### Claim 10 (depends on 7) A method according to claim 7, wherein the pre-form includes at least two trailing plies extending beyond the outer end of the flange region, including a first trailing ply extending a first distance beyond the outer end of the flange region, and a second trailing ply extending a greater second distance beyond the outer end of the flange region and over the first trailing ply to terminate at the respective longitudinal end of the pre-form, such that at least a portion of each trailing ply slides relative the flange-forming portion of the tool during a flange forming operation. ### Claim 11 (depends on 7) A method according to claim 7, wherein the method further comprises removing composite material corresponding to the trailing ply which extends beyond the outer end of the flange region. ### Claim 12 (depends on 1) A method according to claim 1, wherein the composite component has primary and secondary flanges at opposing longitudinal ends of the composite component, the tool having respective primary and secondary flange-forming portions, the pre-form having primary and secondary flange regions and primary and secondary trailing plies. ### Claim 13 (depends on 1) A method according to claim 1, wherein the flange-forming portion of the tool has a lay-up surface that is substantially continuous with a lay-up surface of the main body portion of the tool in a lay-up configuration of the tool, and a side-surface which extends between the lay-up surfaces of the flange-forming portion and the main body portion of the tool in a forming configuration of the tool. ### Claim 14 (depends on 1) A method according to claim 1, wherein a direction of relative movement of the flange-forming portion and the main body portion of the tool is parallel to an extent of the integral flange. ### Claim 15 (depends on 1) A method according to claim 1, wherein the composite component is an annular or a partially annular component, wherein the main body portion and the flange-forming portion of the tool are configured for relative radial movement, and wherein the flange is radial. ### Claim 16 (depends on 1) A method according to claim 1, wherein the fibre-reinforcement material is applied so that the trailing ply is applied first, before other remaining plies of the fibre-reinforcement material. ### Claim 17 (depends on 1) A method according to claim 1, wherein the flange-forming portion of the tool contacts the trailing ply at the longitudinal end closest to the flange region. ### Claim 18 (depends on 1) A method according to claim 1, wherein the trailing ply extends longitudinally outward beyond longitudinal ends of all other plies of the pre-form. ### Claim 19 A pre-form for a composite component having a main body and an integral flange, the pre-form comprising: a body region and a longitudinally adjacent flange region contiguous with the body region, the body region corresponding to the main body of the composite component and the flange region corresponding to the integral flange of the composite component; wherein the pre-form extends longitudinally between two longitudinal ends; and wherein a trailing ply of the pre-form extends longitudinally between the longitudinal end closest to the flange region and an opposing ply end, the trailing ply having an orientation aligned with a longitudinal direction; wherein the pre-form is provided on a tool having a main body portion and a flange-forming portion; wherein the pre-form is configured so that, during a forming operation in which there is relative movement between the flange-forming portion and the main body portion, the flange region of the pre-form deforms to form the flange; and wherein the pre-form is configured so that relative movement of the flange-forming portion and the main body portion causes sliding movement between the trailing ply of the pre-form and the flange-forming portion of the tool, thereby producing a tension force in at least the flange region of the pre-form during forming of the flange.