# US 2019/0168419 A1 · Method for manufacturing a preform for composite materials

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- Number: US 2019/0168419 A1
- Document ID: US20190168419A1
- Status: Published application
- Kind: A1
- Application number: 16/240,092
- Filed: 2019-01-04
- Published: 2019-06-06
- Earliest claimed: 2016-07-06
- Assignees: Safran Nacelles
- Applicants: Safran Nacelles
- Inventors: Benjamin PROVOST; Bertrand DESJOYEAUX; Sébastien LOUCHARD; Fabien DEPEUX
- Web page: https://patentgrep.com/patent/US20190168419A1

## CPC

- B29B 11/16: comprising fillers or reinforcement {(non-woven fabrics per se D04H1/00, D04H3/00)}
- B29C 70/302: {Details of the edges of fibre composites, e.g. edge finishing or means to avoid delamination}
- B32B 1/08: Tubular products
- B32B 5/12: characterised by the relative arrangement of fibres or filaments of {different layers, e.g. the fibres or filaments being parallel or perpendicular to each other}
- B64D 29/00: Power-plant nacelles, fairings or cowlings
- B64F 5/10: Manufacturing or assembling aircraft, e.g. jigs therefor
- B29K 2105/0872: {Prepregs}
- B29L 2031/3076: {Aircrafts (blades, propellers B29L2031/08)}
- B32B 2605/18: Aircraft
- B64C 7/02: Nacelles
- F02C 7/04: Air intakes for gas-turbine plants or jet-propulsion plants
- Y02T 50/40: Weight reduction
- 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)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B64D: EQUIPMENT FOR FITTING IN OR TO AIRCRAFT; FLIGHT SUITS; PARACHUTES; ARRANGEMENT OR MOUNTING OF POWER PLANTS OR PROPULSION TRANSMISSIONS IN AIRCRAFT
- B64F: GROUND OR AIRCRAFT-CARRIER-DECK INSTALLATIONS SPECIALLY ADAPTED FOR USE IN CONNECTION WITH AIRCRAFT; DESIGNING, MANUFACTURING, ASSEMBLING, CLEANING, MAINTAINING OR REPAIRING AIRCRAFT, NOT OTHERWISE PROVIDED FOR; HANDLING, TRANSPORTING, TESTING OR INSPECTING AIRCRAFT COMPONENTS, NOT OTHERWISE PROVIDED FOR
- 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
- B64C: AEROPLANES; HELICOPTERS
- F02C: GAS-TURBINE PLANTS; AIR INTAKES FOR JET-PROPULSION PLANTS; CONTROLLING FUEL SUPPLY IN AIR-BREATHING JET-PROPULSION PLANTS (construction of turbines F01D; jet-propulsion plants F02K; construction of compressors or fans F04; generating combustion products of high pressure or high velocity F23R; using gas turbines in compression refrigeration plants F25B11/00)
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

A method for manufacturing a preform has a non-developable end shape having, about a longitudinal axis (A), an end overall radius of curvature (R2), and, in at least a longitudinal section, curved segments forming bending radii linking straight segments. The method includes a step of depositing successive layers giving the preform an initial substantially rotational shape having, about the longitudinal axis (A), an initial overall radius of curvature, then a step of deploying the preform by increasing the initial overall radius of curvature until the end overall radius of curvature is reached (R2), in order to close the bending radii of the curved segments.

## Claims

### Claim 1

A method for manufacturing a preform having a non-developable shape comprising a plurality of superposed reinforcing layers of fibers to form a part made of composite materials having a final shape comprising a final global radius of curvature about a longitudinal axis and curved segments forming folding radii connecting substantially straight segments in at least one longitudinal section, the method comprising:
depositing successive layers on a surface of a draping tool giving an initial shape substantially of revolution having an initial global radius of curvature about the longitudinal axis, the initial shape including an open contour about the longitudinal axis; and
deploying the preform by increasing the initial global radius of curvature up to the final global radius of curvature in order to close the folding radii of the curved segments.

### Claim 2 (depends on 1)

The manufacturing method according to claim 1 further comprising, prior to the deploying step, if the initial shape includes a closed circular contour about the longitudinal axis, a step of cutting the preform which gives the open contour.

### Claim 3 (depends on 1)

The manufacturing method according to claim 1 further comprising a preliminary step of calculating a boundary reinforcing layer at a curved segment, the boundary reinforcing layer having, in the at least one longitudinal section depending on an orientation of fibers and positioning of the boundary reinforcing layer in a thickness of the segment compared to other reinforcing layers, a smallest change in a developed length during the deployment of the preform.

### Claim 4 (depends on 1)

The manufacturing method according to claim 1 further comprising a preliminary step of calculating a boundary reinforcing layer at a curved segment, the boundary reinforcing layer having in a transversal section depending on an orientation of fibers and positioning of the boundary reinforcing layer in a thickness of the segment compared to other reinforcing layers, a smallest change in a developed length during the deployment of the preform.

### Claim 5 (depends on 1)

The manufacturing method according to claim 1, wherein a ratio between the final and initial global radius of curvature is between 1.5 and 4.

### Claim 6 (depends on 1)

A preform comprising a plurality of superposed reinforcing layers of fibers, to form, after baking an impregnating resin, a part made of composite materials having a final shape, wherein the preform is manufactured according to the method of claim 1.

### Claim 7 (depends on 6)

The preform according to claim 6, wherein each curved segment has an average developed length in the at least one longitudinal section or in a transversal section substantially equal to a developed length of an associated boundary layer in that section.

### Claim 8 (depends on 6)

The preform according to claim 6 further comprising, about the longitudinal axis in the initial shape, a conical portion connected by curved segments to straight segments, the conical portion straightening to give a substantially planar portion in the final shape.

### Claim 9 (depends on 6)

The preform according to claim 6 further comprising a thickness between 1 and 8 mm, and the folding radii of curved segments is between 5 and 30 mm.

### Claim 10 (depends on 6)

The preform according to claim 6 further comprising local geometrical singularities.

### Claim 11 (depends on 10)

The preform according to claim 10, wherein the local geometrical singularities are bosses.

### Claim 12 (depends on 6)

The preform according to claim 6, wherein the initial shape includes a closed circular contour about the longitudinal axis such that the final shape forms an area less than or equal to 180° about the longitudinal axis.

### Claim 13 (depends on 6)

The preform according to claim 6, wherein a number of fiber reinforcing layers is variable.

### Claim 14 (depends on 6)

The preform according to claim 6, wherein at least one layer among the plurality of reinforcing layers comprises fibers oriented longitudinally or transversely.

### Claim 15 (depends on 6)

The preform according to claim 6, wherein fibers of the superposed reinforcing layers have orientations of 90°, +30° and −30°, compared to an orientation of 0° which is an angle of a plane passing through the longitudinal axis.

### Claim 16 (depends on 6)

A turbojet engine nacelle part comprising a preform according to claim 6.

### Claim 17 (depends on 6)

A turbojet engine nacelle part comprising partial or total superposition of at least two preforms according to claim 6.

### Claim 18 (depends on 17)

The turbojet engine nacelle part according to claim 17, wherein at least one of the preforms among the at least two preforms has a thickness decreasing towards an end of an overlap zone with the other preform.