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US 2026/0307787 A1Published application
Systems and Methods for Manufacturing Composite Laminate Structures
OwnerBryan Marshall, Michael Devin Shawinventors
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Abstract
A method is disclosed. The method includes applying a layer of braided fiber material around a tool. The method also includes arranging a composite laminate sheet onto the braided fiber material. The method further includes applying an additional layer of braided fiber material on the composite laminate sheet to form a spar. The method additionally includes joining the spar, such that the layers of braided fiber material are fixedly coupled to the composite laminate sheet. The method includes removing the tool from the spar.
Claims21
A method comprising:
- applying a layer of braided fiber material around a tool;
- arranging a composite laminate sheet onto the braided fiber material;
- applying an additional layer of braided fiber material on the composite laminate sheet to form a spar;
- joining the spar, such that the layers of braided fiber material are fixedly coupled to the composite laminate sheet;
- and
- removing the tool from the spar.
3 more elements
(canceled)
A spar comprising:
- a first end and a second end, wherein the second end comprises an integrally molded root end joint;
- and
- a structure defining a cavity, wherein the structure comprises:
- a layer of thermoplastic impregnated braided fiber material;
- and
- a thermoplastic composite sheet disposed on a portion of the spar between a first layer and a second layer of the thermoplastic braided fiber material, wherein a thermoplastic matrix of the thermoplastic composite sheet is joined with a thermoplastic matrix of the thermoplastic impregnated fiber material.
3 more elements
A rotor blade comprising:
- a thermoplastic composite spar comprising a first surface, a second surface opposite the first surface, a forward end, and an aft end opposite the forward end;
- a leading edge assembly comprising a thermoplastic composite skin and disposed at the forward end of the spar, wherein a portion of the thermoplastic composite skin is coupled to the spar on the first and second surfaces, such that a thermoplastic matrix in the portion of the thermoplastic composite skin is fused with a thermoplastic matrix of the spar;
- and
- an aft body assembly disposed at the aft end of the spar, the aft body assembly comprising:
- a first end;
- a second end opposite the first end;
- a thermoplastic composite upper skin;
- and
- a thermoplastic composite lower skin, wherein the upper skin is coupled to the lower skin at the first end and coupled to the first surface of the spar at the second end, and wherein the lower skin is coupled to the second surface of the spar at the second end.
6 more elements
Dependencies are inferred from the claim text.