Method for making a composite component using a transverse tape

A method for making a composite component comprises the steps of:

• a. applying at least one fiber strand impregnated with a matrix material onto a generally cylindrical mandrel at a predetermined angle relative to a line parallel to the rotational axis of the mandrel to form at least one layer of two crossing windings of unwoven, unknitted, and unstitched matrix impregnated fiber strand portions wherein the fiber strand portions are held together by the tack of the matrix material and wherein the fiber strand portions in each winding are parallel to each other wherein the step of applying at least one fiber strand comprises rotating the generally cylindrical mandrel while holding the generally cylindrical mandrel in a stationary position between its ends, forming the layer of fiber strand portions on a conveyor belt, and moving the conveyor belt to convey the layer of fiber strand portions to the generally cylindrical mandrel and rolling the layer of fiber strand portions on the generally cylindrical mandrel as it is formed on the conveyor belt afterwhich the transverse tape is cut from the layer of fiber strand portions while it is on the generally cylindrical mandrel;
• b. cutting from the layer while it is on the mandrel a transverse tape comprising a strip of unwoven, unknitted, and unstitched fiber strand portions which are held together by the tack of the matrix material whereby the fiber strand portions are not held together by weaving, knitting, or stitching, the transverse tape having at least two plies and a pair of parallel edges wherein fiber strand portions in each ply extend parallel to each other between the edges and are oriented at an angle, relative to a line passing through the edges and perpendicular to the edges, which is substantially equal to said predetermined angle;
• c. winding the transverse tape onto a component mandrel;
• d. compacting and curing the wound matrix impregnated transverse tape;
• and
• e. removing the mandrel, wherein the method further comprises selecting the matrix material from the group of thermoplastic resins and heating the transverse tape while it is on the mandrel to melt the matrix material in the transverse tape as it is being rolled onto the mandrel.

A method for making a composite component comprises the steps of:

• a. applying at least one fiber strand impregnated with a matrix material onto a generally cylindrical mandrel at a predetermined angle relative to a line parallel to the rotational axis of the mandrel to form at least one layer of two crossing windings of unwoven, unknitted, and unstitched matrix impregnated fiber strand portions wherein the fiber strand portions are held together by the tack of the matrix material and wherein the fiber strand portions in each winding are parallel to each other wherein the step of applying at least one fiber strand comprises rotating the generally cylindrical mandrel while holding the generally cylindrical mandrel in a stationary position between its ends, forming the layer of fiber strand portions on a conveyor belt, and moving the conveyor belt to convey the layer of fiber strand portions to the generally cylindrical mandrel and rolling the layer of fiber strand portions on the generally cylindrical mandrel as it is formed on the conveyor belt afterwhich the transverse tape is cut from the layer of fiber strand portions while it is on the generally cylindrical mandrel;
• b. cutting from the layer while it is on the mandrel a transverse tape comprising a strip of unwoven, unknitted, and unstitched fiber strand portions which are held together by the tack of the matrix material whereby the fiber strand portions are not held together by weaving, knitting, or stitching, the transverse tape having at least two plies and a pair of parallel edges wherein fiber strand portions in each ply extend parallel to each other between the edges and are oriented at an angle, relative to a line passing through the edges and perpendicular to the edges, which is substantially equal to said predetermined angle;
• c. winding the transverse tape onto a component mandrel;
• d. compacting and curing the wound matrix impregnated transverse tape;
• and
• e. removing the mandrel, the method further comprising selecting the matrix material to have a glass transition temperature greater than about 400.degree. F.

A method for making a composite component comprises the steps of:

• a. applying at least one fiber strand impregnated with a matrix material onto a generally cylindrical mandrel at a predetermined angle relative to a line parallel to the rotational axis of the mandrel to form at least one layer of two crossing windings of unwoven, unknitted, and unstitched matrix impregnated fiber strand portions wherein the fiber strand portions are held together by the tack of the matrix material and wherein the fiber strand portions in each winding are parallel to each other wherein the step of applying at least one fiber strand comprises rotating the generally cylindrical mandrel while holding the generally cylindrical mandrel in a stationary position between its ends, forming the layer of fiber strand portions on a conveyor belt, and moving the conveyor belt to convey the layer of fiber strand portions to the generally cylindrical mandrel and rolling the layer of fiber strand portions on the generally cylindrical mandrel as it is formed on the conveyor belt afterwhich the transverse tape is cut from the layer of fiber strand portions while it is on the generally cylindrical mandrel;
• b. cutting from the layer while it is on the mandrel a transverse tape comprising a strip of unwoven, unknitted, and unstitched fiber strand portions which are held together by the tack of the matrix material whereby the fiber strand portions are not held together by weaving, knitting, or stitching, the transverse tape having at least two plies and a pair of parallel edges wherein fiber strand portions in each ply extend parallel to each other between the edges and are oriented at an angle, relative to a line passing through the edges and perpendicular to the edges, which is substantially equal to said predetermined angle;
• c. winding the transverse tape onto a component mandrel;
• d. compacting and curing the wound matrix impregnated transverse tape;
• and
• e. removing the mandrel, wherein the step of winding the transverse tape onto a component mandrel comprises applying a plurality of shingled windings on the component material.

A method for making a composite component comprises the steps of:

• a. applying at least one fiber strand impregnated with a matrix material onto a generally cylindrical mandrel at a predetermined angle relative to a line parallel to the rotational axis of the mandrel to form at least one layer of two crossing windings of unwoven, unknitted, and unstitched matrix impregnated fiber strand portions wherein the fiber strand portions are held together by the tack of the matrix material and wherein the fiber strand portions in each winding are parallel to each other wherein the step of applying at least one fiber strand comprises rotating the generally cylindrical mandrel while holding the generally cylindrical mandrel in a stationary position between its ends, forming the layer of fiber strand portions on a conveyor belt, and moving the conveyor belt to convey the layer of fiber strand portions to the generally cylindrical mandrel and rolling the layer of fiber strand portions on the generally cylindrical mandrel as it is formed on the conveyor belt afterwhich the transverse tape is cut from the layer of fiber strand portions while it is on the generally cylindrical mandrel;
• b. cutting from the layer while it is on the mandrel a transverse tape comprising a strip of unwoven, unknitted, and unstitched fiber strand portions which are held together by the tack of the matrix material whereby the fiber strand portions are not held together by weaving, knitting, or stitching, the transverse tape having at least two plies and a pair of parallel edges wherein fiber strand portions in each ply extend parallel to each other between the edges and are oriented at an angle, relative to a line passing through the edges and perpendicular to the edges, which is substantially equal to said predetermined angle;
• c. winding the transverse tape onto a component mandrel;
• d. compacting and curing the wound matrix impregnated transverse tape;
• and
• e. removing the mandrel, wherein the step of winding the transverse tape onto a component mandrel comprises applying a plurality of shingled windings on the component mandrel, the method further comprising selecting the matrix material to have a glass transition temperature greater than about 400.degree. F.

A method for making a composite component comprises the steps of:

• a. applying at least one fiber strand impregnated with a matrix material onto a generally cylindrical mandrel at a predetermined angle relative to a line parallel to the rotational axis of the mandrel to form at least one layer of two crossing windings of unwoven, unknitted, and unstitched matrix impregnated fiber strand portions wherein the fiber strand portions are held together by the tack of the matrix material and wherein the fiber strand portions in each winding are parallel to each other wherein the step of applying at least one fiber strand comprises rotating the generally cylindrical mandrel while holding the generally cylindrical mandrel in a stationary position between its ends, forming the layer of fiber strand portions on a conveyor belt, and moving the conveyor belt to convey the layer of fiber strand portions to the generally cylindrical mandrel and rolling the layer of fiber strand portions on the generally cylindrical mandrel as it is formed on the conveyor belt afterwhich the transverse tape is cut from the layer of fiber strand portions while it is on the generally cylindrical mandrel;
• b. cutting from the layer while it is on the mandrel a transverse tape comprising a strip of unwoven, unknitted, and unstitched fiber strand portions which are held together by the tack of the matrix material whereby the fiber strand portions are not held together by weaving, knitting, or stitching, the transverse tape having at least two plies and a pair of parallel edges wherein fiber strand portions in each ply extend parallel to each other between the edges and are oriented at an angle, relative to a line passing through the edges and perpendicular to the edges, which is substantially equal to said predetermined angle;
• c. winding the transverse tape onto a component mandrel;
• d. compacting and curing the wound matrix impregnated transverse tape;
• and
• e. removing the mandrel, wherein the step of winding the transverse tape onto the component mandrel comprises applying a plurality of shingled windings on the component mandrel, the method further comprising selecting the at least one fiber strand to be composed of a material selected from the group consisting of carbon and graphite.

A method for making a composite component comprises the steps of:

• a. applying at least one fiber strand impregnated with a matrix material onto a generally cylindrical mandrel at a predetermined angle relative to a line parallel to the rotational axis of the mandrel to form at least one layer of two crossing windings of unwoven, unknitted, and unstitched matrix impregnated fiber strand portions wherein the fiber strand portions are held together by the tack of the matrix material and wherein the fiber strand portions in each winding are parallel to each other wherein the step of applying at least one fiber strand comprises rotating the generally cylindrical mandrel while holding the generally cylindrical mandrel in a stationary position between its ends, forming the layer of fiber strand portions on a conveyor belt, and moving the conveyor belt to convey the layer of fiber strand portions to the generally cylindrical mandrel and rolling the layer of fiber strand portions on the generally cylindrical mandrel as it is formed on the conveyor belt afterwhich the transverse tape is cut from the layer of fiber strand portions while it is on the generally cylindrical mandrel;
• b. cutting from the layer while it is on the mandrel a transverse tape comprising a strip of unwoven, unknitted, and unstitched fiber strand portions which are held together by the tack of the matrix material whereby the fiber strand portions are not held together by weaving, knitting, or stitching, the transverse tape having at least two plies and a pair of parallel edges wherein fiber strand portions in each ply extend parallel to each other between the edges and are oriented at an angle, relative to a line passing through the edges and perpendicular to the edges, which is substantially equal to said predetermined angle;
• c. winding the transverse tape onto a component mandrel;
• d. compacting and curing the wound matrix impregnated transverse tape;
• and
• e. removing the mandrel, wherein the step of winding the transverse tape onto a component mandrel comprises applying a plurality of shingled windings on the component mandrel, the method further comprising selecting the at least one fiber strand to be composed of a material selected from the group consisting of carbon and graphite and further comprising selecting the matrix material to have a glass transition temperature greater than about 400.degree. F.