System for continuously manufacturing a composite preform
AssigneeCompsys, Inc.
InventorsScott M. Lewit, Miles Mackaness
Life of this patent
Estimating the term…
Abstract
A continuous composite structure manufacturing apparatus which comprises a conveyor or conveyors for conveying one or more fabric webs along a conveying path. Each of the webs is comprised of a reinforcing fabric, a non-woven fabric, or a layered fabric. The fabric web is passed through the conveyor so that it defines an enclosed foam injection zone. A foam injection system is provided for injecting foam into the foam injection zone to form a foam core preform (or a plurality of same). One or more dies are positioned along the conveying path, to shape each of the foam core preform(s) to a desired cross-sectional profile. The individual stringers or multiple, spaced apart, stringers are produced concurrently in a continuous production process.
Claims32
An apparatus for manufacturing a composite structure having an exposed reinforcing fabric layer free of structural foam and curable resin, said apparatus comprising:
- a conveyor for conveying at least one fabric web along a conveying path, said at least one fabric web comprised of a layered fabric, said layered fabric having said reinforcing fabric layer and a non-woven fabric layer attached to one side thereof, having intestices into which structural foam is filled;
- an injection system for injecting a structural foam into a foam injection zone completely lined by said at least one fabric web, said non-woven fabric layer facing said interior of said foam injection zone;
- a die positioned along said conveying path, defining said injection zone and shaping said composite structure to a desired cross-sectional profile;
- and
- wherein said structural foam fills interstices of said non-woven fabric layer, thereby attaching said structural foam to said at least one fabnic web without allowing penetration of the structural foam into said reinforcing fabric layer, and wherein said reinforcing fabric layer remains free of structural foam and curable resin after said structural foam has cured.
An apparatus for manufacturing a composite structure using a structural foam comprised of two or more component parts, at least one of said parts is pre-mixed with a blowing agent and maintained under pressure, said apparatus comprising:
- a conveyor for conveying at least one fabric web along a conveying path;
- said at least on fabric web comprised of a layered fabric, said layered fabric having a reinforcing fabric layer and a non-woven fabric layer attached to one side thereof;
- a structural foam injection system for injecting said structural foam into a foam injection zone lined by said at least one fabric web, a rate of flow of said foam component part which has been pre-mixed with a blowing agent being controlled by a gear pump which has a speed which is reduced by a braking unit;
- and
- a die positioned along said conveying path, said die provided for defining said injection zone and shaping said composite structure to a desired cross-sectional profile, whereby said structural foam is attached to said fabric web by having filled interstices of said fabric web without allowing penetration of the structural foam into said reinforcing fabric layer.
An apparatus for manufacturing a composite structure having an exposed reinforcing fabric layer free of structural foam and curable resin, comprised of a plurality of foam core stringer members, spaced apart from one another and attached by a fabric web, said apparatus comprising:
- conveyors for conveying together first and second fabric webs along a conveying path, said first fabric web comprised of reinforcing fabric attached to a non-woven fabric on one side thereof, and said second fabric web comprised of a non-woven fabric;
- a compound die positioned along said conveying path, said compound die comprised of a plurality of profiled channels spaced apart from one another, a fabric guide for separating said first and second fabric webs and for defining a plurality of foam injection zones, said non-woven fabric layer facing an interior of each of said foam injection zones;
- and
- a structural foam injection system for injecting a structural foam into each of said plurality of foam injection zones.
Dependencies are inferred from the claim text.