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US 8,263,205 B2Granted
Method of molding complex composite parts using pre-plied multi-directional continuous fiber laminate
AssigneeHexcel Corporation
InventorMatthew Kweder
Life of this patent
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Abstract
Layers of unidirectional (UD) fiber prepreg are formed into a pre-plied, multi-directional, continuous fiber laminate that is used as a molding compound to form three dimensional structures. Cut-outs from the laminate are slotted and folded along fold lines to provide near-net-shaped preforms that may be compression molded to form fiber-reinforced composite structures having complex shapes.
Claims14
A fiber-reinforced composite structure that is made according to a method comprising the steps of:
- providing a pre-plied, multi-directional laminate comprising an interior and an edge, said laminate comprising at least a first layer of prepreg and a second layer of prepreg wherein each of said prepreg layers comprises an uncured resin matrix and unidirectional fibers and wherein the direction of said unidirectional fibers in said first prepreg layer is different from the direction of said unidirectional fibers in said second prepreg layer and wherein said laminate comprises a first tab portion and a second tab portion;
- folding said laminate to form a preform wherein said first tab portion and said second tab portion overlap each other and are pushed together to form a portion of the preform;
- and
- curing said preform to form said composite structure wherein the portion of said preform that is formed by said first and second tab portions is cured to form a cured portion of said composite structure.
1 more element
A preform for use in forming a fiber-reinforced composite structure, said preform being made according to a method comprising the steps of:
- providing a pre-plied, multi-directional laminate comprising an interior and an edge, said laminate comprising at least a first layer of prepreg and a second layer of prepreg wherein each of said prepreg layers comprises an uncured resin matrix and unidirectional fibers and wherein the direction of said unidirectional fibers in said first prepreg layer is different from the direction of said unidirectional fibers in said second prepreg layer and wherein said laminate comprises a first tab portion and a second tab portion;
- and
- folding said laminate to form said preform wherein said first and second tab portions overlap each other and are pushed together to form a portion of the preform.
Dependencies are inferred from the claim text.