# US 9,517,613 B2 · Method of forming a composite structure comprising a flange > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,517,613 B2 - Document ID: US9517613B2 - Status: Granted - Kind: B2 - Application number: 13/991,575 - Filed: 2011-12-06 - Published: 2013-10-10 - Granted: 2016-12-13 - Earliest claimed: 2010-12-07 - Assignees: GKN Aerospace Services Limited - Applicants: Jonathan Paul Moram; Giovanni Antonio Marengo; David James Maclean; Ben Ralfs; Gary Wiles; Marcus Jason Gawn - Inventors: Jonathan Paul Moram; Giovanni Antonio Marengo; David James Maclean; Ben Ralfs; Gary Wiles; Marcus Jason Gawn - Web page: https://patentgrep.com/patent/US9517613B2 ## CPC - B32B 37/02: characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations - B29C 53/04: of plates or sheets {(B29C63/04 takes precedence; bending or folding paper B31F1/0003; folding films B65H45/00)} - B29C 70/342: {using isostatic pressure} - B29C 70/345: {using matched moulds} - B29C 70/541: {Positioning reinforcements in a mould, e.g. using clamping means for the reinforcement (positioning inserts in moulds B29C33/12; lay-up on a mould B29C70/30)} - F01D 21/045: {special arrangements in stators or in rotors dealing with breaking-off of part of rotor} - F01D 25/24: Casings (modified for heating or cooling F01D25/14); Casing parts, e.g. diaphragms, casing fastenings (casings for rotary machines or engines in general F16M {; special arrangements in stators dealing with breaking-off of part of rotor F01D21/045}) - B29C 57/00: Shaping of tube ends, e.g. flanging, belling or closing; Apparatus therefor {, e.g. collapsible mandrels} - B29K 2105/0881: {unidirectional} - B29L 2009/00: Layered products - B29L 2031/30: Vehicles, e.g. ships or aircraft, or body parts thereof {(vanes or blades B29L2031/08, air bags B29L2022/027)} - B29L 2031/7504: {Turbines} - F05D 2300/603: Composites; e.g. fibre-reinforced - Y02T 50/60: Efficient propulsion technologies, e.g. for aircraft - Y10T 156/1044: of parallel stacked sheets only - Y10T 428/24628: Nonplanar uniform thickness material - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - 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) - F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D) - 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 - F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS - Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract Method forming a composite structure (9) comprising a main body and a flange. The composite structure is manufactured by laying-up a preform (7) on a mold (6). The preform (7) does not have the first and second bends and comprises a first part which corresponds to the main body of the composite structure and a second part which corresponds to the flange of the composite structure. The second part of the (preform (7) has a proximal portion which corresponds to the wall portion of the flange and a distal portion which corresponds to the lip portion of the flange. The preform (7) comprises a plurality of plies and uni-directional ply material extends from the first part of the preform (7) to the distal portion of the second part of the preform (7). The flange is formed by advancing movable portion(s) (62) of the mold 6 to form the proximal portion of the second part of the preform (7) to create the first bend (81) and by forming the distal portion of the second part of the preform (7) around the advancing movable portion(s) (62) of the mold (6) to create the second bend (83). The presence of the two bends (81, 83) ensures that the ply material (78) is kept in tension during the forming operation. ## Claims ### Claim 1 A method of manufacturing a composite structure comprising a main body and a flange which is positioned along a first edge of the main body and which has a wall portion which is connected to the main body through a first bend and a lip portion which is connected to the wall portion through a second bend in the opposite direction to the first bend, the method comprising the steps of: laying-up a curved preform on a mould, wherein the preform does not have the first and second bends and comprises a first part which corresponds to the main body of the composite structure and a second part which corresponds to the flange of the composite structure, the second part of the preform has a proximal portion which corresponds to the wall portion of the flange and a distal portion which corresponds to the lip portion of the flange, the first and second parts of the preform comprise a plurality of plies and uni-directional ply material extends from the first part of the preform to the distal portion of the second part of the preform; forming the flange by advancing movable portions of the mould to form the proximal portion of the second part of the preform to create the first bend and by forming the distal portion of the second part of the preform around the advancing movable portions of the mould to create the second bend; and curing resin in the formed flange and the first part of the preform; wherein the movable mould portions are blocks which are spaced apart along the first edge and which, in the forming step, are moved from a retracted configuration to a radially outwardly-advanced configuration with respect to the curved preform. ### Claim 2 (depends on 1) A method according to claim 1, wherein the uni-directional ply material is pre-impregnated uni-directional tape. ### Claim 3 (depends on 1) A method according to claim 1, wherein: the mould comprises a first mould portion, the movable mould portions adjacent the first mould portion, and a second mould portion adjacent the movable mould portions; and in the laying-up step, the first part of the preform is laid-up on the first mould portion, the proximal portion of the second part of the preform is laid-up on the movable mould portions, and the distal portion of the second part of the preform is laid-up on the second mould portion. ### Claim 4 (depends on 1) A method according to claim 1, wherein the preform is covered with a vacuum bag membrane and during the forming step a vacuum is applied to the preform. ### Claim 5 (depends on 1) A method according to claim 1, wherein: the method further comprises the step of positioning a forming tool to hold the first part of the preform against the mould; and in the forming step, the advancing movable portions of the mould form the proximal portion of the second part of the preform around the forming tool to create the first bend. ### Claim 6 (depends on 1) A method according to claim 1, wherein: the preform is heated to a first temperature and the forming step is performed; and the curing step is performed at a second temperature higher than the first temperature. ### Claim 7 (depends on 2) A method according to claim 2, wherein the plies of the first and second parts of the preform include tape laid at an oblique angle to the boundary between the first and second preform parts. ### Claim 8 (depends on 2) A method according to claim 2, wherein the plies of the first and second parts of the preform include tape laid at a perpendicular angle to the boundary between the first and second preform parts. ### Claim 9 (depends on 8) A method according to claim 8, wherein: the first part of the preform has a central zone and an edge zone which is adjacent the boundary between the first and second preform parts; the central zone of the first part of the preform does not include the perpendicular-angle tape; and the edge zone of the first part of the preform includes the perpendicular-angle tape. ### Claim 10 (depends on 1) A method according to claim 1, further comprising the step of: after the curing step, trimming off the lip portion of the flange. ### Claim 11 A method of manufacturing a containment case for a gas turbine engine, wherein the containment case comprises an annular housing and an annular flange which is positioned at an end of the housing and which has an annular wall portion which is connected to the housing through a first bend and an annular lip portion which is connected to the wall portion through a second bend in the opposite direction to the first bend, the method comprising the steps of: laying-up an annular preform on a mould, wherein the preform does not have the first and second bends and comprises a first part which corresponds to the housing of the containment case and a second part which corresponds to the flange of the containment case, the second part of the preform has a proximal portion which corresponds to the wall portion of the flange and a distal portion which corresponds to the lip portion of the flange, the first and second parts of the preform comprise a plurality of plies and uni-directional ply material extends from the first part of the preform to the distal portion of the second part of the preform; forming the flange by radially outwardly-moving movable portions of the mould to form the proximal portion of the second part of the preform to create the first bend and by forming the distal portion of the second part of the preform around the outwardly-moving movable portions of the mould to create the second bend; and curing resin in the formed flange and the first part of the preform.