Interlayer-toughened filament-wound composite structure

Patent metadata

Field	Value
Publication number	US-10773467-B2
Application number	US-201615380963-A
Country	US
Kind code	B2
Filing date	Dec 15, 2016
Priority date	Dec 15, 2016
Publication date	Sep 15, 2020
Grant date	Sep 15, 2020

Abstract

Disclosed herein is a method for filament winding. The method includes bonding a veil material to the unidirectional fabric to veil-stabilize the unidirectional fabric. The method also includes slitting the veil-stabilized unidirectional fabric to separate a veil-stabilized fabric portion. The method also includes directing the veil-stabilized fabric portion to an application head. The method also includes winding the veil-stabilized fabric portion on a winding mandrel.

First claim

What is claimed is:

1. A method of filament winding, comprising:
bonding a veil material to a unidirectional fabric to veil-stabilize the unidirectional fabric, wherein the unidirectional fabric is a dry-fiber fabric;
slitting the veil-stabilized unidirectional fabric to separate a veil-stabilized fabric portion;
collecting the veil-stabilized fabric portion on a collection structure;
unspooling the veil-stabilized fabric portion from the collection structure;
impregnating the veil-stabilized fabric portion with a resin after the veil-stabilized fabric portion is veil-stabilized and after the veil-stabilized fabric portion is unspooled;
directing the veil-stabilized fabric portion to an application head after the veil-stabilized fabric portion is veil-stabilized and impregnated with the resin; and
winding the veil-stabilized fabric portion on a winding mandrel to form a wound veil-stabilized fabric portion on the winding mandrel, the wound veil-stabilized fabric portion having a lay-up arrangement on the winding mandrel in which a first section of the wound veil-stabilized fabric portion is arranged by the application head to be at an angle relative to a second section of the wound veil-stabilized fabric portion to form at least a portion of a layering structure of a part.

2. The method according to claim 1 , wherein the bonding of the veil material to the unidirectional fabric to veil-stabilize the unidirectional fabric comprises applying heat and pressure to the veil material to bond the veil material to the unidirectional fabric.

3. The method according to claim 1 , wherein the veil material comprises a thermoplastic material and the veil-stabilized fabric portion is stabilized with the thermoplastic material.

4. The method according to claim 1 , further comprising removing the wound veil-stabilized fabric portion from the mandrel as a flat laminate.

5. The method according to claim 1 , further comprising curing the wound veil-stabilized fabric portion after winding.

6. The method according to claim 1 , wherein the impregnating of the veil-stabilized fabric portion.

7. The method according to claim 1 , further comprising passing the veil-stabilized fabric portion through a nip roller to remove excess resin from the veil-stabilized fabric portion.

8. The method according to claim 1 , wherein the collection structure comprises a creel.

9. The method according to claim 1 , further comprising passing a tow over a spreader bar to form the unidirectional fabric before bonding the veil material to the unidirectional fabric.

10. The method according to claim 1 , wherein the veil material comprises a non-woven fabric.

11. The method according to claim 1 , wherein the slitting of the veil-stabilized unidirectional fabric comprises isolating one or more veil-stabilized tows from the unidirectional fabric.

12. The method according to claim 11 , wherein the slitting of the veil-stabilized unidirectional fabric yields multiple veil-stabilized fabric portions.

13. The method according to claim 1 , wherein the application head is configured to move along one or more axes.

14. The method according to claim 13 , further comprising curing the wound veil-stabilized fabric portion after winding.

15. The method according to claim 1 , wherein the slitting of the veil-stabilized unidirectional fabric yields multiple veil-stabilized fabric portions.

16. The method according to claim 2 , further comprising curing the wound veil-stabilized fabric portion after winding.

17. The method according to claim 2 , wherein the veil material comprises a nonwoven fabric.

18. The method according to claim 3 , wherein the bonding of the veil material to the unidirectional fabric to veil-stabilize the unidirectional fabric comprises applying heat and pressure to the veil material to bond the veil material to the unidirectional fabric.

19. The method according to claim 6 further comprising passing the veil-stabilized fabric portion through a nip roller to remove excess resin from the veil-stabilized fabric portion.

20. The method according to claim 10 , wherein the bonding of the veil material to the unidirectional fabric to veil-stabilize the unidirectional fabric comprises applying heat and pressure to the veil material to bond the veil material to the unidirectional fabric.

Assignees

• Boeing Co

Inventors

• Tsotsis Thomas

Classifications

• B29C53/58

  helically · CPC title

• B29K2105/0809

  Fabrics · CPC title

• B29K2101/12

  Thermoplastic materials · CPC title

• B29C69/002 Primary

  Winding (cutting of individual length B26D) · CPC title

• B29C53/582

  comprising reinforcements, e.g. wires, threads · CPC title