Compaction method for composite discs

Patent metadata

Field	Value
Publication number	US-12049049-B2
Application number	US-202017097801-A
Country	US
Kind code	B2
Filing date	Nov 13, 2020
Priority date	Nov 13, 2019
Publication date	Jul 30, 2024
Grant date	Jul 30, 2024

Abstract

Method and apparatus for splaying fibers for the forming preform charges for the production of composite discs, and for the production of composite disc, wherein rotary compaction is applied to an appropriately arranged assemblage of preforms.

First claim

What is claimed:

1. A method comprising:
providing an assemblage of preforms, each preform in the assemblage comprising resin and a plurality of substantially unidirectionally aligned, and substantially equal length fibers;
heating the assemblage of preforms; and
applying compaction pressure and rotationally induced shear stress to the preforms, wherein:
(a) the assemblage of preforms has configuration that is suitable for splaying via the rotationally induced shear stress;
(b) wherein applying rotationally-induced shear stress comprises partially rotating a plunger that contacts the assemblage of preforms; and
(c) wherein partial rotation of the plunger is passively induced.

2. The method of claim 1 wherein the assemblage of preforms is a lay-up of individual preforms.

3. The method of claim 2 wherein heating the assemblage comprises heating the assemblage to a temperature that is less than a melting temperature of the resin, but which equals or exceeds a heat deflection temperature of the resin.

4. The method of claim 3 wherein applying compaction pressure comprises applying an amount of pressure that is insufficient to fully compact the fibers, resulting in a preform charge having splayed preforms.

5. The method of claim 4 comprising molding a composite disc by applying heat and pressure to the preform charge having the splayed preforms.

6. The method of claim 1 wherein the assemblage of preforms comprises a preform charge.

7. The method of claim 6 wherein heating the assemblage comprises heating the assemblage to a temperature that equals or exceeds a melting temperature of the resin.

8. The method of claim 7 wherein applying compaction pressure comprises applying an amount of pressure that is sufficient to fully compact the fibers, resulting, after cooling, in a composite disc.

9. A method comprising:
providing an assemblage of preforms, each preform in the assemblage comprising resin and a plurality of substantially co-aligned fibers, wherein the assemblage includes a first plurality of layers of preforms in which successive layers thereof are offset from one another by angle β, wherein 0°<β<90°;
heating the first plurality of layers in the assemblage of preforms; and
splaying the fibers in the preforms of the first plurality of layers by applying rotary compaction—compaction pressure and rotationally induced shear stress—to the preforms, the fibers so splayed having a curved form, wherein the rotary compaction is applied by:
(a) partially rotating a plunger that contacts the assemblage of preforms; and
(b) passively inducing partial rotation of the plunger.

10. The method of claim 9 wherein the assemblage of preforms is a lay-up of individual preforms, and wherein heating the assemblage comprises heating the assemblage to a temperature that equals or exceeds a melting temperature of the resin.

11. A method comprising:
forming a preform charge, the preform charge comprising a plurality of preforms, each preform comprising resin and a plurality of fibers, wherein the preform charge is formed by:
(a) arranging the plurality of preforms in plural layers in which successive layers thereof are offset from one another by angle β, wherein 0°<β<90°;
(b) heating the resin in the preforms to a temperature that is less than a melt temperature of the resin, but which equals or exceeds a heat deflection temperature of the resin; and
(c) splaying the preforms by applying rotary compaction—compaction pressure and rotationally induced shear stress- to the preforms, the splayed preforms having a curved form, wherein the rotary compaction is applied by:
(i) partially rotating a plunger that contacts the assemblage of preforms, applying an amount of pressure that is insufficient to fully consolidate the preforms; and
(ii) passively inducing partial rotation of the plunger; and

(d) cooling the splayed preforms, thereby causing adjacent preforms to tack together, forming the preform charge.

12. The method of claim 11 comprising molding a composite disc by applying heat and pressure to the preform charge having the splayed preforms.

13. The method of claim 11 wherein, in each layer of the plural layers, the preforms are arranged in a grid pattern.

14. The method of claim 12 wherein the pressure applied during rotary compaction of the preforms is less than the pressure applied to the preform charged during molding of the composite disc.

15. The method of claim 12 wherein the successive layers of preforms are arranged so that fibers are variably splayed through the thickness of the composite disc.

16. A method comprising:
providing an assemblage of preforms, the assemblage comprising a plurality of preforms, each preform comprising resin and a plurality of fibers;
heating the resin in the preforms; and
subjecting a portion, but not all, of the assemblage to rotary compaction by:
(a) partially rotating a plunger that contacts the portion of the assemblage and applies pressure thereto; and
(b) passively inducing partial rotation of the plunger.

17. The method of claim 16 wherein:
heating the resin comprises heating to a temperature that is less than a melt temperature of the resin, but which equals or exceeds a heat deflection temperature of the resin; and
wherein the pressure applied by the plunger is insufficient to fully consolidate the fibers and resin.

18. The method of claim 16 wherein:
heating the resin comprises heating to a temperature heating to a temperature that equals or exceeds a melting temperature of the resin; and
wherein the pressure applied by the plunger is sufficient to fully consolidate the fibers and resin.

Assignees

• Arris Composites Inc

Inventors

• Escowitz Ethan
• Reese Riley
• Davidson Erick
• Perkins J Scott

Classifications

• B29C70/54

  Component parts, details or accessories; Auxiliary operations {, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing} · CPC title

• B29K2105/0881

  unidirectional · CPC title

• B29C70/465 Primary

  and impregnating by melting a solid material, e.g. sheets, powders of fibres · CPC title