Forming a preform into a shaped body

Patent metadata

Field	Value
Publication number	US-12485575-B2
Application number	US-202217889164-A
Country	US
Kind code	B2
Filing date	Aug 16, 2022
Priority date	Aug 16, 2022
Publication date	Dec 2, 2025
Grant date	Dec 2, 2025

Abstract

A manufacturing method is provided. A preform is arranged over a surface of an inner mold line. The preform is folded over sides of the inner mold line. An end of the preform is pressed into a grip strip coupled to a side of the inner mold line. The grip strip is translated in a first direction to tension the preform into a shaped body.

First claim

What is claimed:

1 . A manufacturing method, comprising:
arranging a preform over a top surface of an inner mold line, wherein the inner mold line comprises the top surface and at least two side sections on opposing sides of the inner mold line relative to the top surface, wherein the inner mold line comprises a plurality of pockets in each of the at least two side sections, wherein a first floating plate of a plurality of floating plates is coupled to a first tensioning system through at least two first pockets of the plurality of pockets in a first side section of the at least two side sections of the inner mold line, wherein a second floating plate of the plurality of floating plates is coupled to a second tensioning system through at least two second pockets of the plurality of pockets in a second side section of the at least two side sections of the inner mold line, wherein a first gear rack of the first tensioning system runs parallel to an inner surface of the first side section, and wherein a second gear rack of the second tensioning system operates parallel to an inner surface of the second side section; folding the preform over the at least two side sections of the inner mold line; responsive to folding the preform over the at least two side sections of the inner mold line:
pressing an end of the preform into a grip strip, wherein the grip strip is coupled to a floating plate of the plurality of floating plates and wherein the grip strip includes at least one of pins angled downward with respect to the top surface of the inner mold line or sharp teeth; and
translating at least one of the first floating plate or the second floating plate of the plurality of floating plates in a first direction substantially parallel to a respective side section of the at least two side sections and away from the top surface of the inner mold line to tension the preform into a shaped body.

2 . The manufacturing method of claim 1 , wherein the first tensioning system and the second tensions system are gear rack-based tensioning systems.

3 . The manufacturing method of claim 2 , wherein each of the gear rack-based tensioning systems comprises a respective gear rack and a respective tensioning mechanism, wherein threads on a gear of the respective tensioning mechanism interact with threads on a respective gear rack to translate the respective gear rack in a translation direction.

4 . The manufacturing method of claim 3 , wherein the respective tensioning mechanism comprises a threaded stud knob, an inner thread standoff, a ball bearing assembly, the gear, and an outer standoff, wherein:
the threaded stud knob applies a rotary action to the gear, the inner thread standoff provides spacing between the threaded stud knob and the gear, the inner thread standoff comprises a slot on an outside diameter of the inner thread standoff, the ball bearing assembly holds the threaded stud knob and the gear in place with respect to a surface of at least one side section of the at least two side sections of the inner mold line, the outer standoff encompasses a portion of the inner thread standoff, and set screws in the outer standoff provide a mechanical stop by interfacing with the slot in the inner thread standoff once the preform is in a desired position.

5 . The manufacturing method of claim 1 , further comprising:
clamping the preform to the floating plate, wherein the clamping is provided by a self-supporting clamp that is coupled to a tensioning system.

6 . The manufacturing method of claim 1 , wherein the grip strip is coupled to the floating plate via an adhesion material.

7 . The manufacturing method of claim 1 , wherein the grip strip is two or more grip strips, wherein a first grip strip of the two or more grip strips is coupled to the first floating plate of the plurality of floating plates, wherein the first floating plate is translated in the first direction at a first angle, wherein in a second grip strip of the two or more grip strips is coupled to the second floating plate of the plurality of floating plates, wherein the second floating plate is translated in the first direction at a second angle, and wherein the second angle is different than the first angle.

Assignees

• Rohr Inc

Inventors

• Pujar Vijay V
• Waugh Katherine E
• Koroly Christopher C

Classifications

• B29C70/541 Primary

  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) · CPC title

• B29C70/56

  Tensioning reinforcements before or during shaping · CPC title

• B29C53/04

  of plates or sheets {(B29C63/04 takes precedence; bending or folding paper B31F1/0003; folding films B65H45/00)} · CPC title

• C04B2235/5252

  having a specific pre-form · CPC title

• C04B35/83

  Carbon fibres in a carbon matrix · CPC title