Sikorsky Aircraft Corporation

Allen E Trudeau

David A Kovalsky

Jeffry C Purse

Nicholas Iszczyszyn

Steven J Bullied

A bonding preparation patch for application to a resin treated surface is provided. The patch includes a strip having first and second portions, each of which has corresponding first and second sides. The strip is formed of resin porous material and is foldable such that the respective first sides of the first and second portions face each other. The patch further includes a resin barrier interposable between corresponding portions of the respective first sides and a tape including at least one adhesive side, which is securable relative to the first portion and disposable in contact with the second side of the second portion.

Bonding preparation patch

A fiber orientation verification system includes a sensor and an indicator to identify the fiber orientation within each sequentially laid composite material layer. The indicator projects visible indicator lines upon the lay-up surface which are indicative of a desired orientation for the composite material layer. The sensor and the indicator communicate with a computer module which contains a database including a detailed sequence to assure that each layer is proper placed. The operator is thereby provided with an exact location to lay-up each composite material layer and the proper fiber orientation of that layer. Continued verification is thus provided to the operator.

Fiber orientation verification for a composite article

A transfer device for picking up and placing resin preimpregnated composite plies. The transfer device includes a movable transfer head with a plurality of transfer feet movably mounted within it. Each transfer foot includes a support cage with a plurality of spaced posts extending between upper and lower ends. A mounting plate is located on the support cage. A pickup foot extends from the lower end of the support cage and has a channel formed through it which communicates with an opening in the lower end of the support cage. The pickup foot includes a tip end adapted to contact the resin preimpregnated composite ply. A valve is mounted within the support cage and includes a valve member located adjacent to the opening in the lower end of the support cage. The valve member is movable between a closed position and an open position. A spring surrounds at least a portion of the periphery of the transfer foot and biases the transfer foot into the transfer head. A pressure source supplies a pressurized medium to the valve for actuating the valve member. A stripper is preferably attached to the valve and actuatable in conjunction with the valve member for dislodging a composite ply from the tip end. An actuation assembly is mounted to the transfer foot and adapted to move the transfer foot with respect to the transfer head in response to a flow of pressurized air.

Vacuum transfer device

A method for manufacture of a fiber reinforced composite spar for a helicopter rotor blade including upper and lower sidewall regions and forward and aft conic regions. Constant width crossplies and unidirectional plies are stacked and arranged to form crossply and unidirectional laminates. The composite spar is manufactured via a vacuum forming technique which includes forming the composite laminates directly over an inflatable mandrel assembly. Regarding the latter method, a spar forming apparatus is used to position and manipulate the mandrel assembly as composite laminates are laid. The spar forming apparatus includes first and second pedestal supports being suitably configured so as to facilitate formation of the butt joints in the conic regions of the composite spar. The pedestal supports are movable from a first orientation to facilitate lay-up of composite laminates over the mandrel assembly, to a second orientation to facilitate transfer of the mandrel assembly from one to the other of the pedestal supports. The spar forming apparatus further includes an electromagnetic coil system comprising at least one electrically activated coil and a controllable power source. The electrically activated coils are disposed in combination with each of the pedestal supports and the controllable power source selectively energizes the electrically activated coils to effect a magnetic clamping force between the mandrel assembly and one of the pedestal supports. Such electromagnetic coil system accurately positions the inflatable mandrel assembly during lay-up of the composite laminates and effects transfer of the mandrel assembly.

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Manchester, CT, United States of America

Allen E Trudeau