Cytec Industries Inc.

Robert Parkinson

Sebastien Luc Greber

Samuel Jestyn Hill

Riccardo Moraglia

Johannes Wolf Georg Treiber

A method for producing a three-dimensional preform from an intermediate preform blank (), which contain undulations () in a portion thereof. The preform blank () may be formed on a tool surface () containing undulations () using an automated placement method such as Automated Tape Laying (ATL) or Automated Fiber Placement (AFP), in which narrow-width strips of material are dispensed side-by-side. Various preform blanks () and molding tools () have been designed to produce shaped preforms having generally C-shape and Z-shape cross-sections.

Fabrication of three-dimensional structures from preform blanks

A controlled shear vacuum forming method that includes forming a three-dimensional (3D) structure from a preform material on a molding tool using restraints during vacuuming to prevent wrinkling. The restraints are withdrawn during vacuuming to allowing the preform material to come into contact with the sidewalls of the molding tool in a gradual manner. Such forming method is particularly suitable for forming wing spars with bent sections and/or curved contours.

Controlled shear vacuum forming for shaping preforms

A method for the manufacturing of three-dimensional (3D) preforms and composite structures having non-planar surfaces and flanges such that the fibrous or composite material used for shaping the final 3D structure has the necessary length and surface area to conform to the desired contours of the molding tool without wrinkling. The manufacturing method begins with the formation of an intermediate preform blank by automated placement of fiber tapes or prepreg tapes, followed by shaping the blank on a molding tool with 3D contours to form the final 3D structure.

Fabrication of three-dimensional composite structures

An automated method for producing a fibrous preform on a tool surface. Such fibrous preform is configured to receive liquid resin via resin infusion. A disposable layer containing a small amount of radiation absorbing material is placed onto the tool surface prior to the automated placement of the first ply of dry fibrous material. Particles of a polymeric or resinous binder are applied on an exposed surface of the disposable layer to enhance adhesion of the first ply. The dry fibrous material may be in the form of elongated, narrow-width fiber tapes or broader fabrics that can be deposited onto the tool surface by an automated placement method. The disposable layer may be in the form of a flexible polymeric film, a release film, a peel ply or a polymer-coated glass cloth.

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Wrexham, United Kingdom

Robert Parkinson