Composite components with impact detection

A fiber-reinforced polymer composite component formed from a polymer matrix material containing fiber reinforcement. The component comprises a main portion and at least one raised feature extending from a surface plane s of said main portion. The at least one raised feature is arranged to incur visually perceptible damage when the component is subject to an impact with an energy above a predetermined impact energy threshold and to resist an impact with an energy below the predetermined impact energy threshold.

Method of manufacturing a composite component

A method of manufacturing a monolithic fiber-reinforced polymer composite component is provided. The method comprises providing a mould comprising a main cavity and at least one additional cavity that extends from the main cavity; introducing a polymer matrix material containing chopped fiber reinforcement into the mould to fill the main cavity and the at least one additional cavity to form a monolithic fiber-reinforced polymer composite component with a main portion formed in the main cavity and at least one raised feature formed in the additional cavity and extending from a surface plane of said main portion. The at least one raised feature is arranged to incur visually perceptible damage when the component is subject to an impact with an energy above a predetermined impact energy threshold and to resist an impact with an energy below the predetermined impact energy threshold.

COMPOSITE CONNECTORS AND METHODS OF MANUFACTURING THE SAME

A method of manufacturing a composite connector for a fluid transfer conduit is provided which comprises applying continuous fibre reinforcement, oriented at least partially circumferentially and pre-impregnated with a thermoplastic polymer to a tubular mould portion which extends substantially parallel to a central axis C; applying at least one further mould portion to form a complete mould in which the continuous fibre reinforcement is enclosed and injecting a thermoplastic polymer into the mould to form a connector with a tubular hub portion and a flange portion which extends from the hub portion at an angle to the central axis C. The tubular hub portion comprises a tubular seal section with an inner layer and an outer wherein the inner layer comprises the continuous fibre reinforcement and the outer layer comprises the injected thermoplastic polymer. 2. The method of manufacturing a composite connector according to claim 1 , wherein the tubular mould portion comprises at least a first tubular part and a second tubular part claim 1 , and the continuous fibre reinforcement is applied only to the first tubular part.3. The method of manufacturing a composite connector according to claim 1 , wherein injecting the thermoplastic polymer into the mould consolidates the pre-impregnated continuous fibre-reinforcement.4. The method of manufacturing a composite connector according to claim 1 , wherein chopped fibre reinforcement is injected into the mould with the thermoplastic polymer.6. The composite connector according to claim 5 , wherein the inner layer provides a sealing surface which is parallel to the central axis across an axial seal length.7. The composite connector according to claim 6 , wherein the sealing surface has a low coefficient of friction.8. The composite connector according to claim 5 , wherein the outer layer has a radial thickness of at least 0.5 mm.9. The composite connector according to claim 5 , wherein the outer layer further comprises chopped ...

Weight balanced rotor blade with thermoplastic composite weight

A rotor blade is provided that includes an airfoil extending spanwise from a base to a tip. The airfoil extends longitudinally (e.g., chordwise) from a leading edge to a trailing edge. The airfoil extends laterally between a first side and a second side. The airfoil includes a body and a weight. The body includes a plurality of body layers. Each of the body layers includes fiber reinforcement within a body thermoplastic matrix. The weight includes a weight layer embedded within the body. The weight layer includes metal powder within a weight thermoplastic matrix.

Composite thermoplastic rotor blade with integral cuff

An apparatus is provided for rotational equipment. This apparatus includes a rotor blade including an airfoil body, a spar structure and a cuff. The airfoil body extends spanwise from a base to a tip. The airfoil body extends longitudinally (e.g., chordwise) from a leading edge to a trailing edge. The airfoil body extends laterally between a first side and a second side. The spar structure extends spanwise within and supports the airfoil body. The cuff projects out from the spar structure and away from the base of the airfoil body. The cuff is formed integral with the spar structure. The cuff and the spar structure are configured from or otherwise include thermoplastic material.

Composite components with impact detection

A fibre-reinforced polymer composite component 2 formed from a polymer matrix material containing fibre reinforcement. The component 2 comprises a main portion 4 and at least one raised feature 6 extending from a surface plane s of said main portion 4. The at least one raised feature 6 is arranged to incur visually perceptible damage when the component 2 is subject to an impact with an energy above a predetermined impact energy threshold and to resist an impact with an energy below the predetermined impact energy threshold.

componente compósito de polímero reforçado por fibra

Um componente compósito de polímero reforçado por fibra (2) formado a partir de um material de matriz polimérica contendo reforço de fibra. O componente (2) compreende uma porção principal (4) e pelo menos um recurso elevado (6) que se estende a partir de um plano de superfície s da referida porção principal (4). O pelo menos um recurso elevado (6) é disposto para incorrer em danos visualmente perceptíveis quando o componente (2) é submetido a um impacto com uma energia acima de um limiar de energia de impacto predeterminado e para resistir a um impacto com uma energia abaixo do limiar de energia de impacto predeterminado.

Método para fabricar um conector de compósito, conector de compósito, e, sistema de conexão

um método para fabricar um conector de compósito (2, 124) para um conduto de transferência de fluido é fornecido, o qual compreende aplicar reforço de fibra contínuo (103), orientado pelo menos parcialmente circunferencialmente e pré-impregnado com um polímero termoplástico a uma porção de molde tubular (104) que se estende substancialmente paralela a um eixo central c; aplicar pelo menos uma porção de molde adicional (106) para formar um molde completo (108) no qual o reforço de fibra contínuo (103) é encerrado e injetar um polímero termoplástico (122) no molde (108) para formar um conector (2, 124) com uma porção de cubo tubular (6, 128) e um porção de flange (8, 126) que se estende da porção de cubo (6, 128) em ângulo ao eixo central c. a porção de cubo tubular (6, 128) compreende uma seção de vedação tubular (7) com uma camada interna (11, 130) e uma camada externa (9, 132), em que a camada interna (11, 130) compreende o reforço de fibra contínuo (15, 103) e a camada externa (9, 132) compreende o polímero termoplástico injetado (122).

Composite thermoplastic rotor blade with integral cuff

An apparatus is provided for rotational equipment. This apparatus includes a rotor blade (26) including an airfoil body (36), a spar structure (38) and a cuff (40). The airfoil body (36) extends spanwise from a base (44) to a tip (46). The airfoil body (36) extends longitudinally (e.g., chordwise) from a leading edge (50) to a trailing edge (52). The airfoil body (36) extends laterally between a first side (54) and a second side (56). The spar structure (38) extends spanwise within and supports the airfoil body (36). The cuff (40) projects out from the spar structure (38) and away from the base (44) of the airfoil body (36). The cuff (40) is formed integral with the spar structure (38). The cuff (40) and the spar structure (38) are configured from or otherwise include thermoplastic material.

Thermoplastic composite panel with corrugated peaks and troughs stiffening systems and methods

A method for forming a fiber-reinforced thermoplastic control surface may comprise: stacking plies of thermoplastic composite sheets to a first desired thickness to form a first skin; stacking plies of thermoplastic composite sheets to a second desired thickness to form a second skin; forming the first skin in a first contour; forming the second skin in a second contour; forming a stiffening member including a thermoplastic resin, the stiffening member including a shape having a plurality of peaks and troughs; assembling the stiffening member between the first skin and the second skin; and joining the stiffening member to the first skin and the second skin.

Weight balanced rotor blade with thermoplastic composite weight

A rotor blade (20) is provided that includes an airfoil (22) extending spanwise from a base (26) to a tip (28). The airfoil (22) extends longitudinally (e.g., chordwise) from a leading edge (32) to a trailing edge (34). The airfoil (22) extends laterally between a first side (36) and a second side (38). The airfoil (22) includes a body (40) and a weight (42). The body (40) includes a plurality of body layers (44). Each of the body layers (44) includes fiber reinforcement within a body thermoplastic matrix. The weight (42) includes a weight layer (46) embedded within the body (40). The weight layer (46) includes metal powder within a weight thermoplastic matrix.

Corrugated stiffening devices utilizing peaks and valleys and methods of manufacture

A method may comprise: laying up a first plurality of plies of material comprising thermoplastic resin and fiber to form an inner skin preform, the inner skin preform being a continuous sheet including alternating peaks and valleys; laying up a second plurality of plies of material comprising thermoplastic resin and fiber to form an outer skin preform; and joining the inner skin preform to the outer skin preform.

Composite connectors and methods of manufacturing the same

A method of manufacturing a composite connector 2, 124 for a fluid transfer conduit is provided which comprises applying continuous fibre reinforcement 103, oriented at least partially circumferentially and pre-impregnated with a thermoplastic polymer to a tubular mould portion 104 which extends substantially parallel to a central axis C; applying at least one further mould portion 106 to form a complete mould 108 in which the continuous fibre reinforcement 103 is enclosed and injecting a thermoplastic polymer 122 into the mould 108 to form a connector 2, 124 with a tubular hub portion 6, 128 and a flange portion 8, 126 which extends from the hub portion 6, 128 at an angle to the central axis C. The tubular hub portion 6, 128 comprises a tubular seal section 7 with an inner layer 11, 130 and an outer layer 9, 132, wherein the inner layer 11, 130 comprises the continuous fibre reinforcement 15, 103 and the outer layer 9, 132 comprises the injected thermoplastic polymer 122.

Método para fabricar um conector de compósito, conector de compósito, e, sistema de conexão

um método para fabricar um conector de compósito (2, 124) para um conduto de transferência de fluido é fornecido, o qual compreende aplicar reforço de fibra contínuo (103), orientado pelo menos parcialmente circunferencialmente e pré-impregnado com um polímero termoplástico a uma porção de molde tubular (104) que se estende substancialmente paralela a um eixo central c; aplicar pelo menos uma porção de molde adicional (106) para formar um molde completo (108) no qual o reforço de fibra contínuo (103) é encerrado e injetar um polímero termoplástico (122) no molde (108) para formar um conector (2, 124) com uma porção de cubo tubular (6, 128) e um porção de flange (8, 126) que se estende da porção de cubo (6, 128) em ângulo ao eixo central c. a porção de cubo tubular (6, 128) compreende uma seção de vedação tubular (7) com uma camada interna (11, 130) e uma camada externa (9, 132), em que a camada interna (11, 130) compreende o reforço de fibra contínuo (15, 103) e a camada externa (9, 132) compreende o polímero termoplástico injetado (122).

Composite thermoplastic rotor blade with integral cuff

An apparatus is provided for rotational equipment. This apparatus includes a rotor blade (26) including an airfoil body (36), a spar structure (38) and a cuff (40). The airfoil body (36) extends spanwise from a base (44) to a tip (46). The airfoil body (36) extends longitudinally (e.g., chordwise) from a leading edge (50) to a trailing edge (52). The airfoil body (36) extends laterally between a first side (54) and a second side (56). The spar structure (38) extends spanwise within and supports the airfoil body (36). The cuff (40) projects out from the spar structure (38) and away from the base (44) of the airfoil body (36). The cuff (40) is formed integral with the spar structure (38). The cuff (40) and the spar structure (38) are configured from or otherwise include thermoplastic material.

Weight balanced rotor blade with thermoplastic composite weight

A rotor blade is provided that includes an airfoil extending spanwise from a base to a tip. The airfoil extends longitudinally (e.g., chordwise) from a leading edge to a trailing edge. The airfoil extends laterally between a first side and a second side. The airfoil includes a body and a weight. The body includes a plurality of body layers. Each of the body layers includes fiber reinforcement within a body thermoplastic matrix. The weight includes a weight layer embedded within the body. The weight layer includes metal powder within a weight thermoplastic matrix.

Método para fabricar um componente compósito de polímero reforçado, e, componente compósito de polímero reforçado

MÉTODO PARA FABRICAR UM COMPONENTE COMPÓSITO DE POLÍMERO REFORÇADO, E, COMPONENTE COMPÓSITO DE POLÍMERO REFORÇADO. É fornecido um método de fabricação de um componente compósito de polímero reforçado por fibra monolítica (228). O método compreende fornecer um molde (206) compreendendo uma cavidade principal (208) e pelo menos uma cavidade adicional (210) que se estende a partir da cavidade principal (208); introduzir um material de matriz polimérica (222) contendo reforço de fibra cortada no molde (206) para preencher a cavidade principal (208) e a pelo menos uma cavidade adicional (210) para formar um componente compósito de polímero monolítico reforçado por fibra (228) com uma porção principal (230) formada na cavidade principal (208) e pelo menos um recurso elevado (232) formado na cavidade adicional (210) e se estendendo a partir de um plano de superfície da dita porção principal (230). O pelo menos um recurso elevado (232) é disposto para incorrer em danos visualmente perceptíveis quando o componente (228) é submetido a um impacto com uma energia acima de um limiar de energia de impacto predeterminado e para resistir a um impacto com uma energia abaixo do limiar de energia de impacto predeterminado

método para fabricar um componente compósito de polímero reforçado, e, componente compósito de polímero reforçado

É fornecido um método de fabricação de um componente compósito de polímero reforçado por fibra monolítica (228). O método compreende fornecer um molde (206) compreendendo uma cavidade principal (208) e pelo menos uma cavidade adicional (210) que se estende a partir da cavidade principal (208); introduzir um material de matriz polimérica (222) contendo reforço de fibra cortada no molde (206) para preencher a cavidade principal (208) e a pelo menos uma cavidade adicional (210) para formar um componente compósito de polímero monolítico reforçado por fibra (228) com uma porção principal (230) formada na cavidade principal (208) e pelo menos um recurso elevado (232) formado na cavidade adicional (210) e se estendendo a partir de um plano de superfície da dita porção principal (230). O pelo menos um recurso elevado (232) é disposto para incorrer em danos visualmente perceptíveis quando o componente (228) é submetido a um impacto com uma energia acima de um limiar de energia de impacto predeterminado e para resistir a um impacto com uma energia abaixo do limiar de energia de impacto predeterminado.

Composite component with means to visually detect barely visible impact damage

A method of manufacturing a monolithic fibre-reinforced polymer composite component 228 is provided. The method comprises providing a mould 206 comprising a main cavity 208 and at least one additional cavity 210 that extends from the main cavity 208; introducing a polymer matrix material 222 containing chopped fibre reinforcement into the mould 206 to fill the main cavity 208 and the at least one additional cavity 210 to form a monolithic fibre-reinforced polymer composite component 228 with a main portion 230 formed in the main cavity 208 and at least one raised feature 232 formed in the additional cavity 210 and extending from a surface plane of said main portion 230. The at least one raised feature 232 is arranged to incur visually perceptible damage when the component 228 is subject to an impact with an energy above a predetermined impact energy threshold and to resist an impact with an energy below the predetermined impact energy threshold.

Apparatus and method for making composite shafts

Corrugated acoustic stiffening devices and methods

A method for forming a fiber-reinforced thermoplastic acoustic panel (300) may comprise: stacking plies of thermoplastic composite sheets to a first thickness to form a top sheet (320); stacking plies of thermoplastic composite sheets to a second thickness to form a backskin (330); staking plies of thermoplastic composite sheets to a third thickness to form a stiffening member (312); forming the top sheet (320) in a first contour; forming the backskin (330) in a second contour, the second contour being different from the first contour; forming the stiffening member (312) comprising a shape having a plurality of peaks (314) and troughs (316); bonding the stiffening member (312) to the top sheet (320) and the backskin (330); and perforating the top sheet (320).

Corrugated acoustic stiffening devices and methods

A method for forming a fiber-reinforced thermoplastic acoustic panel may comprise: stacking plies of thermoplastic composite sheets to a first thickness to form a top sheet; stacking plies of thermoplastic composite sheets to a second thickness to form a backskin; staking plies of thermoplastic composite sheets to a third thickness to form a stiffening member; forming the top sheet in a first contour; forming the backskin in a second contour, the second contour being different from the first contour; forming the stiffening member comprising a shape having a plurality of peaks and troughs; bonding the stiffening member to the top sheet and the backskin; and perforating the top sheet.

Apparatus and method for making composite shafts

An apparatus for forming a composite shaft may comprise an axial fiber strip dispensing assembly and a hoop fiber strip dispensing assembly. The axial fiber strip dispensing assembly may include a plurality of fiber strip guides located circumferentially about a center axis. The plurality of fiber strip guides may be configured to dispense a plurality of circumferentially adjacent first fiber strips with the plurality of circumferentially adjacent first fiber strips extending in a generally axial direction. The hoop fiber strip dispensing assembly may be configured to dispense a second fiber strip circumferentially about the center axis.

Apparatus and method for making composite shafts

An apparatus for forming a composite shaft may comprise an axial fiber strip dispensing assembly and a hoop fiber strip dispensing assembly. The axial fiber strip dispensing assembly may include a plurality of fiber strip guides located circumferentially about a center axis. The plurality of fiber strip guides may be configured to dispense a plurality of circumferentially adjacent first fiber strips with the plurality of circumferentially adjacent first fiber strips extending in a generally axial direction. The hoop fiber strip dispensing assembly may be configured to dispense a second fiber strip circumferentially about the center axis.

aparelho e método para formar um eixo composto.

Trata-se de um aparelho para formar um eixo composto que pode compreender uma montagem de distribuição de tira de fibra axial e uma montagem de distribuição de tira de fibra de arco. A montagem de distribuição de tira de fibra axial pode incluir uma pluralidade de guias de tira de fibra localizadas circunferencialmente em torno de um eixo geométrico central. A pluralidade de guias de tira de fibra pode ser configurada para distribuir uma pluralidade de primeiras tiras de fibra circunferencialmente adjacentes com a pluralidade de primeiras tiras de fibra circunferencialmente adjacentes que se estendem em uma direção geralmente axial. A montagem de distribuição de tira de fibra de arco pode ser configurada para distribuir uma segunda tira de fibra circunferencialmente em torno do eixo geométrico central.

Corrugated stiffening devices utilizing peaks and valleys and methods of manufacture

A method may comprise: laying up a first plurality of plies of material comprising thermoplastic resin and fiber to form an inner skin preform, the inner skin preform being a continuous sheet including alternating peaks and valleys; laying up a second plurality of plies of material comprising thermoplastic resin and fiber to form an outer skin preform; and joining the inner skin preform to the outer skin preform.

Weight balanced rotor blade with thermoplastic composite weight

A rotor blade is provided that includes an airfoil extending spanwise from a base to a tip. The airfoil extends longitudinally (e.g., chordwise) from a leading edge to a trailing edge. The airfoil extends laterally between a first side and a second side. The airfoil includes a body and a weight. The body includes a plurality of body layers. Each of the body layers includes fiber reinforcement within a body thermoplastic matrix. The weight includes a weight layer embedded within the body. The weight layer includes metal powder within a weight thermoplastic matrix.