Composite article and methods therefor

Abstract

A method is provided for forming a composite article to have a primary composite structure and an integral secondary composite structure that extends out of a plane defined by the primary composite structure. The method includes laying-up first plies to construct the primary composite structure. The first plies contain continuous reinforcement material and extend from a first zone that will define the primary composite structure into a second zone that will define the secondary composite structure. During laying-up of the first plies, additional plies are interleaved with the first plies within the second zone but not the first zone. The additional plies originate within a build-up zone between the first and second zones and extend therefrom into the second zone.; After interleaving the plies, the build-up zone is deformed to orient the second zone and form the secondary composite structure that extends out of the plane defined by the continuous reinforcement material of the first plies.

Description

[0001] Cross references to related applications [0002] This application claims priority from U.S. Provisional Patent No. 61 / 639,900 filed on April 28, 2012, the content of which is incorporated herein by reference. Technical field [0003] This application generally relates to methods for making composite structures. More specifically, this application relates to making composite articles with integral composite secondary structures, for example, integral flanges for composite casings of turbomachines. Background technique [0004] The composite material generally includes a fibrous reinforcing material embedded in a matrix material, which in the case of a polymer composite material is a polymer material (polymer matrix composite, or PMC). The fibrous reinforcement of the composite material is used as a secondary component of the material, while the matrix material protects the reinforcement, maintains the orientation of its fibers, and serves to dissipate the load to the reinfor...

AI Technical Summary

Problems solved by technology

However, such fiber preform design options tend to be very limited

The plies used in the construction of composite shells and the integral flanges of composite shells are typically woven or braided preforms with limited fiber orientation and the resulting stiffness and strength are not easily optimized

The degree of interleaving between fiber tows within the shell and within the flange body is also typically limited, resulting in limited resistance to delamination

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