# Patent

## Title
Radially extending composite structures

## Abstract

A composite structure having at least one radially extending part is provided. The composite structure is formed with ply layers. At least one of the ply layers used to form the radially extending part has fibers oriented at an angle offset from an edge of the at least one ply layer.

## Background
BACKGROUND
In aerospace applications there is a need for light weight high strength structures. To meet these requirements fiber reinforced composite materials are often used. Sometimes the structures include radially extending parts. Laying up plies of material in forming radially extending parts leads either to the formation of defects such as wrinkles, which weakens the part, or cannot be achieved since the fiber cannot be stretched radially. Darting can be used to lessen the formation of wrinkles and allow for radial changes, but darting itself weakens the part. This invention provides a method of laying up fiber plies in a radially extending part without darting and without the formation of wrinkles or necessity of darts.
For the reasons stated above and for other reasons stated below, which will become apparent to those skilled in the art upon reading and understanding the present specification, there is a need in the art for improved radially extending composite structures.
SUMMARY OF INVENTION
The above-mentioned problems of current systems are addressed by embodiments of the present invention and will be understood by reading and studying the following specification. The following summary is made by way of example and not by way of limitation. It is merely provided to aid the reader in understanding some of the aspects of the invention.
In one embodiment, a composite structure is provided. The composite structure includes a radially extending part that is formed with ply layers. At least one of the ply layers used to form the radially extending part has fibers oriented at 17.5 to 27.5 degrees in relation to an edge of the ply layer.



BRIEF DESCRIPTION OF THE DRAWINGS
The present invention can be more easily understood and further advantages and uses thereof more readily apparent, when considered in view of the detailed description and the following figures in which:
FIG. 1 is a top view of a radially extending part of one embodiment of the present invention;
FIGS. 2A and 2B are side perspective views of composite structures having radially extending parts of another embodiment of the present invention;
FIG. 3 is a side perspective view of a tool used to form composite structures of an embodiment of the present invention;
FIGS. 4A, 4B, 4C, and 4D illustrate possible fiber orientations of embodiments of the present invention;
FIG. 5A is an illustration of patterned flags of one embodiment of the present invention;
FIG. 5B is an illustration of spliced flags of one embodiment of the present invention;
FIG. 5C is a close up view of a spliced area of FIG. 5B;
FIG. 5D is a top view of a produced layer of ply having a desired fiber orientation of one embodiment of the present invention;
FIG. 6 illustrates an orientation of fibers in adjacent ply layers of one embodiment of the present invention;
FIG. 7 is an illustration of a forming head of an embodiment used to form ply layers;
FIG. 8 is a forming machine used to form composite structures of one embodiment of the present invention; and
FIG. 9 illustrates a formation flow diagram of one embodiment of the present invention.



In accordance with common practice, the various described features are not drawn to scale but are drawn to emphasize specific features relevant to the present invention. Reference characters denote like elements throughout the figures and the specification.
DETAILED DESCRIPTION
In the following detailed description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the inventions may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the claims and equivalents thereof.
Embodiments of the present invention provide methods and apparatus for forming composite structures with radially extending parts without the need for darting and without the formation of wrinkles that can weaken the structure. In embodiments, plies of fiber having select orientations are laid up one at a time. Materials used to form the composite structures are generally described as ply layers. The ply layers can be made of any materials with fibers (or plies) that exhibit desired characteristics including, but not limited to, pre-preg material and dry fiber material. The pre-preg material and the dry fiber material can include, but are not limited to, tapes, woven fabrics, non-woven fabrics and non-crimp fabrics. The orientation of the fibers (or plies) within the materials are described further below. Example orientations of fibers in a ply layer are +22.5/−67.5 degrees or −22.5/+67.5 degrees. In fabric embodiments the fibers have at least two fiber orientations per layer. That is, two sets of fibers with orientations that are typically orientated 90 degrees apart from each other are present in fabric embodiments. For example, fiber orientations in a fabric include 22.5 and 112.5 degrees and −22.5 and 67.5 degrees. Due in part to variations in formed ply layers, the above examples of orientation degrees can vary. In some cases, the orientation degrees can vary up to 5 degrees or more. In a tape embodiment, the fibers have only one fiber orientation.
Referring to FIG. 1, an example of a radially extending composite structure 100 is provided. In particular, FIG. 1 illustrates a top view of a radially extending composite structure 100. The composite structure 100 in this example is annular shaped. As this example illustrates, the part extends radially about a center point 102 from an inner edge 103 to an outer edge 104 of the composite structure 100. FIGS. 2A and 2B further illustrate full circumference composite structures 200 and 202 that include radially extending parts 204, 206, 208, and 210, respectively. FIG. 3 illustrates an example of a tool 300 that can be used to form the full circumference composite structures 200 and 202, as shown in FIGS. 2A and 2B.
As discussed above, embodiments use specific fiber orientations in the ply layers. Examples of different orientations used in embodiments are provided in FIGS. 4A, 4B, 4C and 4D. In particular, FIG. 4A illustrates a fiber orientation of 22.5 degrees. The 22.5 degrees is in relation to an edge of a ply layer that is further described below. The 0 degree line represents the edge of the ply layer. FIG. 4B illustrates a −22.5 degree orientation. The Fiber orientations illustrated in FIGS. 4A and 4B would typically be used in ply layers prepreg and dry fiber tapes. FIG. 4C illustrates two orientations of fibers, 22.5 degrees and 112.5 degrees. FIG. 4D also illustrates two orientations of fibers, −22.5 degrees and 67.5 degrees. In particular, FIGS. 4C and 4D illustrate fibers in a fabric that have two sets of fibers each 90 degrees apart from each other.
Typically a stock supply roll of fibers is provided by suppliers in either a 90 degree orientation or a 0 degree orientation. However, the application of the 90 degree ply or 0 degree ply on radially extending parts requires darting (cut out sections) to the radius of the part. In embodiments of the present invention, ply rolls of material are made from the stock rolls to a desired orientation that does not require darting. Referring to FIG. 5A, patterned cut flags 502 of material that have been pattern cut out of a supply roll to have a desired fiber orientation are illustrated. The patterned cut flags 502 having the desired fiber orientation are then spliced together as illustrated in FIG. 5B. In one embodiment, the flags 502 are lined up with the ends overlapping as illustrated in the close up view of area 504, which is illustrated in FIG. 5C. The amount of the overlap is a function of the design requirements. For example, overlap is 0.5 inch. In some designs, this overlap ensures that the load in a given ply 506 can be transferred in shear to an adjacent play 508 subject to the strength of the resin used. Splice locations are staggered when laying up plies on a tool so they do not overlap. In embodiments, where no overlap is desired, the flags 502 are butt-spliced. In this embodiment, an additional ply can be added to the lay-up to compensate for the discontinuous material. As long as the splices are staggered, there is always the same number of continuous plies to carry the load. FIG. 5D is a top view of a ply layer illustrating a produced ply layer 500 having a fiber orientation of 22.5 degrees. It will be understood, that lines 520 representing fibers are only provided to illustrate the fiber orientation in relation to an edge 522 of the ply layer 500. Fibers in an actual ply layer would be relatively close to each other.
In embodiments, composite structures are created by ply layers formed on a tool one ply at a time. In one embodiment, ply layers having alternating fiber orientations are used to form the composite structure. For example, in one embodiment, alternating ply layers having orientations of +22.5/−67.5 degrees and −22.5/+67.5 degrees are used to form the radially extending composite structures. An example of alternating ply layers 602 and 604 having orientations of +22.5/−67.5 degrees and −22.5/+67.5 degrees is illustrated in FIG. 6. One method of applying and forming ply layers on a tool is with a forming head 726 and automatic ply feeder (dispensing device) 724. An example of a forming head can be found in commonly assigned U.S. Pat. No. 7,513,769 (Benson et al.) filed on Jul. 30, 2004, titled “Apparatus and Methods for Forming Composite Stiffeners and Reinforcing Structures,” which is herein incorporated by reference. In particular, FIG. 7 provides an exemplary example of the material dispensing device 724 and the forming head 726. Material 740 (e.g., a ply layer or pre-preg cloth) having the desired fiber orientation is fed from a supply and tension roller 742 and over a redirect roller 744 as motivated by a pair of feed rollers 746. The material 740 passes beyond a cutting device 748 that may be used to cut the material 740 to a specified length, width, or both, such as described hereinabove with respect to other embodiments of the present invention. The material 740 is then disposed onto a portion of a tool 706A by a tack roller 750.
It is noted that the tack roller 750 (and subsequent rollers encountered by the material 740) is shown in a first elevational view with a second, rotated elevational view depicted immediately therebeneath to provide additional understanding of how the material 740 is being shaped by the interaction of various rollers with the material 740 and the underlying tool 706A.
The forming head 726 includes a plurality of rollers 728A-728D used to shape and debulk material 740 disposed over the tool 706A (or over previously shaped material plies disposed on the tool 706A). Thus, for example, a first roller 728A engages the tool 706A to generally conform the material 740 to the shape of the tool 706A. Second, a set of rollers 728B may be used to press the material 740 against the side walls 754 of the tool 706A. If desired, this may be accomplished with multiple sets of rollers 728B working from an upper portion of the tool 706A to a bottom portion as depicted in the rotated elevational views of the rollers 728B. Another set of rollers 728C may be used to press the material 740 into interior lower corners 756 of the tool 706A. A squeegee 758 (or shoe) may be used to help pull wrinkles from the material 740 at one or more intermediate locations among the rollers 728A-728D. Finally, a set of rollers 728D may be used to press and form the flange members of a composite structure 702.
It is noted that the process of forming the composite structure 702 includes forming, shaping and debulking the material 740 from the inside out. In other words, the tack roller 750 applies pressure to the tool 706A and material 740 disposed thereon at the center, with subsequent rollers 728A-728D each sequentially applying pressure at a location further toward the outer edges of the material 740. Such a process has been determined to be efficient and effective in removing wrinkles and air gaps between laminar plies of material, thereby producing a highly consolidated and debulked composite member.
A take-up roller 760 may be associated with the forming head 726 (or independently coupled with the carriage assembly) to collect carrier material 762 (also referred to as backing), which may be disposed on a surface of, for example, a pre-preg material used to form the composite structure 702. The carrier material 762, which may include a suitable polymer material, not only keeps the pre-preg material from adhering to itself when in rolled form 742 (i.e., such as, when on the supply and tension roller) but also may remain on the material 740 while the material 740 is being shaped, formed and debulked so that the various rollers 750 and 728A-728D do not stick to the material 740 or collect and build-up resin of a surface thereof. Additionally, the presence of such carrier material 762 may serve to protect the material 740 used to form a composite structure 702 when the various rollers 728A-728D press and rub against the material 740 during forming of the composite structure 702.
Another example of a forming head 804 used to form ply layers is illustrated in FIG. 8. Forming head 804 is part of a composite forming system disclosed in commonly assigned patent application Ser. No. 12/615,908, filed Nov. 10, 2009, now U.S. Pat. No. 8,282,757, issued Oct. 9, 2012, titled “Automated Composite Annular Structure Forming,” which is incorporated in its entirety herein. FIG. 8 illustrates a tool 800 that is mounted on a tool holding assembly 860 that is in turn rotationally coupled to a tool holding support. Ply layers are applied and then formed on the tool 800 in this embodiment. As illustrated, the tool 800 rotates in relation to a tool holding support as an operator 812 applies the material (ply layer) 810 to the tool 800. The forming head 804, which includes forming rollers, forms the ply layer 810 on the tool 800. Once, the ply layers 810 have been formed, the forming head 804 is pulled back from the tool 800 via track 840. The tool 800, with the formed ply layers 810, can then be removed for curing to form a composite structure. For example, tool 800 forms a composite structure such as composite structures 200 and 202, as shown in FIGS. 2A and 2B that have radially extending parts 204, 206, 208, and 210, respectively. Embodiments are not limited to specific cross-sectional geometries of formed composite structures. Any geometry that includes radially extending parts has application.
Referring to FIG. 9, a formation flow diagram 900 of a composite structure of an embodiment is illustrated. As discussed above, the process starts by making a ply layer. This process involves cutting flags from a stock supply having a desired orientation (902). The flags are then lined up end to end (904) and spliced together (906) to form the ply layer. The ply layer is then applied to a forming surface of a tool or mandrel (910). The ply layer on the tool is then formed on the forming surface of the tool (912). It is then determined if more ply layers are required to form the composite structure (914). If more ply layers are required (914), a ply layer having a desired fiber orientation is selected (916). As discussed above, in some embodiments it is desired to alternate the fiber orientations between adjacent ply layers. Once, the ply layer with the desired orientation has been selected (916) it is applied to the forming surface of the forming tool (910). Hence, ply layers are formed one at a time over each other until a desired number of layers have been reached (914). Once, it is determined the ply layering is complete at (914), the formed ply layers on the tool are then cured (918) to form the desired composite structure.
Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement, which is calculated to achieve the same purpose, may be substituted for the specific embodiments shown. For example, slight variations in orientation of the fibers could be implemented with the same result. Hence, variations of 5 degrees or more may be possible. This application is intended to cover any adaptations or variations of the present invention. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof.

## Claims

1. A composite structure produced by an at least partially automated layup process, the composite structure comprising:
a cylindrical portion extending in an axial direction around a centerline;
at least one flange portion exhibiting a substantially elliptical shape, the at least one flange portion extending and positioned radially outward from one side portion of the cylindrical portion in a direction along an axis substantially perpendicular to the centerline of the cylindrical portion, the cylindrical portion having a different geometry than the at least one flange portion; and
at least one continuous ply layer comprising a plurality of flags each comprising fibers and a matrix material, the plurality of flags each being positioned adjacent another flag of the plurality of flags to define the at least one continuous ply layer having the fibers oriented at an angle offset from an edge of the at least one continuous ply layer, wherein the fibers of each flag of the plurality of flags of the at least one continuous ply layer are oriented at the same angle, the fibers of the at least one continuous ply layer being substantially evenly placed relative to adjacent fibers along a length of the fibers on the cylindrical portion, the at least one continuous ply layer extending continuously from the cylindrical portion, over an interface between the cylindrical portion and the at least one flange portion, and along the at least one flange portion.

2. The composite structure of claim 1, wherein the fibers of the at least one continuous ply layer are oriented at +17.5 to +27.5 degrees in relation to the edge of the at least one continuous ply layer.

3. The composite structure of claim 1, wherein the fibers of the at least one continuous ply layer are oriented −22.5 degrees in relation to the edge of the at least one continuous ply layer.

4. The composite structure of claim 1, wherein the at least one continuous ply layer is a plurality of ply layers having alternating orientations of fiber oriented at +22.5 degrees and −22.5 degrees in relation to an edge of a respective continuous ply layer of the plurality of ply layers.

5. The composite structure of claim 1, wherein the at least one continuous ply layer comprises a fabric layer, wherein the fibers of fabric layer are oriented at 17.5 to 27.5 degrees in relation to the edge of the at least one continuous ply layer, and wherein the fabric layer comprises additional fibers oriented at 107.5 to 117.5 degrees in relation to the edge of the at least one continuous ply layer.

6. The composite structure of claim 1, wherein the at least one continuous ply layer is a plurality of continuous ply layers with at least some of the plurality of continuous ply layers having differing fiber orientations.

7. The composite structure of claim 1, wherein the fibers of the at least one continuous ply layer are oriented at +/−17.5 to +/−27.5 degrees in relation to the edge of the at least one continuous ply layer.

8. The composite structure of claim 1, wherein the fibers of the at least one continuous ply layer are oriented at 62.5 to 72.5 degrees in relation to the edge of the at least one continuous ply layer.

9. The composite structure of claim 1, wherein the fibers of the at least one continuous ply layer are oriented at −62.5 to −72.5 degrees in relation to the edge of the at least one continuous ply layer.

10. The composite structure of claim 1, wherein the at least one continuous ply layer comprises a fabric having a first set of fibers and a second set of fibers, the first set of fibers and the second set of fibers having different orientations that are offset 90 degrees from each other.

11. The composite structure of claim 10, wherein the first set of fibers have a fiber orientation of 17.5 to 27.5 degrees in relation to the edge of the at least one continuous ply layer and the second set of fibers have a fiber orientation of 107.5 to 117.5 degrees in relation to the edge of the at least one continuous ply layer.

12. The composite structure of claim 11, further comprising at least one other ply layer comprising a fabric having a third set of fibers and a fourth set of fibers, the third set of fibers and the fourth set of fibers having different orientations that are offset 90 degrees from each other.

13. The composite structure of claim 12, wherein the third set of fibers have a fiber orientation of −17.5 to −27.5 degrees in relation to an edge of the at least one other ply layer and the fourth set of fibers have a fiber orientation of 62.5 to 72.5 degrees in relation to the edge of the at least one other ply layer.

14. The composite structure of claim 1, wherein at least one flag of the plurality of flags does not overlap with an adjacent flag of the plurality of flags.

15. The composite structure of claim 1, wherein each flag of the plurality of flags overlaps with at least one adjacent flag of the plurality of flags.

16. The composite structure of claim 1, wherein each flag of the plurality of flags is butt-spliced with at least one adjacent flag of the plurality of flags.

17. The composite structure of claim 1, wherein the cylindrical portion comprises an elliptical cross section.

18. A composite structure comprising:
a cylindrical portion extending in an axial direction about a centerline; and
at least one radially extending part extending outward from one side portion of the cylindrical portion in a direction along an axis substantially perpendicular to the centerline of the cylindrical portion, the cylindrical portion having a different geometry than the at least one radially extending part, the cylindrical portion and the at least one radially extending part including at least one continuous ply layer having fibers oriented at an angle offset from an edge of the at least one continuous ply layer, the at least one continuous ply layer comprising a plurality of flags each comprising fibers, the plurality of flags each being positioned adjacent another flag of the plurality of flags to define the at least one continuous ply layer, the at least one continuous ply layer extending from the cylindrical portion to the at least one radially extending part, wherein the fibers of the at least one continuous ply layer extend continuously along the at least one radially extending part such that spacing between the fibers in a portion of the at least one continuous ply layer on the at least one radially extending part gradually increases and expands as the at least one continuous ply layer extends toward a radially outer edge of the at least one radially extending part.

19. The composite structure of claim 18, wherein the fibers of the at least one continuous ply layer are oriented at 17.5 to 27.5 degrees in relation to the edge of the at least one continuous ply layer.

20. The composite structure of claim 18, wherein the at least one continuous ply layer extends continuously along the cylindrical portion and the at least one radially extending part without the area within the outer edges of each flag of the plurality of flags of the at least one continuous ply layer having been cut before or during layup of the at least one continuous ply layer to form the composite structure.

21. A composite structure comprising:
a first portion extending around a centerline; and
a radially extending part extending outward from at least one end of the first portion in a direction along an axis transverse to the centerline of the first portion, the first portion having a different geometry than the radially extending part, the first portion and the radially extending part including at least one continuous ply layer having fibers therein, the at least one continuous ply layer comprising at least two flags each comprising fibers, at least one flag of the at least two flags being positioned adjacent another flag of the at least two flags to define the at least one continuous ply layer, the at least one continuous ply layer extending continuously from the first portion to the radially extending part, wherein the at least one continuous ply layer extends continuously along the radially extending part to an outer edge of the radially extending part, and wherein relative spacing of the fibers in the at least one continuous ply layer in the at least one radially extending part gradually increases as the at least one continuous ply layer extends toward a radially outer edge of the at least one radially extending part.

22. The composite structure of claim 21, wherein the first portion exhibits a cylindrical shape.

23. The composite structure of claim 21, further comprising another radially extending part extending outward from another end of the first portion in the direction along the axis transverse to the centerline of the first portion.

24. A composite structure comprising:
a portion of a cylinder extending in an axial direction around a centerline; and
at least one flange portion extending radially outward from at least one side portion of the portion of the cylinder in a direction along an axis transverse to the centerline of the portion of the cylinder, the portion of the cylinder having a different geometry than the at least one flange portion, the portion of the cylinder and the at least one flange portion including at least one continuous ply layer having fibers oriented at an angle offset from an edge of the at least one continuous ply layer, the at least one continuous ply layer comprising a plurality of flags each comprising fibers, at least one flag of the plurality of flags being positioned adjacent another flag of the plurality of flags to define the at least one continuous ply layer, wherein the at least one continuous ply layer extends continuously along the portion of the cylinder and the at least one flange portion without the at least one continuous ply layer having been cut during layup of the at least one continuous ply layer to form the composite structure.