Patent Description:
Pre-preg manufacture is a widely used technique in the manufacture of composite articles. Pre-pregs are widely used in e.g. aerospace, and for the construction of wind turbine blades. "Pre-pregs" comprise a layer of fibre reinforcement which has been impregnated with an uncured or partially cured matrix material. The term pre-preg also includes so-called semi-preg materials in which the matrix is bonded to the surface of the fibers of the reinforcement, but not so that the fibers are wet out, i.e. the matrix material is on the surface of the fibers and not fully dispersed throughout the reinforcement. The fibre may be selected from a wide range of materials, including carbon, glass, aramids or a combination of materials. The fibre may be woven or non-woven, and each layer of pre-preg may have various fibre sub-layers within. These sub-layers may be at the same orientation (unidirectional) or at different orientations (bi-axial, tri-axial, multi-axial or in the form of non-crimped fabric), e.g. <NUM>/+<NUM>/-<NUM>/<NUM> degrees. The matrix material is generally a polymer and may be a thermoset (e.g. epoxy) or a thermoplastic material.

Laying-up of multiple pre-preg layers can be time consuming. Automated processes are known in the art, such as ATL (automated tape layup) which speeds up the layup process. The critical constraint for layup is deposition rate (whether manual or automated). Ultimately, the manufacture of a composite component is dependent on the maximum speed at which the layers can be deposited. Therefore, it is generally desirable to use fewer, thicker layers. Use of fewer, thicker layers has been adopted in the construction of wind turbine blades for some time, but now the aerospace industry is looking to take on this approach to increase manufacturing efficiency.

A problem with any layup process, and the resulting component, is so-called "ply drop-off". This occurs at the edges of adjacent layers of vertically stacked but off-set composite materials; i.e. where one layer is located above another layer but the edge the of the upper layer falls inside the surface of the lower layer. This abrupt change of cross section is known as a "drop-off". Currently, ply drop-off results in a step change in material thickness caused by the abrupt edge of one layer on another, producing a sharp corner in the surface of the pre-preg. This is problematic, not only aesthetically, but also mechanically as such a feature can cause undesirable stress concentrations in the component. The problem becomes exacerbated with thicker pre-preg layers, as the drop-off becomes more severe. Therefore, there is a tension between the need to use fewer, thicker layers to increase manufacturing efficiency on the one hand, and to reduce layer thickness to reduce the effects of ply drop-off on the other hand.

<CIT> discloses forming stacks of fibrous layers having reduced thicknesses at the edges of the stacks by staggering the widths of the individual fibre layers.

<CIT> discloses a method of fabricating a thermosetting matrix, fiber reinforced composite structure wherein a stack of fiber reinforced thermosetting plies are assembled; an ultrasonic horn is engaged with a top surface of the uppermost ply, oriented at an acute angle with respect to the top surface, and energized to induce a shear wave in the plies to heat the plies.

It is an aim of the present invention to overcome, or at least mitigate, this problem and/or to provide improvements generally.

According to the present invention, there is provided a method and a composite material as detailed in any of the accompanying claims.

According to a first aspect of the invention there is provided a method of manufacture of a composite component comprising the steps of:.

By the edge of the second layer being "adjacent a surface of the first layer" it is meant that the second layer is in contact with a surface of the first layer but that at least one edge of the second layer is displaced from any edge of the first layer, so that a step is formed between the upper surface of the second layer and the upper surface of the first layer.

Preferably, the initial <NUM>° angle between the edge of the second layer and the surface of the first layer is reduced to less than <NUM>°, more preferably to from <NUM> to <NUM>°.

The pressure and any vibrational energy applied to the second layer of pre-preg composite material may be applied directly to the layer or may be applied via an intervening layer, such as a removable sheet of siliconized paper.

In a particular embodiment of the method of the invention the step of applying pressure and, optionally, vibrational energy to the edge of the second layer is carried out at a first position; and the method comprises a further step of applying pressure and, optionally, vibrational energy to the second layer at a second position, the second position being offset in a direction normal to the edge of the second layer with respect to the first position.

The pressure applied to the edge of the second layer of pre-preg composite material in order to smooth the ply drop will depend upon a number of factors, including the nature and thickness of the material and whether or not vibrational energy is also applied. In the absence of vibrational energy very high pressures may be necessary; however, particularly when vibrational energy is also applied, the pressure is preferably more than or equal to 20kPa and/or less than or equal to 500kPa. More preferably, the pressure is from <NUM> to 200KPa, even more preferably from <NUM> to 150kPa.

In a preferred embodiment of the method of the invention both pressure and vibrational energy are applied to the edge of the second layer of pre-preg composite material. The pressure and vibrational energy may be applied separately, but are preferably applied simultaneously. Applying both pressure and vibrational energy when smoothing the edge of the second layer of pre-preg composite material, particularly applying both simultaneously, is particularly advantageous as it generates a very concentrated form of energy which is capable of displacing fibres within the composite material, thereby providing maximal smoothing with reduced resin displacement. Any form of vibrational energy may be applied, but, preferably, the vibrational energy is ultrasonic energy. Suitably, pressure and ultrasonic energy may be applied to the edge of the second layer of pre-preg composite material simultaneously by means of an ultrasonic transducer, or sonotrode, for example as the ultrasonic transducer is moved along the edge of the second layer. In a particular embodiment, the method of the present invention may include depositing the second layer onto the first layer using an automated pre-preg laying apparatus, and following the automated pre-preg laying apparatus with an ultrasonic transducer.

The vibrational energy applied to the edge of the second layer of pre-preg composite material in order to smooth the ply drop in the method of the present invention will depend upon a number of factors, including the nature and thickness of the material, the amount of pressure also applied, and the form of the vibrational energy. Preferably however, when the vibrational energy is in the form of ultrasonic energy the energy applied to the edge is more than or equal to <NUM> kW/m<NUM> and/or less than or equal to <NUM> kW/m<NUM>. More preferably, the ultrasonic energy is from <NUM> to <NUM> kW/m<NUM>. The value of the energy applied is calculated as the energy input over the application area in the application time.

In a preferred embodiment of the method of the present invention the edge of the second layer of pre-preg composite material defines an undulating formation. Advantageously, the provision of an undulating formation allows the fibres of the second layer of pre-preg composite material to "spread" upon the application of the force and any vibrational energy, causing the thickness of the material in that area to taper instead of being an otherwise severe "step".

By an undulating formation it is meant that the edge of the composite material is not linear but is shaped; for example the edge may comprise a plurality of protrusions. The protrusions of the undulating formation may be irregularly shaped and/or irregularly spaced, but preferably they are regularly shaped and regularly spaced. The protrusions may be any suitable shape to promote fibre spreading, such as triangular or curved - for example sinusoidal or formed as a series of alternating and adjacent circle-segments. The protrusions of the undulating formation need not be adjacent, there may be flat edge portions between each protrusion, but in preferred embodiments of the method of the invention the plurality of the protrusions are adjacent. It is also preferred that the protrusions are triangular or have curved edges. In embodiments of the invention in which the protrusions are triangular, the triangles preferably have a height of from <NUM> to <NUM> and a base of from <NUM> to <NUM>, more preferably a height of from <NUM> to <NUM> and a base of from <NUM> to <NUM>.

The method of the present invention is suitable to smooth ply drop associated with the laying up of any pre-preg composite material, however it is particularly suitable for smoothing the ply drop produced by laying up relatively thick materials. In preferred embodiments of the present invention the second layer of pre-preg composite material has a thickness of from <NUM> to <NUM>, preferably from <NUM> to <NUM> or from <NUM> to <NUM>.

Similarly, the method of the present invention may be used when laying up pre-preg composite materials comprising any arrangement of fibres, including materials in which the fibres are unidirectional, multi-axial or in the form of a non-crimped fabric.

The method of the present invention may also be used when laying up pre-preg composite materials comprising any types of fibres such as carbon, glass, aramids or a combination of materials; however, the method of the invention is particularly suitable for use when laying up pre-preg composite materials comprising carbon or glass fibres.

The method of the present invention is particularly suitable for laying up multiple layers of pre-preg composite materials and smoothing the ply drop associated with each layer. In a particular aspect of the invention the method of the invention may therefore further comprise the steps of:.

In an alternative embodiment of this aspect of the invention, multiple layers of pre-preg composite materials may be laid up before pressure and, optionally, vibrational energy is applied to smooth the associated ply drops. In this embodiment, if the edges are relatively close together, the pressure and optional vibrational energy may be applied to each of the edges simultaneously, for example by a single transducer head large enough to overlap each of the edges. Alternatively, if the edges are sufficiently widely spaced, the pressure and optional vibrational energy may be applied to each of the edges separately, for example by a single transducer head moving sequentially from one edge to another or by multiple transducer heads.

The method of the present invention may also include the step of curing the laid up materials after smoothing of the ply drops, and any curing method suitable for curing the particular laid-up pre-preg composite materials may be used.

The invention also provides a composite component comprising:.

Example methods according to the invention will now be described with reference to the accompanying Figures, in which:.

Referring to <FIG>, there is shown a workpiece <NUM> constructed from a first layer <NUM> and a second layer <NUM> of pre-impregnated composite material. Each layer <NUM>, <NUM> comprises a mat of several sub-layers of non-woven carbon fibre material impregnated with an uncured resin matrix. Final curing has not taken place, and as such the workpiece <NUM> retains a degree of flexibility, with the fibres being mobile in the matrix.

The layers <NUM>, <NUM> are aligned to an X-Y plane, with Z being the out-of-plane (thickness) direction.

The first layer <NUM> has a first surface <NUM>, a second surface <NUM> and an edge <NUM>. The second layer <NUM> has a first surface <NUM>, a second surface <NUM> and an edge <NUM>. The edges <NUM>, <NUM> are not aligned, in other words the edge <NUM> of the second layer <NUM> terminates at a position offset from the edge <NUM> of the first layer <NUM>, and adjacent to the first surface <NUM> of the first layer <NUM>.

This creates a "ply drop" <NUM>, i.e. an abrupt step from the first surface <NUM> of the second layer <NUM> to the first surface <NUM> of the first layer <NUM>. This is the feature which the present invention seeks to mitigate.

As shown in <FIG>, an ultrasonic transducer <NUM> is provided which is configured to emit ultrasonic energy (specifically ≥<NUM>) in the -Z direction (i.e. towards the workpiece <NUM>). According to the invention, the transducer <NUM> is placed into contact with the workpiece <NUM> (as shown in hidden line in <FIG>) at the ply drop <NUM> and a force F applied in the -Z direction. An intermediate layer (not shown) may be present between the ultrasonic transducer <NUM> and the upper surface of the second layer <NUM>, such as a sheet of siliconized paper. The transducer <NUM> is activated to transfer pressure and ultrasonic energy to the second layer <NUM> proximate the edge <NUM>, and preferably at the edge <NUM>. The time over which the ultrasonic energy is applied may be adjusted based on the area of the transducer head and the rate of energy transfer. This has the effect of spreading /splaying the fibres of the second layer <NUM> to reduce the local thickness and to therefore spread out, or "smooth", the ply drop <NUM>.

The transducer <NUM> can be incrementally moved along the width of the ply drop <NUM> (<FIG>).

Referring to <FIG>, the workpiece <NUM> is shown with an alternative ultrasonic transducer <NUM>. The transducer <NUM> is rotational, and as such can remain in contact with the workpiece <NUM>, applying a force to the ply drop <NUM> as it moves in the X direction.

Referring to <FIG>, an automated layup and process according to the invention is shown. In <FIG>, an automatic tape laying (ATL) head <NUM> is provided, which is configured to deposit prepreg material. The ATL head <NUM> deposits a first layer <NUM> in the +X direction. The ATL head finishes depositing the first layer <NUM> and returns in direction -X without depositing, as shown in <FIG>. Moving from <FIG>, the head <NUM> completes a further deposition run, depositing a second layer <NUM> of prepreg. A ply drop <NUM> is defined between the first and second layers <NUM>, <NUM> per <FIG>.

A mobile ultrasonic transducer <NUM> is provided which is configured to follow behind the ATL head <NUM> and to provide pressure and ultrasonic energy transfer to the ply drop <NUM> as with the previous embodiments.

In each of the above embodiments, it is preferable that the edge <NUM> defining the ply drop <NUM> is configured in a certain way. In the following embodiments, various edges <NUM> are described, each of which may be employed in any of the above-described processes.

Referring to <FIG>, the layer <NUM> is shown having edge <NUM> defining a ply drop <NUM> per the above embodiments. The edge <NUM> is undulating in the X-Y plane. In this embodiment, the edge <NUM> describes a repeating triangular formation comprising a plurality of adjacent, identical, triangular regions <NUM>. This results in a series of peaks <NUM> and troughs <NUM>. Each region has a "height" in the Y direction of H, and a "base" in the X direction of B (between peaks). In this embodiment, H=<NUM> and B=<NUM>. Force and ultrasonic energy is applied across the Y length of the formation, for example by a mobile ultrasonic transducer <NUM> (as shown in <FIG>) progressing in the X direction. As the force and ultrasonic energy is applied, the fibres within the layer <NUM> displace and spread. <FIG> shows the fibre part of the layer <NUM>, and how it reacts to ultrasonic energy and force input. It progresses from an undeformed state S1 through stages S2, S3, S4 to a deformed state S5 as the force and pressure is applied.

Referring to <FIG>, a section view of the layer <NUM> is shown, corresponding to stage S5 in <FIG>. In <FIG>, both the fibre component <NUM>-<NUM> and matrix component <NUM>-<NUM> are shown. The transducer <NUM> is also shown. The fibres <NUM>-<NUM> have spread (per <FIG>) providing a taper, but the polymer matrix has flowed to create two regions or "bumps" on either side of the transducer <NUM>. This will be discussed further below.

Referring to <FIG>, various results of experiments applying the present invention are shown.

<FIG> shows a starting profile P1 (dashed line) of an undeformed ply drop <NUM> which has a thickness of <NUM> and a straight edge profile. In this case the material is multiaxial glass pre-preg (<NUM>°/+<NUM>°/- <NUM>°). The ply drop <NUM> has been subjected to the application of force and ultrasonic energy from the transducer <NUM> per <FIG>. The vertical axis represents Z thickness in microns. The force and energy is applied over a sonotrode width S in the Y direction (which in this embodiment is <NUM>). The sonotrode had an area of <NUM>,<NUM><NUM>. It is to be noted that the sonotrode width S overlaps the ply drop <NUM>. The sonotrode was provided with 1600N force in the -Z direction, resulting in a pressure of 150kPa over the area of the sonotrode, and 1000J energy (converted to ultrasonic energy), over a time period of <NUM> seconds, resulting in an energy transfer of <NUM>/Wm<NUM>.

The profile P2 shows the deformed YZ section through the layup. As can be seen, the otherwise severe ply drop has been softened, however the transition remains significant. It is to be noted that resin flow either side of the sonotrode <NUM> (both in the +Y and -Y directions) has produced an uneven or "bumpy" profile P2.

<FIG> shows a starting profile P1 with an undulating or oscillating edge at the ply drop <NUM>. It will be noted that the sonotrode <NUM> overlaps both the peaks <NUM> and troughs <NUM> (i.e. the entire height H of the formation). The sonotrode, force and ultrasonic treatment are the same as for <FIG>. The profile P2 shows the deformed YZ section through the layup. As can be seen, the otherwise severe ply drop has been softened, and the transition is smoother than that of <FIG>. This is a result of the lateral "spreading" effect described with reference to <FIG>. It is to be noted that some resin flow either side of the sonotrode is still visible.

<FIG> is identical to the test of <FIG>, but the ultrasonic energy has been dropped from 1000J to 750J.

<FIG> is identical to the test of <FIG>, but the force has been decreased from 1000N to 200N, and the ultrasonic energy has been increased from 1000J to 2000J. Resin flow is more pronounced than in <FIG>.

<FIG> is representative of a test identical to <FIG>, but a second dose of force and energy has been applied sequentially, and after the first. For the second dose, the sonotrode has been moved from the initial position (dashed line) in the -Y direction to a further position which overlaps only the troughs <NUM>. The second dose of force and ultrasonic energy is identical to the first (200N/2000J). The "bump" which developed in the -Y direction behind the sonotrode <NUM> in <FIG> has been smoothed out, and the profile of <FIG> is a significant improvement thereon.

<FIG> is identical to the test of <FIG>, but the force has been decreased from 1000N to 500N, and the ultrasonic energy has been decreased from 1000J to 500J. There is minimal resin flow behind the sonotrode at this level. There was also limited lateral displacement and "spreading" of the fibres.

<FIG> is a repeat of <FIG>, but with a second dose of force and energy applied sequentially, and after the first. For the second dose, the sonotrode has been moved from the initial position (dashed line) in the -Y direction to a further position which overlaps only the troughs <NUM>. The second dose of force and ultrasonic energy is identical to the first (500N/ 500J). The "bump" which developed in the -Y direction behind the sonotrode <NUM> in <FIG> has been smoothed out, and the profile of <FIG> is a significant improvement thereon.

Claim 1:
A method of manufacture of a composite component comprising the steps of:
providing a first layer of pre-preg composite material (<NUM>);
providing a second layer of pre-preg composite material (<NUM>), the second layer (<NUM>) having an edge (<NUM>);
laying-up the first and second layers of pre-preg composite material (<NUM>, <NUM>) such that the edge (<NUM>) of the second layer (<NUM>) is adjacent a surface (<NUM>) of the first layer of pre-preg composite material (<NUM>); and characterized by
applying pressure and, optionally, vibrational energy to the edge (<NUM>) of the second layer (<NUM>) to thereby smooth the ply drop (<NUM>) at the edge (<NUM>) of the second layer (<NUM>) so that the sharp, vertical drop-off at the edge (<NUM>) of the second layer (<NUM>) is converted to a gradual, generally smooth slope (P2), and the initial <NUM>° angle between the edge (<NUM>) of the second layer (<NUM>) and the surface (<NUM>) of the first layer (<NUM>) is reduced.