Device and method for positioning a ply of material of a composite component along an arcuate surface

Abstract

A method and device of positioning a ply of material for a composite component along an arcuate surface are presented. The ply comprises two end portions and a plurality of fiber tows extending longitudinally between the two end portions. The arcuate surface has a curved edge and a planar surface extending from the curved edge. The method comprises placing a first longitudinal edge portion of the ply along the curved edge; and rotating at least one of the two end portions away from the arcuate surface about a pivot axis normal to the ply, so as to cause sliding of at least some of the plurality of fiber tows relative to each other, and substantial aligning of the plurality of fiber tows in a curved direction along the arcuate surface. A method of positioning a ply of material for a composite component onto a curved mandrel is also presented.

1 . A method of positioning a ply of material for a composite component along an arcuate surface, the ply comprising two end portions and a plurality of fiber tows extending longitudinally between the two end portions, the arcuate surface having a curved edge and a planar surface extending from the curved edge, the method comprising:
 placing a first longitudinal edge portion of the ply along the curved edge; and   rotating the two end portions away from the arcuate surface about a pivot axis normal to the ply, so as to cause:
 sliding of at least some of the plurality of fiber tows relative to each other; and 
 substantial aligning of the plurality of fiber tows in a curved direction along the arcuate surface. 
   
     
     
         2 . The method as defined in  claim 1 , wherein the ply includes a plurality of bonds maintaining the plurality of fibre tows in an original position, the method further comprising breaking the at least some of the plurality of bonds in order to allow the fibre tows to slide in relation to each other when rotating the at least one of the two end portions. 
     
     
         3 . The method as defined in  claim 2 , wherein the ply has a first shearing angle before rotating the at least one of the two end portions of the ply away from the arcuate surface; and
 a resulting ply having the plurality of fiber tows substantially aligned in the curved direction has a second shearing angle larger than the first shearing angle after breaking the at least some of the plurality of bonds.   
     
     
         4 . The method as defined in  claim 1 , wherein the curved edge is an outer curved edge, the arcuate surface having an inner curved edge, and the plurality of fiber tows being substantially aligned in the curved direction between the outer curved edge and the inner curved edge after rotating the at least one of the two end portions away from the arcuate surface. 
     
     
         5 . The method as defined in  claim 1 , to further comprising clamping the at least one of the two end portions within a clamping unit before rotating the at least one of the two end portions, the clamping unit being operative for differential displacement of adjacent ones of the plurality of fiber tows within the ply along the curved direction. 
     
     
         6 . The method as defined in  claim 1 , wherein the ply is a dry fabric. 
     
     
         7 . The method as defined in  claim 1 , wherein the pivot axis is aligned with the curved edge of the arcuate surface in the curved direction. 
     
     
         8 . The method as defined in  claim 1 , wherein placing the first longitudinal edge portion of the ply along the curved edge comprises folding at least a portion of the ply over the arcuate surface thereby creating at least one bulge in the ply; and
 removing the at least one bulge as a result of rotating the at least one of the two end portions of the ply away from the arcuate surface.   
     
     
         9 . The method as defined in  claim 1 , wherein the ply is a 0 degree ply. 
     
     
         10 . The method as defined in  claim 1 , wherein the plurality of fibre tows comprises carbon fibres. 
     
     
         11 . (canceled) 
     
     
         12 . The method as defined in  claim 1 , wherein the rotation is of between 6 and 20 degrees. 
     
     
         13 . The method as defined in  claim 1 , wherein the arcuate surface has a radius of curvature of between 42 inches and 46 inches. 
     
     
         14 . The method as defined in  claim 11 , further comprising providing an extension of the fiber tows together with the rotation. 
     
     
         15 . The method as defined in  claim 14 , wherein the extension of the fiber tows is provided by a clamp. 
     
     
         16 . The method as defined in  claim 4 , wherein tows of the plurality of fiber tows closer to the inner curved edge undergo greater relative sliding than tows of the plurality of fiber tows closer to the outer curved edge. 
     
     
         17 .- 35 . (canceled)