Manufacturing fiber-reinforced composite body with multiple laminated layers
A method is provided for manufacturing an object. This method includes: arranging a first portion of a fabric over a tool; cutting out a section of the first portion of the fabric to provide a first ply, and disposing the first ply on the tool; arranging a second portion of the fabric over the tool; cutting out a section of the second portion of the fabric to provide a second ply, and stacking the second ply on the first ply; and consolidating a laminate stack on the tool to form the object, the laminate stack including the first ply, the second ply and a polymer matrix impregnating the first ply and the second ply.
1 . A method for manufacturing an object, comprising:
arranging a first portion of a fabric over a tool;
cutting out a section of the first portion of the fabric to provide a first ply, and disposing the first ply on the tool;
re-orienting the tool using a support device following the disposing of the first ply on the tool, wherein the support device rotates about an axis to re-orient the tool relative to the fabric;
arranging a second portion of the fabric over the tool;
cutting out a section of the second portion of the fabric to provide a second ply, and stacking the second ply on the first ply, wherein the cutting out of the section of the second portion of the fabric is after the re-orienting the tool; and
consolidating a laminate stack on the tool to form the object, the laminate stack including the first ply, the second ply and a polymer matrix impregnating the first ply and the second ply.
2 . The method of claim 1 , wherein the section cut out of the first portion of the fabric is an interior section of the first portion of the fabric.
3 . The method of claim 1 , further comprising
impregnating the first ply with the polymer matrix following the cutting out of the section of the first portion of the fabric; and
impregnating the second ply with the polymer matrix following the cutting out of the section of the second portion of the fabric.
4 . The method of claim 1 , wherein
the fabric comprises a prepreg fabric; and
the prepreg fabric includes fiber-reinforcement impregnated with the polymer matrix.
5 . The method of claim 1 , wherein the polymer matrix comprises a thermoset matrix.
6 . The method of claim 1 , wherein the polymer matrix comprises a thermoplastic matrix.
7 . The method of claim 1 , wherein the arranging of the first portion of the fabric comprises pulling the first portion of the fabric over the tool.
8 . The method of claim 7 , further comprising unrolling the fabric from a roll of the fabric during the pulling the first portion of the fabric over the tool.
9 . The method of claim 7 , further comprising:
rolling up a remnant of the fabric during the pulling the first portion of the fabric over the tool;
the first portion of the fabric located between the remnant of the fabric and the second portion of the fabric.
10 . The method of claim 7 , further comprising removing a backer from the fabric during the pulling of the first portion of the fabric over the tool.
11 . The method of claim 1 , further comprising:
forming the fabric upstream of the tool along a manufacturing line;
the forming of the fabric comprising weaving fibers together.
12 . The method of claim 1 , wherein the section of the first portion of the fabric is cut out using a knife attached to a robotic manipulator.
13 . The method of claim 1 , wherein the section of the first portion of the fabric is cut out using an energy beam.
14 . The method of claim 1 , further comprising pressing the first ply against the tool.
15 . The method of claim 1 , further comprising pressing the laminate stack between the tool and a second tool.
16 . The method of claim 1 , wherein the object is configured as a component for an aircraft.
17 . A method for manufacturing an object, comprising:
disposing a first portion of a fabric over a tool;
cutting the first portion of the fabric to leave a first ply of the fabric on the tool;
rotating the tool about an axis using a support device to reorient the tool relative to the fabric after cutting the first portion of the fabric;
disposing a second portion of the fabric over the first ply of the fabric by moving a remnant of the first portion of the fabric following the cutting of the first portion of the fabric;
cutting the second portion of the fabric to leave a second ply of the fabric on the first ply of the fabric; and
consolidating a laminate stack on the tool, the laminate stack including the first ply of the fabric, the second ply of the fabric and a polymer matrix.
18 . The method of claim 17 , further comprising:
drawing the first portion of the fabric and the second portion of the fabric from a supply roll of the fabric; and
rolling up the remnant of the first portion of the fabric onto a remnant roll of the fabric.
19 . A method for manufacturing an object, comprising:
forming a fabric upstream of a tool along a manufacturing line, the forming of the fabric comprising weaving fibers together;
dipping the fabric into an impregnation bath upstream of the tool along the manufacturing line to impregnate at least a portion of the fibers with a polymer matrix;
pulling the fabric over the tool;
cutting the fabric using a robotic manipulator to leave a first ply of the fabric on the tool;
rotating the tool about an axis using a support device to reorient the tool relative to the fabric after cutting the fabric using the robotic manipulator to leave the first ply of the fabric on the tool;
further pulling the fabric over the first ply;
cutting the fabric using the robotic manipulator to leave a second ply of the fabric on the first ply of the fabric; and
consolidating a laminate stack, the laminate stack including the first ply of the fabric, the second ply of the fabric and a polymer matrix.