System and method for consolidating dry fabric around a mandrel

Abstract

A system and method for wrapping fabric around a mandrel including providing a drum of fabric and a mandrel, removing a portion of the fabric from the drum and securing the fabric to the mandrel, rotating the mandrel such that the fabric wraps around the mandrel, and applying pressure to the fabric as the fabric is being wrapped around the mandrel to consolidate the fabric about the mandrel.

Description

BACKGROUND OF THE INVENTION[0001]Embodiments of the present invention generally relate to a system and method for making fiber preforms by consolidating dry fiber fabric around a mandrel tool and, more particularly, to a system and method for applying an external force to dry fabric as it is consolidated in layers around a mandrel tool in order to prevent the fabric from sagging, distorting, and moving during the consolidation process.[0002]In the composite industry, cylindrical fiber preforms made of consolidated dry fiber fabric are used in numerous applications requiring a sturdy, hollow, generally cylindrical structure, such as a plane fuselage, a nacelle, the tail cone of a helicopter, and / or a case. The fiber preforms are made by tightly wrapping a sheet of dry fiber fabric, with the option of applying or pre-applying a light adhesive / resin, around a generally cylindrical mandrel in a series of layers—not unlike a long sheet of paper towels being wrapped around a tube—until th...

AI Technical Summary

Benefits of technology

[0006]Certain embodiments of the present invention include a system for wrapping fabric around a mandrel. The system may include a sheet of fabric, a mandrel configured to receive the fabric, and at least one fiber and / or fabric tow line. The sheet of fabric is secured to the mandrel and the tow line is secured to one of the fabric and mandrel, and the mandrel rotates such that the fabric and the tow line are wrapped around the mandrel. The tow line is configured under specified tension to apply pressure to the fabric as the fabric is wrapped around the mandrel.

Problems solved by technology

However, as the fabric is wrapped around the mandrel, and is overlapped around itself, the fabric can become loose and move, bulky in areas, and in general, not tightly wrapped around the mandrel.

The conventional method and system of consolidating dry fabric around a mandrel to make a fiber preform suffers from several drawbacks.

The process of vacuum debulking the fabric is very time consuming and costly, especially when the process is performed numerous times while making a single fiber preform.

Another drawback is the application of heat treatment option, which requires time to heat and cool the fabric before the solid film may be removed.

The additional cost of the tools, labor, and energy for performing the vacuum debulking process is also considerable.

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