Thermoplastic braid for manufacturing composite article

Abstract

The invention relates to a thermoplastic braid for manufacturing a composite article. A method (800) of manufacturing a composite article (894) includes forming a braid stack (1110) including one or more braid plies (310, 410, 510) around a braid mandrel (110) along at least a portion of a longitudinal axis (112) of the braid mandrel (110). Each braid layer (310) may be formed by weaving belt segments (320) of a fiber reinforced thermoplastic resin belt applied in a belt tow orientation (322) with wire segments (330-1) applied in a wire tow orientation (332-1), the wire tow orientation (332-1) being offset at an angle (334-1) relative to the belt tow orientation (322). In one example, the line segment (332-1) includes a thermoplastic resin thread (818) that is integrated into a consolidated formation (886) of the braided stack (1110) after a consolidation process. In another example, the line segment (332-1) includes a metal wire (820) that is removed from the braid stack (1110) prior to consolidation.

Description

[0001] Cross references to related applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 588,955, filed on October 9, 2023, entitled “Thermoplastic Braids for Making Composite Articles,” the entire contents of which are hereby incorporated by reference for all purposes. Technical Field

[0003] The presently disclosed subject matter relates generally to the manufacture of composite articles and, more particularly, to braiding fiber reinforced thermoplastic resin tapes with wires. Background Art

[0004] Thermoplastic materials can be formed into various composite articles. For example, a thermoplastic resin can be reinforced with fibers to form a fiber reinforced thermoplastic resin tape. Segments of the fiber reinforced thermoplastic resin tape can be woven together to form a lay-up, which is then heated to obtain a consolidated shape of the woven tape segments. The consolidated shape can be post-processed by cutting or forming to obtain the composite article in its final form. Summary of the invention

[0005] An example method for manufacturing a composite article includes forming one or more braided layers around a braiding mandrel. Each braided layer is formed by braiding a tape segment of a fiber-reinforced thermoplastic resin tape applied on a tape tow orientation with a thread segment applied on a thread tow orientation. For each braided layer, the thread tow orientation is offset at a certain angle relative to the tape tow orientation. Braiding the thread segments with fiber-reinforced thermoplastic resin tape segments on different thread tow orientations provides the potential to stabilize the tape segments within the braided layer, while also addressing potential challenges associated with the braiding of fiber-reinforced materials.

[0006] In one example, the line segment includes a thermoplastic resin wire that is integrated into a consolidated shape with a fiber-reinforced thermoplastic resin tape by the application of heat. Compared with weaving fiber-reinforced materials with each other, weaving thermoplastic resin wires with fiber-reinforced thermoplastic resin tapes provides the potential for providing high composite material placement rates without introducing significant bulk or mass. Integrating thermoplastic resin wires into the consolidated shape can reduce the undulation of the fibers of the fiber-reinforced thermoplastic resin tape retained in the consolidated shape. For example, integrating thermoplastic resin wires into the surrounding resin matrix during consolidation can enable the fibers of the fiber-reinforced thermoplastic resin tape to relax into a configuration that exhibits less undulation, compared with weaving with fiber-reinforced thermoplastic resin tapes. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1A segment of an exemplary braiding mandrel having a longitudinal axis is depicted.

[0008] Figure 2 Depicts the cross section perpendicular to the longitudinal axis. Figure 1 Braiding mandrel.

[0009] Figure 3 Depicted around Figure 1 A first instance of a braided layer is formed along at least a portion of the longitudinal axis of the braiding mandrel.

[0010] Figure 4 Depicted around Figure 1 A second instance of a braided layer is formed along at least a portion of the longitudinal axis of the braiding mandrel.

[0011] Figure 5 Depicted around Figure 1 A third instance of a braided layer is formed along at least a portion of the longitudinal axis of the braiding mandrel.

[0012] Figure 6 Depicts the use of a braided ring around Figure 1 The braided mandrel is formed Figure 3 , Figure 4 and Figure 5 The braided layer.

[0013] Figure 7 Depicts the surrounding observed in the cross section Figure 1 The braiding mandrel is formed circumferentially Figure 6 Woven overlay.

[0014] Fig. 8A , Figure 8B , Figure 8C and Fig.8D is a flow chart depicting an example method of manufacturing a composite article.

[0015] Fig. 9 Another example of a braiding mandrel having a longitudinal axis is depicted.

[0016] Fig.10 Depicts the cross section perpendicular to the longitudinal axis. Fig. 9 Braiding mandrel.

[0017] Fig.11 Another example of a braided stack formed about a braiding mandrel along at least a portion of the longitudinal axis of the braiding mandrel is depicted.

[0018] Fig.12 Depicted in it Fig.11 An example of a braided layup being trimmed to form a tab portion of a structural rib of an aerospace vehicle.

[0019] Fig.13Depicts the cross section perpendicular to the longitudinal axis. Fig.11 Braided laminate and Fig. 9 Braiding mandrel.

[0020] Fig.14 Describes from Fig. 9 The braiding mandrel is removed Fig.11 The first part of the braided stack.

[0021] Fig.15 Depicts loading onto the consolidation mandrel Fig.11 The first portion and the second portion of the braided laminate are provided. DETAILED DESCRIPTION

[0022] According to the examples disclosed herein, a composite article can be formed using a braided stack including one or more braided layers. For example, one or more braided layers can be formed circumferentially around a braided mandrel along at least a portion of the longitudinal axis of the braided mandrel. Each braided layer can include a fiber-reinforced thermoplastic resin tape segment braided with a wire segment. The fiber-reinforced thermoplastic resin tape segment of each braided layer can be applied in a corresponding tape tow orientation, and the wire segment of the braided layer can be applied in a wire tow orientation different from the tape tow orientation.

[0023] The use of fibers to reinforce thermoplastic resins can facilitate the braiding process by increasing the strength and elasticity of the thermoplastic resin. In addition, fiber reinforcement of thermoplastic resins can increase the strength and elasticity of the resulting composite product. However, potential disadvantages of braiding with fiber-reinforced thermoplastic resin tapes or other fiber-reinforced resin materials can include the introduction of bulk into the braided form and / or the undulation of the fibers remaining in the composite product after consolidation.

[0024] For example, woven fiber reinforced thermoplastic resin tape or other fiber reinforced resin materials may introduce undulations for fibers in the consolidated forming part. Fiber reinforced thermoplastic tape weaving can have undulations because each section of the tape alternately passes through other band segments in the braid along its length in the braid, alternately on other band segments and then under other band segments. Therefore, the reinforcing fibers in each band segment can present such undulations, particularly when the reinforcing fibers extend parallel to the length of the thermoplastic tape. When the braided form is compacted and the thermoplastic material is consolidated, such undulations are reduced to a certain extent, but due to the "over-under" nature of the braid, the fibers are prevented from relaxing to a non-undulating state, so such undulations still exist in the consolidated forming part. Such as compared with a form in which the fibers are not undulating, the fiber undulations maintained in the consolidated forming part may adversely affect some material properties of the consolidated forming part. Such as by incorporating thermoplastic resin into the braided form according to the present disclosure to reduce fiber undulations can improve the material properties of the form such as compared with a form that does not reduce fiber undulations.

[0025] As another example, braiding fiber reinforced thermoplastic resin tapes or other fiber reinforced resin materials may introduce bulk into the braided form. This is generally attributed to the elasticity or stiffness of the tape segments braided together. Prior to consolidation, the form must be compacted (generally compressed). According to the present disclosure, reducing bulk, for example by incorporating thermoplastic resin strands into the braided form (which are generally more flexible than fiber reinforced thermoplastic resin tapes) can simplify the pre-consolidation step. Braiding wire segments with fiber reinforced thermoplastic resin tape segments at different tow orientations provides the potential to stabilize the fiber reinforced thermoplastic resin tape segments within the braided layer and provides a high composite placement rate without adding significant bulk or mass compared to braiding the fiber reinforcements together.

[0026] In a first example of the disclosed method, the wire segment comprises a thermoplastic resin wire. For example, the thermoplastic resin wire may be in the form of a monofilament wire or a multifilament wire. A preform comprising a fiber-reinforced thermoplastic resin tape and the thermoplastic resin wire, comprising at least a portion of the one or more braided layers, may be heated to obtain a consolidated shape in which the thermoplastic resin wire is integrated into the consolidated shape. For example, the thermoplastic resin wire may be integrated with the resin of the fiber-reinforced thermoplastic resin tape into a surrounding resin matrix of the consolidated shape.

[0027] Integrating thermoplastic resin threads into the consolidated shape provides the potential to reduce the undulation of fibers from the fiber-reinforced thermoplastic resin tapes retained in the consolidated shape. Since the thermoplastic resin threads are not reinforced with fibers, the thermoplastic resin threads can be fully integrated into the resin matrix of the consolidated shape. For example, integrating the thermoplastic resin threads into the surrounding resin matrix during consolidation can allow the fibers of the fiber-reinforced thermoplastic resin tape to relax into a configuration that exhibits less undulations than braiding with fiber-reinforced thermoplastic resin tapes. Although unreinforced thermoplastic resin threads can provide less strength or elasticity than fiber-reinforced materials, thermoplastic resin threads can provide a suitable alternative for braiding and stabilizing fiber-reinforced thermoplastic resin tape segments within a braided layer before consolidation.

[0028] In a second example of the disclosed method, the wire segment comprises a metal wire. As an example, the metal wire may take the form of a monofilament wire or a multifilament wire. A preform comprising at least a portion of one or more braided layers may be heated to obtain a consolidated form. Prior to consolidation into the consolidated form, the metal wire may be removed from the preform. Removing the metal wire from the preform prior to consolidation provides a potential to reduce the undulation of fibers from the fiber-reinforced thermoplastic resin tape retained within the consolidated form. For example, removing the metal wire prior to consolidation may allow the fibers of the fiber-reinforced thermoplastic resin tape to relax into a configuration exhibiting less undulation than braiding with the fiber-reinforced thermoplastic resin tape.

[0029] In at least some examples, braiding fiber-reinforced thermoplastic resin tape segments with wire segments to form a braided layer can be performed using a braiding ring. For example, each braided layer can be formed using a corresponding braiding ring that applies the fiber-reinforced thermoplastic resin tape segments in a tape tow orientation defined for a particular braided layer and applies the wire segments in a wire tow orientation. For example, a stack including three braided layers can be formed circumferentially around a braiding mandrel using three braiding rings.

[0030] As further described herein, the fiber reinforced thermoplastic resin tape segments of each braided layer can have a different tow orientation than the fiber reinforced thermoplastic resin tape segments of other braided layers. Changing the tow orientation of the tape segments between two braided layers or more braided layers provides the potential to increase or change the strength of the consolidated shape.

[0031] As an illustrative example, a first braided layer includes a tape segment having a tape strand orientation of 0 degrees relative to the longitudinal axis of the braiding mandrel. A second braided layer includes a tape segment having a tape strand orientation offset in a first angular direction (e.g., negative 60 degrees) relative to the longitudinal axis of the braiding mandrel. A third braided layer may include a tape segment having a tape strand orientation offset in a second angular direction (e.g., positive 60 degrees) relative to the longitudinal axis of the braiding mandrel. At each braided layer, a wire segment braided with the tape segment of that braided layer may be offset at an angle relative to the tape segment to stabilize the tape segment for consolidation.

[0032] Figure 1 A segment 100 of an exemplary braiding mandrel 110 having a longitudinal axis 112 is depicted. For illustrative purposes, the braiding mandrel 110 takes the form of a cylinder in this example. It will be appreciated that the braiding mandrel can take other suitable forms as further examples, such as reference Fig. 9 and Fig.10 described in further detail.

[0033] Figure 2 The braiding mandrel 110 is depicted as viewed from within a cross section 120 perpendicular to the longitudinal axis 112. In this example, the braiding mandrel 110 has a circular cross-section corresponding to the cross-section of a cylinder.

[0034] Figure 3 A first example of a braided layer 310 formed around a braiding mandrel 110 along the longitudinal axis 112 of the braiding mandrel corresponding to at least a portion of the segment 100 is depicted. The braided layer 310 is formed by braiding a tape segment 320 of a fiber reinforced thermoplastic resin tape applied in a tape tow orientation 322 with a wire segment (e.g., 330-1, 330-2) applied in a wire tow orientation (e.g., 332-1, 332-2).

[0035] In the example of the braided layer 310, the first subset of wire segments 330-1 are applied on the wire tow orientation 332-1, which is offset at an angle 334-1 in a first angular direction 336-1 relative to the tape tow orientation 322. For example, the first subset of wire segments 330-1 may pass over and under the tape segments 320 according to a braid pattern that stabilizes the tape segments within the braided layer 310. The exemplary braid pattern may feature the first subset of wire segments 330-1 that pass over one or more of the tape segments 320 and then pass under one or more of the tape segments 320 in a repeating pattern throughout the braided layer 310.

[0036] Additionally, in the example of the braided layer 310, the second subset of wire segments 330-2 are applied in a wire strand orientation 332-2 that is offset at an angle 334-2 in a second angular direction 336-2 relative to the tape strand orientation 322. For example, the second subset of wire segments 330-2 may pass over and under the tape segments 320 according to a braid pattern that further stabilizes the tape segments within the braided layer 310. An exemplary braid pattern may feature the second subset of wire segments 330-2 that pass over one or more of the tape segments 320 and then pass under one or more of the tape segments 320 in a repeating pattern throughout the braided layer 310.

[0037] As an illustrative example, the ribbon tow orientation 322 is parallel to the longitudinal axis 112, the angle 334-1 of the tow orientation 332-1 is -60 degrees relative to the ribbon tow orientation 322, and the angle 334-2 of the tow orientation 332-2 is +60 degrees relative to the ribbon tow orientation 322. It will be appreciated that other suitable tow orientations that are offset at an angle relative to the ribbon tow orientation may be used.

[0038] As described above, the ribbon strand orientation 322 of the ribbon segments 320 of the braided layer 310 is parallel to the longitudinal axis 112, which can be referred to as the axial configuration of the ribbon segments. Figure 4 and Figure 5 As described in further detail, other examples of braided layers may include tape segments applied in a tape tow orientation that is offset at an angle relative to the longitudinal axis 112, which may be referred to as a biaxial configuration.

[0039] Figure 4A second example of a braided layer 410 formed around a braiding mandrel 110 corresponding to at least a portion of the segment 100 along the longitudinal axis 112 of the braiding mandrel is depicted. In this example, the braided layer 410 is formed by braiding a tape segment 420 of a fiber-reinforced thermoplastic resin tape applied at a tape tow orientation 422 with a wire segment 430 applied at a wire tow orientation 432 offset relative to the tape tow orientation at an angle 434. Furthermore, in this example, the tape tow orientation 422 is offset at an angle 424 relative to the longitudinal axis 112, which is referred to as a biaxially configured tape segment 420.

[0040] As an illustrative example, angle 424 of ribbon tow orientation 422 is -60 degrees relative to longitudinal axis 112, and angle 434 of wire tow orientation 432 is -60 degrees relative to ribbon tow orientation 422. In this example, wire tow orientation 432 may be described as being offset at an angle of +60 degrees relative to longitudinal axis 112. It will be appreciated that other suitable ribbon tow orientations and wire tow orientations may be used.

[0041] Wire segments 430 may be threaded over and under the band segments 420 according to a weave pattern that stabilizes the band segments within the braided layer 410. An exemplary weave pattern may feature wire segments 430 that are threaded over and then under one or more of the band segments 420 in a repeating pattern throughout the braided layer 410.

[0042] Figure 5 A third example of a braided layer 510 formed around a braiding mandrel 110 corresponding to at least a portion of the segment 100 along the longitudinal axis 112 of the braiding mandrel is depicted. In this example, the braided layer 510 is formed by braiding a tape segment 520 of a fiber-reinforced thermoplastic resin tape applied at a tape tow orientation 522 with a wire segment 530 applied at a wire tow orientation 532 offset relative to the tape tow orientation at an angle 534. Further, in this example, the tape tow orientation 522 is offset at an angle 524 relative to the longitudinal axis 112, which is referred to as a biaxially configured tape segment 520.

[0043] As an illustrative example, angle 524 of ribbon tow orientation 522 is +60 degrees relative to longitudinal axis 112, and angle 534 of wire tow orientation 532 is +60 degrees relative to ribbon tow orientation 522. In this example, wire tow orientation 532 may be described as being offset at an angle of -60 degrees relative to longitudinal axis 112. It will be appreciated that other suitable ribbon tow orientations and wire tow orientations may be used.

[0044] Wire segments 530 may be passed over and under the band segments 520 according to a weave pattern that stabilizes the band segments within the braided layer 510. An exemplary weave pattern may feature wire segments 530 that pass over and then under one or more of the band segments 520 in a repeating pattern throughout the braided layer 510.

[0045] Figure 6 An example of a braided stack 600 is depicted that includes a plurality of braided layers that are schematically shown in the process of being formed circumferentially around a braiding mandrel 100 along at least a portion of a longitudinal axis 112. Figure 6 In the example of the braided stack 600, the braided stack 600 includes a first braided loop 610. Figure 3 The braided layer 310 is formed as a first layer circumferentially around the braiding mandrel 110. The first braiding ring 610 can be sized to accommodate the braiding mandrel 110 and any braided layers previously applied to the braiding mandrel within the interior area defined by the braiding ring.

[0046] The braided stack 600 further includes a second braided loop 612. Figure 4 The braided layer 410 is formed as a second layer circumferentially around the braiding mandrel 110 and the braided layer 310. The second braiding loop 612 can be sized to accommodate the braiding mandrel 110 and any braided layer (e.g., 310) previously applied to the braiding mandrel within the interior area defined by the braiding loop.

[0047] The braided stack 600 further includes a third braided loop 614. Figure 5 The braided layer 510 is formed as a third layer circumferentially around the braiding mandrel 110, the braided layer 310, and the braided layer 410. The third braiding loop 614 can be sized to accommodate the braiding mandrel 110 and any braided layers (e.g., 310 and 410) previously applied to the braiding mandrel within the interior area defined by the braiding loop.

[0048] like Figure 6 As schematically depicted by arrow 620 , the braiding mandrel 110 may move relative to the braiding rings 610 , 612 , and 614 throughout the braiding process.

[0049] It will be understood that if Figure 6 The configurations of the braiding loops 610, 612, and 614 shown in FIG. 6 are merely representative and are shown schematically for purposes of illustration. As an example, Figure 6The braiding rings 612 and 614 in are shown as being in the process of dispensing two braided materials in a biaxial configuration, while the braiding ring 610 is shown dispensing multiple axial band segments and opposing biaxial wire segments. However, the braiding rings can be configured as desired, such as a separate winding spool (not shown) with any number of braided materials (such as bands, wires, etc.), which can be stationary and / or configured to travel around the ring in either or both directions at a desired speed when the braiding ring moves relative to the mandrel, for example, to dispense material segments at a desired angle or orientation relative to the ring and / or mandrel. In fact, any number and / or configuration of braiding rings can be used.

[0050] It will also be understood that if Figure 6 The braided stack of the exemplary braided stack 600 may include any suitable number and configuration of braided layers. In the example of the braided stack 600, adjacent braided layers have different orientations of the ribbon strands relative to the longitudinal axis 112 and are offset at a certain angle relative to each other. For example, as shown in reference Figure 3 As described, the ribbon tow orientation 322 of the braided layer 310 can be parallel to the longitudinal axis 112. The ribbon tow orientation 422 of the braided layer 410 can be offset at an angle (e.g., -60 degrees) in a first angular direction relative to the longitudinal axis 112, and thus offset at an angle relative to the ribbon tow orientation 322 of the braided layer 310. As another example, the ribbon tow orientation 522 of the braided layer 510 can be offset at an angle (e.g., +60 degrees) in a second angular direction relative to the longitudinal axis 112, and thus offset at an angle relative to the ribbon tow orientation 422 of the braided layer 410. As described above, using different ribbon tow orientations between braided layers can be used to increase or change the strength of the braided stack.

[0051] Figure 7 Describes as Figure 6 1 and 2. The braided stack 600 is formed circumferentially around the braiding mandrel 110 as viewed in the cross section 120 shown in FIG. Figure 3 The braided layer 310 forms a first braided layer of the braided stack 600, Figure 4 The braided layer 410 forms a second braided layer of the braided stack, and Figure 5 The braided layer 510 forms the third braided layer of the braided stack. As described above, the braided stack may include any suitable number and configuration of braided layers.

[0052] Fig. 8A , Figure 8B , Figure 8C and Fig.8D 8 is a flow chart depicting an example method 800 for manufacturing a composite article. A composite article may be formed using a woven layup including one or more woven layers. Fig. 8A , Figure 8B and Figure 8C In the embodiment of the present invention, as depicted at operation 802, a plurality of braided layers can be formed circumferentially around a braiding mandrel along at least a portion of a longitudinal axis of the braiding mandrel. As part of operation 802, each braided layer can be formed by braiding a tape segment of a fiber-reinforced thermoplastic resin tape applied at a tape tow orientation with a wire segment applied at a wire tow orientation that is offset at a certain angle relative to the tape tow orientation. In addition, in at least some examples, adjacent braided layers of the braided stack can have different tape tow orientations relative to each other, as previously described with reference to Figure 6 as described.

[0053] refer to Fig. 8A At 810, the method includes forming a first braided layer around the braiding mandrel along at least a portion of the longitudinal axis of the braiding mandrel. As an example, the first braided layer may include Figure 3 Braided layer 310, Figure 4 Braided layer 410 or Figure 5 One of the braided layers 510. As previously referred to Figure 6 As described, the first braided layer may include Figure 3 A braided layer 310 is provided in which the ribbon tow orientation is parallel to the longitudinal axis of the braiding mandrel. In at least some examples, the ribbon tow orientation parallel to the longitudinal axis of the braiding mandrel can provide a suitable base for the braided stack, on which additional braided layers can be formed. However, it will be understood that in other examples, a ribbon tow orientation offset at an angle relative to the longitudinal axis of the braiding mandrel can be used for the first braided layer.

[0054] As depicted at 812, the orientation of the ribbon strands of the first braided layer has a first angular orientation relative to the longitudinal axis of the braiding mandrel. Figure 3 As described with reference to the braided layer 310, the ribbon tows may be oriented parallel to the longitudinal axis of the braiding mandrel. Figure 4 and Figure 5 As described with respect to braided layers 410 and 510 , the ribbon tow orientation may be offset at an angle relative to the longitudinal axis of the braiding mandrel.

[0055] As depicted at 814 , the wire tow orientation of the wire segments of the first braided layer may be offset at an angle relative to the tape tow orientation of the tape segments of the first braided layer.

[0056] As a portion of the first braided layer is formed at 810, at 816, the method includes braiding a tape segment of a fiber-reinforced thermoplastic resin tape applied in a tape tow orientation with a wire segment applied in a wire tow orientation. As an example, as previously referenced Figure 6 As described, the strap segment and the wire segment may be braided using the first braiding loop.

[0057] The wire segments of the first braided layer can take a variety of forms. As a first example, the wire segments of the first braided layer include thermoplastic resin wires 818. As a second example, the wire segments of the first braided layer include metal wires 820.

[0058] At 822, the method may include securing one or more of the wire segments to one or more of the band segments of the first braided layer to further stabilize the first braided layer. As an example, the wire segments may be secured to the band segments by spot welding, which may include selectively applying heat to locations of the first braided layer where the wire segments are to be secured to the band segments.

[0059] At 824, the method may include securing one or more pad-ups to the first woven layer. Pads may be used to define and add reinforcement structures to the woven stack. For example, the pads may take the form of fiber-reinforced resin pads. Each pad may be secured to the first woven layer by spot welding the pads to one or more locations of the first woven layer, such as to portions of one or more wire segments and / or band segments.

[0060] refer to Figure 8B At 830, the method includes forming a second braided layer around the first braided layer and the braided mandrel along at least a portion of the longitudinal axis of the braided mandrel. As an example, the first braided layer may include Figure 3 Braided layer 310, Figure 4 Braided layer 410 or Figure 5 Another of the braided layers 510 is provided to provide a different ribbon tow orientation relative to the first braided layer.

[0061] As depicted at 832, the ribbon tow orientation of the ribbon segment of the second braided layer has a second angular orientation relative to the longitudinal axis of the braiding mandrel. Figure 3 As described in the braided layer 310, the belt tows of the second braided layer can be oriented parallel to the longitudinal axis of the braiding mandrel. Figure 4 and Figure 5 As described with respect to braided layers 410 and 510 , the orientation of the ribbon tows of the second braided layer may be offset at an angle relative to the longitudinal axis of the braiding mandrel.

[0062] As depicted at 834 , the wire tow orientation of the wire segments of the second braided layer may be offset at an angle relative to the tape tow orientation of the tape segments of the second braided layer.

[0063] As part of forming a second braided layer at 830, the method at 836 includes braiding a tape segment of a fiber-reinforced thermoplastic resin tape applied in a tape tow orientation with a wire segment applied in a wire tow orientation. As an example, as previously referenced Figure 6 As described, the wire segment and the tape segment may be braided using a second braiding loop.

[0064] The wire segments of the second braided layer can take a variety of forms. As a first example, the wire segments of the second braided layer include thermoplastic resin wires 838. As a second example, the wire segments of the second braided layer include metal wires 840.

[0065] At 842, the method may include securing one or more of the wire segments to one or more of the tape segments of the second braided layer to further stabilize the second braided layer. For example, the wire segments may be secured to the tape segments by spot welding.

[0066] At 844, the method may include securing the second braided layer to the first braided layer to further stabilize the braided stack. As an example, the wire segments and / or strap segments of the second braided layer may be secured to the wire segments and / or strap segments of the first braided layer by spot welding.

[0067] At 846, the method may include securing one or more pads to the second braided layer. As previously described, pads may be used to define and add reinforcement structures to the braided stack. Each pad may be secured to the second braided layer by spot welding the pad to one or more locations of the second braided layer (e.g., to portions of one or more wire segments and / or strap segments).

[0068] refer to Figure 8C At 850, the method includes forming a third braided layer around the braided layer, the second braided layer, and the braided mandrel along at least a portion of the longitudinal axis of the braiding mandrel. As an example, the third braided layer may include Figure 3 Braided layer 310, Figure 4 Braided layer 410 or Figure 5 Another of the braided layers 510 may be provided to provide a different ribbon tow orientation relative to some or all of the preceding layers including the second braided layer and the first braided layer.

[0069] As depicted at 852, the ribbon tow orientation of the ribbon segment of the third braided layer has a third angular orientation relative to the longitudinal axis of the braiding mandrel. Figure 3 As described in the braided layer 310, the belt tows of the third braided layer can be oriented parallel to the longitudinal axis of the braiding mandrel. Figure 4 and Figure 5 As described with respect to braided layers 410 and 510 , the orientation of the ribbon tows of the third braided layer may be offset at an angle relative to the longitudinal axis of the braiding mandrel.

[0070] As depicted at 854 , the wire tow orientation of the wire segments of the second braided layer may be offset at an angle relative to the tape tow orientation of the tape segments of the third braided layer.

[0071] As part of forming a third braided layer at 850, the method at 856 includes braiding a tape segment of a fiber-reinforced thermoplastic resin tape applied in a tape tow orientation with a wire segment applied in a wire tow orientation. As an example, as previously referenced Figure 6 As described, the tape segment and the wire segment may be braided using a third braiding loop.

[0072] The segments of the third braided layer can take a variety of forms. As a first example, the segments of the third braided layer include thermoplastic resin wires 858. As a second example, the segments of the third braided layer include metal wires 860.

[0073] At 862, the method can include securing one or more of the wire segments to one or more of the tape segments of the third braided layer to further stabilize the third braided layer. For example, the wire segments can be secured to the tape segments by spot welding.

[0074] At 844, the method may include securing the third braided layer to the second braided layer to further stabilize the braided stack. As an example, the wire segments and / or strap segments of the third braided layer may be secured to the wire segments and / or strap segments of the second braided layer by spot welding.

[0075] At 846, the method may include securing one or more pads to the third braided layer. As previously described, pads may be used to define and add reinforcement structures to the braided stack. Each pad may be secured to the third braided layer by spot welding the pad to one or more locations of the third braided layer (e.g., to portions of one or more wire segments and / or strap segments).

[0076] In some examples, the braided stack formed by method 800 may include four or more braided layers. In this example, the portion of method 800 used to form the first braided layer, the second braided layer, and / or the third braided layer may be repeated once or more additional times to add one or more additional braided layers to the braided stack. For example, another instance of the first braided layer formed at 810 or the second braided layer formed at 830 may be formed around the third braided layer. Since each additional braided layer is formed around the previous braided layer, the additional braided layer may have a different orientation of the band tows than the previous braided layer. This configuration provides angled band segments relative to each other at continuous braided layers, thereby changing the strength of the braided stack and / or increasing the stability of the braided stack.

[0077] refer to Fig.8D At 868, the method includes processing the braided layup to obtain one or more preforms for consolidation. As part of the processing performed at 868, the method at 870 may include performing one or more of operations 870-880.

[0078] At 870, the method may include trimming the braided stack to obtain a desired form. Fig.12 Examples of trimming braided stacks are described in further detail.

[0079] At 872, the method can include cutting the braided stack into two or more portions. In at least some examples, the braided stack can be cut into two or more portions to enable the braided stack to be removed from the braiding mandrel. Fig.13 Examples of cutting braided laminates are described in further detail.

[0080] At 874, the method may include removing the braided laminate or a portion thereof from the braiding mandrel. Removing the braided laminate or a portion thereof from the braiding mandrel enables further processing of the braided laminate or a portion thereof, such as for consolidation on a consolidation mandrel. However, in some instances, the braiding mandrel may also be used as a consolidation mandrel. In these instances, operation 874 may be omitted. In addition, in some instances, the braiding mandrel may take the form of a collapsible braiding mandrel, which expands the collapsible braiding mandrel to provide support for the braided laminate during the formation of various braided layers. In these instances, the cutting of the braided laminate at 872 may be omitted because the collapsible braiding mandrel may be removed from the braided laminate without cutting the braided laminate.

[0081] At 876, the method may include forming and securing any additional structures based on the characteristics of the braided laminate. Fig.14 Examples of forming and securing attachment structures are described in further detail.

[0082] At 878, the method may include loading the braided layup or portion thereof onto a consolidation mandrel. Fig.15 Exemplary consolidation mandrels are described in further detail.

[0083] After the processing performed at operation 868, the one or more preforms obtained from the braided layup or portion are ready for consolidation.

[0084] At 884, the method includes heating and compressing the one or more preforms to obtain one or more consolidated forms 886. Any suitable technique for heating and compressing the preforms may be used to obtain the consolidated forms. As an example, induction heating may be used to heat the preforms compressed onto the consolidation mandrel by one or more inflatable bladders. Compressing the preforms during heating and consolidation can reduce the bulk of the preforms to produce consolidated forms by reducing or eliminating the volume area of ​​free air space or pores within individual braided layers and / or between braided layers.

[0085] The heat applied to the one or more preforms causes the thermoplastic resin of the fiber-reinforced thermoplastic resin tapes and thermoplastic resin cords (if used for braiding) of each braided layer to integrate into the resin matrix of the consolidated form. Where thermoplastic resin cords are used in one or more of the braided layers, the fibers of the fiber-reinforced thermoplastic resin tapes of those braided layers may relax during the heating process, thereby potentially reducing fiber undulation.

[0086] In an instance where one or more segments of the braided laminate include metal wires, the method at 888 may include removing the one or more segments including the metal wires while heating is performed at 884, but before compressing and consolidating the preform into a consolidated form. As an example, the metal wire segments may be removed from the one or more preforms by pulling the metal wire segments from the preform while the preform is heated. After removing the metal wire segments, the preform can be compressed to obtain a consolidated form. Heating the preform can be used to melt or soften the resin contained in the preform to facilitate removal of the metal wire segments. In another example, the metal wire segments may be removed from the preform prior to heating. Removing the metal wire segments prior to consolidation may allow the fibers of the fiber-reinforced thermoplastic resin tape to relax during the heating process, thereby potentially reducing the undulation of the fibers in the consolidated form.

[0087] At 890, the method includes removing the one or more consolidated forms from the consolidation mandrel. At 892, the method includes performing post-processing of the one or more consolidated forms. As an example, the consolidated forms may be trimmed, cut, polished, painted, etc. to obtain one or more composite articles 894 in a final form.

[0088] Thermoplastic materials including fiber-reinforced thermoplastic resin tapes, thermoplastic resin wires and thermoplastic resin pads described herein may include, for example, polyaryletherketone (PAEK) thermoplastic materials such as polyetheretherketone (PEEK) and / or polyetherketoneketone (PEKK), polyphenylene sulfide (PPS) and / or polyetherimide (PEI). The fibers contained in the fiber-reinforced thermoplastic resin tapes and thermoplastic resin pads may include, for example, graphite fibers. As an example, the fiber-reinforced thermoplastic resin tapes described herein may take the form of thermoplastic slit tapes in which the fibers are pre-impregnated with thermoplastic resins. Other suitable types of thermoplastic resins and / or reinforcing fibers may be used.

[0089] Fig. 9 Another example of a braiding mandrel 910 is depicted around which one or more braided layers may be formed along at least a portion of a longitudinal axis 912 of the braiding mandrel. Figure 1 Compared to braiding mandrel 110, braiding mandrel 910 has a cross-section that varies along longitudinal axis 912. As an example, braiding mandrel 910 may be used to form a composite article including a pair of structural ribs for an aerospace vehicle.

[0090] Fig.10 Depicted is a cross-section 920 viewed perpendicular to the longitudinal axis 912. Fig. 9 . In this example, the braiding mandrel 910 is a closed form that approximates a rectangle when viewed in cross section 920.

[0091] Fig.11 An example of a braided stack 1110 of one or more braided layers that can be formed around a braiding mandrel 910 is depicted. As an example, the method 800 of FIG. 8 can be performed to obtain the braided stack 1110. In the example of the braided stack 1110, each braided layer can have a wire strand orientation that is offset at an angle relative to the ribbon strand orientation of the braided layer. Additionally, in at least some examples, each braided layer of the braided stack 1110 can have a ribbon strand orientation that is offset at an angle relative to the ribbon strand orientation of an adjacent braided layer.

[0092] Fig.12 Depicted is a diagram in which at 1210 and 1212 Fig.11 12 is an example of a braided laminate 1110 that is trimmed to form a first tab portion 1214 and trimmed at 1220 and 1222 to form a second tab portion 1224. In this example, the first tab portion 1214 and the second tab portion 1224 are located on opposite ends of the braided laminate 1110 as oriented along the longitudinal axis 912.

[0093] Fig.13 Depicted is a braided laminate 1110 and a braided mandrel 910 viewed in a cross section 920 perpendicular to the longitudinal axis 912. In this example, the braided laminate 1110 is cut into a first portion 1310 and a second portion 1312 along a path indicated by arrows 1320. The first portion 1310 of the braided laminate 1110 is also cut into a first portion 1310 and a second portion 1312. Fig.12 . As previously described, cutting the braided laminate into two or more portions can remove the braided laminate or portions thereof from the braiding mandrel. Additionally, as an example, two or more portions of the braided laminate can form a corresponding composite article, such as a pair of structural ribs for an aircraft. In this example, a right structural rib for the right side of the aircraft and a left structural rib for the left side of the aircraft can be formed on a common braiding mandrel.

[0094] Fig.14 A first portion 1310 of the braided stack 1110 is depicted being removed from the braiding mandrel 910. Fig.14 Depicted in Fig.121230 is a side view of the first portion 1310 indicated by the arrow in FIG. In this example, the accessory structure including flanges 1410 and 1420 is formed by tab portions 1214 and 1224 of the braided laminate 1110. As an example, the tab portion 1214 can be folded or bent at room temperature to form a Fig.14 The shape schematically represented by flange 1410 in FIG. The flange 1410 can be secured by spot welding two or more braided layers of the braided stack 1110 to maintain Fig.14 Similarly, the flange 1420 can be fixed by spot welding two or more braided layers of the braided stack 1110 to maintain the Fig.14 The shape shown in for subsequent consolidation. The second portion 1312 can be similarly processed to form and secure any additional structures from the features of the braided laminate.

[0095] Fig.15 Depicted are first portion 1310 and second portion 1312 loaded onto consolidation mandrel 1510 as viewed within cross section 920. In this example, first portion 1310 refers to first preform 1520 and second portion 1312 refers to second preform 1522. First cover portion 1530 may be used to hold and compress first preform 1520 onto consolidation mandrel 1510 during heating and consolidation. Similarly, second cover portion 1532 may be used to hold and compress preform 1522 onto consolidation mandrel 1510 during heating and consolidation. In at least some examples, consolidation mandrel 1510 and / or cover portions 1530 and 1532 may take the form of one or more aluminum pressure bladders that expand to support the preform during consolidation. It will be appreciated that other suitable techniques can be used to compress the preform during heating and consolidation.

[0096] As previously described, compressing the preform during heating and consolidation can reduce the bulk of the preform to produce a consolidated shape by reducing or eliminating the volume area of ​​free air space or pores within a single woven layer and / or between woven layers. In the disclosed example where the woven layer of the preform includes a thermoplastic resin wire woven with a fiber-reinforced thermoplastic resin tape, compressing the preform can reduce the undulation of the fibers within the woven layer due to the displacement of the resin contained in the wire. This displacement of the resin enables segments of the fibers to overlap with the wire within the braid, thereby displacing into the area previously occupied by the wire. In such an example, an increase in the displacement of the fibers during the consolidation process can be achieved by weaving with thermoplastic resin wire compared to weaving with fiber-reinforced material, resulting in a greater reduction in the undulation of the fibers within the consolidated shape.

[0097] In the disclosed examples where the braided layers of the preform are formed of metal wires braided with fiber-reinforced thermoplastic resin tapes, compressing the preform after the metal wires are removed can reduce the undulation of the fibers within the braided layers due to displacement of the fibers into areas previously occupied by the metal wires. In such examples, an increase in fiber displacement during the consolidation process can be achieved with the metal wire braid removed prior to consolidation, resulting in a greater reduction in undulation of the fibers within the consolidation form, compared to fiber reinforcement material remaining within the consolidation form.

[0098] Additionally, the present disclosure includes configurations and methods according to the following clauses.

[0099] A.1. A method for manufacturing a composite product, the method comprising: forming one or more braided layers around a braiding mandrel along at least a portion of the longitudinal axis of the braiding mandrel by: for each braided layer, weaving a tape segment of a fiber-reinforced thermoplastic resin tape applied in a tape tow orientation with a wire segment applied in a wire tow orientation, and the wire tow orientation is offset at a certain angle relative to the tape tow orientation.

[0100] A.2. A method according to clause A.1, wherein the wire segments of each of the one or more braided layers comprise thermoplastic resin wire; wherein the method further comprises heating a preform comprising at least a portion of the one or more braided layers to obtain a consolidated part; and wherein the thermoplastic resin wire present in the preform is integrated into the consolidated part.

[0101] A.3. A method according to clause A.1, wherein the wire segments of each of the one or more woven layers include metal wire; and wherein the method further includes: heating a preform including at least a portion of the one or more woven layers to obtain a consolidated part; and removing the metal wire from the preform before consolidating the preform into the consolidated part.

[0102] A.4. The method of clause A.1, wherein for a first braided layer of the one or more braided layers, the ribbon tows are oriented parallel to a longitudinal axis of the braiding mandrel.

[0103] A.5. A method according to clause A.4, wherein for the first woven layer: the wire bundle orientation of a first subset of the wire segments is offset in a first angular direction relative to the tape bundle orientation; and the wire bundle orientation of a second subset of the wire segments is offset in a second angular direction opposite to the first angular direction relative to the tape bundle orientation.

[0104] A.6. The method of clause A.1, wherein for a first braided layer of the one or more braided layers, the ribbon tow orientation is offset at an angle relative to a longitudinal axis of the braiding mandrel.

[0105] A.7. The method of clause A.1, wherein the one or more braided layers comprises a plurality of braided layers; wherein the orientation of the ribbon tows of a first braided layer in the plurality of braided layers is offset at an angle relative to the orientation of the ribbon tows of a second braided layer in the plurality of braided layers.

[0106] A.8. The method of clause A.7, further comprising: spot welding the second braid layer to the first braid layer.

[0107] A.9. The method of clause A.7, further comprising: heating the preform including at least a portion of the first woven layer and the second woven layer to obtain a consolidated form.

[0108] A.10. The method of clause A.7, wherein the plurality of braided layers includes a third braided layer; wherein a ribbon tow orientation of the third braided layer is offset at an angle relative to a ribbon tow orientation of the first braided layer and relative to a ribbon tow orientation of the second braided layer.

[0109] B.1. A method for manufacturing a composite product, the method comprising: forming a plurality of braided layers around a braiding mandrel along at least a portion of the longitudinal axis of the braiding mandrel by: for each of the plurality of braided layers, weaving a tape segment of a fiber-reinforced thermoplastic resin tape applied in a tape tow orientation with a line segment of a thermoplastic resin line applied in a line tow orientation, the line tow orientation being offset at a certain angle relative to the tape tow orientation; and heating and compressing a preform including at least a portion of the one or more braided layers to obtain a consolidated part; wherein the thermoplastic resin line present in the preform is integrated into the consolidated part.

[0110] B.2. The method of clause B.1, wherein the orientation of the ribbon tows of a first braided layer in the plurality of braided layers is offset at an angle relative to the orientation of the ribbon tows of a second braided layer in the plurality of braided layers.

[0111] B.3. A method according to clause B.2, wherein the tape tows of the first braided layer are oriented parallel to the longitudinal axis of the braiding mandrel; and

[0112] The orientation of the ribbon tows of the second braided layer is offset at a certain angle relative to the longitudinal axis of the braiding mandrel.

[0113] B.4. The method of clause B.3, wherein a tape tow angle of a third braided layer of the plurality of braided layers is offset at an angle relative to the longitudinal axis of the braiding mandrel in an opposite angular direction to the tape tow angle of the second braided layer.

[0114] C.1. A method for manufacturing a composite product, the method comprising: forming a plurality of braided layers around a braiding mandrel along at least a portion of the longitudinal axis of the braiding mandrel by: for each braided layer in the plurality of braided layers, braiding a tape segment of a fiber-reinforced thermoplastic resin tape applied in a tape tow orientation with a wire segment of a thermoplastic resin wire applied in a wire tow orientation, the wire tow orientation being offset at a certain angle relative to the tape tow orientation; spot welding a braided layer in the plurality of braided layers to another braided layer in the plurality of braided layers to stabilize the braided stack; cutting the braided stack into two or more parts; and heating and compressing a preform including a portion of the braided stack to obtain a consolidated formed part; wherein the thermoplastic resin wire present in the preform is integrated into the consolidated formed part.

[0115] C.2. A method according to clause C.1, wherein the composite article is in the form of a structural rib of an aerospace vehicle.

[0116] C.3. The method of clause C.1, further comprising: heating another preform, the other preform comprising another portion of the braided layup on the consolidation mandrel.

[0117] C.4. The method of clause C.1, wherein the orientation of the ribbon tows of a first braided layer in the plurality of braided layers is offset at an angle relative to the orientation of the ribbon tows of a second braided layer in the plurality of braided layers.

[0118] C.5. The method of clause C.4, wherein the tape tow orientation of a third braided layer in the plurality of braided layers is offset at an angle relative to the tape tow orientation of a second braided layer in the plurality of braided layers.

[0119] C.6. A method according to clause C.5, wherein the tape tow orientation of the third braided layer is offset at an angle relative to the tape tow orientation of the first braided layer.

[0120] It will be understood that the configurations and / or methods described herein are exemplary in nature, and these specific examples should not be considered as limiting in nature, because multiple variations are possible. The specific methods and operations described herein may represent one or more of any number of processing techniques. Thus, the illustrated instructions and / or various actions described may be performed in the order illustrated and / or described, in other orders, in parallel, or omitted. Likewise, the order of the above-mentioned processing may be changed.

[0121] The subject matter of the present disclosure includes all novel and non-obvious combinations and sub-combinations of the various configurations, approaches, methods, operations, and other features, functions, acts, and / or properties disclosed herein, as well as any and all equivalents thereof.

[0122] Parts List:

[0123] Segment 100

[0124] Braiding mandrel 110

[0125] Longitudinal axis 112

[0126] Section 120

[0127] Braid 310

[0128] Band 320

[0129] With tow orientation 322

[0130] Line segment 330-1

[0131] Line segment 330-2

[0132] Tow Orientation 332-1

[0133] Tow Orientation 332-2

[0134] Angle 334-1

[0135] Angle 334-2

[0136] First angle direction 336-1

[0137] Second angular direction 336-2

[0138] Braid 410

[0139] Band 420

[0140] With tow orientation 422

[0141] Angular 424

[0142] Line segment 430

[0143] Tow Orientation 432

[0144] Angular 434

[0145] Braided layer 510

[0146] Band 520

[0147] With tow orientation 522

[0148] Angle 524

[0149] Line segment 530

[0150] Tow Orientation 532

[0151] Angle 534

[0152] Braided laminate 600

[0153] First braiding ring 610

[0154] Second braiding ring 612

[0155] The third braiding ring 614

[0156] Arrow 620

[0157] Method 800

[0158] Thermoplastic resin wire 818

[0159] Metal Wire 820

[0160] Thermoplastic resin wire 838

[0161] Metal Wire 840

[0162] Thermoplastic resin wire 858

[0163] Metal Wire 860

[0164] Consolidated forming parts 886

[0165] Composite products 894

[0166] Braiding mandrel 910

[0167] Longitudinal axis 912

[0168] Section 920

[0169] Braided laminate 1110

[0170] First tab portion 1214

[0171] Second tab portion 1224

[0172] Side view 1230

[0173] Part I 1310

[0174] Part II 1312

[0175] Arrow 1320

[0176] Subsidiary structures

[0177] Flange 1420

[0178] Consolidation Mandrel 1510

[0179] First prefab 1520

[0180] Second prefabricated part 1522

[0181] First cover portion 1530

[0182] Second cover portion 1532

Claims

1. A method (800) of manufacturing a composite article (894), the method comprising: One or more braided layers (310) are formed around the braiding mandrel (110) along at least a portion of the longitudinal axis (112) of the braiding mandrel (110) by: For each braided layer (310), a tape segment (320) of a fiber-reinforced thermoplastic resin tape applied in a tape tow orientation (322) is braided with a wire segment (330-1) applied in a wire tow orientation (332-1), wherein the wire tow orientation (332-1) is offset at an angle (334-1) relative to the tape tow orientation (322).

2. The method (800) of claim 1, wherein the wire segment (330-1) of each of the one or more braided layers (310) comprises a thermoplastic resin wire (818); wherein the method (800) further comprises heating a preform (868, 1520) comprising at least a portion of the one or more braided layers (310) to obtain a consolidated form (886); and The thermoplastic resin strands (818) present in the preform (868, 1520) are integrated into the consolidated shape (886).

3. The method (800) of claim 1, wherein the wire segment (330-1) of each of the one or more braided layers (310) comprises a metal wire (820); and The method (800) further comprises: heating a preform (868) comprising at least a portion of the one or more braided layers (310) to obtain a consolidated form (886); as well as The metal wire (820) is removed from the preform (868, 1520) prior to consolidating the preform into the consolidated shape (886).

4. The method (800) of claim 1, wherein for a first braided layer (310) of the one or more braided layers (310), the ribbon tow orientation (322) is parallel to the longitudinal axis (112) of the braiding mandrel (110).

5. The method (800) according to claim 4, wherein for the first woven layer (310): The wire tow orientation (332-1) of a first subset of the wire segments (330-1) is offset in a first angular direction (336-1) relative to the ribbon tow orientation (322); and The wire tow orientation (332-2) of a second subset of the wire segments (330-2) is offset relative to the ribbon tow orientation (322) in a second angular direction (336-2) opposite the first angular direction (336-1).

6. The method (800) of claim 1, wherein for a first braided layer (410) of the one or more braided layers (310, 410), the ribbon strand orientation (422) is offset at an angle (424) relative to the longitudinal axis (112) of the braiding mandrel (110).

7. The method (800) of claim 1, wherein the one or more braided layers (310, 410) comprises a plurality of braided layers (310, 410); The ribbon tow orientation (322) of a first braided layer (310) among the plurality of braided layers (310, 410) is offset at an angle (424) relative to the ribbon tow orientation (422) of a second braided layer (410) among the plurality of braided layers (310, 410).

8. The method (800) of claim 7, further comprising: The second braided layer (410) is spot welded to the first braided layer (310).

9. The method (800) of claim 7, further comprising: A preform (868) including at least a portion of the first woven layer (310) and the second woven layer (410) is heated to obtain a consolidated form (886).

10. The method (800) of claim 7, wherein the plurality of braided layers (310, 410, 510) includes a third braided layer (510); The ribbon tow orientation (522) of the third braided layer (510) is offset at an angle (524) relative to the ribbon tow orientation (322) of the first braided layer (310) and relative to the ribbon tow orientation (422) of the second braided layer (410).

11. A method (800) of manufacturing a composite article (894), the method (800) comprising: A plurality of braided layers (310, 410, 510) are formed around a braiding mandrel (110) along at least a portion of a longitudinal axis (112) of the braiding mandrel (110) by: For each braided layer (310, 410, 510) of the plurality of braided layers (310, 410, 510), a tape segment (320, 420, 520) of a fiber-reinforced thermoplastic resin tape applied in a tape tow orientation (322, 422, 522) is braided with a line segment (330-1, 430, 530) of a thermoplastic resin line (818, 838, 858) applied in a line tow orientation (332-1, 432, 532), the line tow orientation (332-1, 432, 532) being offset at an angle (334-1, 434, 534) relative to the tape tow orientation (322, 422, 522); as well as heating and compressing a preform (868) including at least a portion of the one or more braided layers (310, 410, 510) to obtain a consolidated shape (886); The thermoplastic resin strands (818, 838, 858) present in the preform (868) are integrated into the consolidated shape (886).

12. The method (800) of claim 11, wherein the belt tow orientation (322) of a first woven layer (310) among the plurality of woven layers (310, 410, 510) is offset at an angle (424) relative to the belt tow orientation (422) of a second woven layer (410) among the plurality of woven layers (310, 410, 510).

13. The method (800) of claim 12, wherein the ribbon tow orientation (322) of the first braided layer (310) is parallel to the longitudinal axis (112) of the braiding mandrel (110); and Wherein the ribbon tow orientation (422) of the second braided layer (410) is offset at an angle (424) relative to the longitudinal axis (112) of the braiding mandrel (110).

14. The method (800) of claim 13, wherein the band tow orientation (522) of a third braided layer (510) among the plurality of braided layers (310, 410, 510) is offset at an angle (524) relative to the longitudinal axis (112) of the braiding mandrel (110) in an angular direction opposite to the band tow angle (424) of the second braided layer (410).

15. A method (800) of manufacturing a composite article (894), the method (800) comprising: A plurality of braided layers (310, 410, 510) are formed around a braiding mandrel (110) along at least a portion of a longitudinal axis (112) of the braiding mandrel (110) by: For each braided layer (310, 410, 510) of the plurality of braided layers (310, 410, 510), a tape segment (320, 420, 520) of a fiber-reinforced thermoplastic resin tape applied in a tape tow orientation (322, 422, 522) is braided with a line segment (330-1, 430, 530) of a thermoplastic resin line (818, 838, 858) applied in a line tow orientation (332-1, 432, 532), the line tow orientation (332-1, 432, 532) being offset at an angle (334-1, 434, 534) relative to the tape tow orientation (322, 422, 522); spot welding a braided layer (410) among the plurality of braided layers (310, 410, 510) to another braided layer (310) among the plurality of braided layers (310, 410, 510) to stabilize the braided stack (1110); cutting the braided laminate (1110) into two or more portions (1310, 1312); and heating and compressing a preform (1520) comprising a portion of the braided laminate (1110) to obtain a consolidated shape (886); The thermoplastic resin strands (818, 838, 858) present in the preform (1520) are integrated into the consolidated shape (886).

16. The method (800) of claim 15, wherein the composite article (894) is in the form of a structural rib for an aerospace vehicle.

17. The method (800) of claim 15, further comprising: Another preform (1522) is heated, the other preform comprising another portion of the braided layup (1110) on the consolidation mandrel (1510).

18. The method (800) of claim 15, wherein the belt tow orientation (322) of a first woven layer (310) among the plurality of woven layers (310, 410, 510) is offset at an angle (424) relative to the belt tow orientation (422) of a second woven layer (410) among the plurality of woven layers (310, 410, 510).

19. The method (800) of claim 18, wherein the belt tow orientation (522) of a third woven layer (510) among the plurality of woven layers (310, 410, 510) is offset at an angle (524) relative to the belt tow orientation (422) of the second woven layer (410) among the plurality of woven layers (310, 410, 510).

20. The method (800) of claim 19, wherein the ribbon tow orientation (522) of the third braided layer (510) is offset at an angle (524) relative to the ribbon tow orientation (322) of the first braided layer (310).

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