Automatic fiber placement assembly with pressure roller

Abstract

The present disclosure relates to an automatic fiber placement assembly for forming a component by continuously laminating fiber bundle strips with a pressure roller. The pressure roller has an axis of rotation about which the pressure roller rotates to apply the fiber band to the component. The pressure roller may be shaped to complement the non-uniform surface of the component to apply the fiber band evenly to the component.

Description

Technical Field

[0001] The present disclosure relates generally to automated fiber placement assemblies for forming composite parts, and in particular, to pressure rollers for applying fiber tows during fiber placement to form composite parts. Background Art

[0002] Many components, such as those for turbine engines, are made from composite materials, which can include a fiber-reinforced matrix and exhibit a high strength-to-weight ratio. Due to their high strength-to-weight ratio and formability into relatively complex shapes, composite materials are used in a variety of applications. Components made from composite materials can be used in aerospace applications, for example, to form at least a portion of one or more of a fuselage, a wing, a rudder, a manifold, a turbine engine, an airfoil, a blade, a vane, or other components of an aircraft. BRIEF DESCRIPTION OF THE DRAWINGS

[0003] A full and enabling disclosure of the present disclosure, including the best mode thereof, to one of ordinary skill in the art is set forth in the specification with reference to the accompanying drawings, in which:

[0004] Figure 1 is a schematic cross-sectional view of a turbine engine according to an exemplary aspect of the present disclosure.

[0005] Figure 2 is suitable for use in accordance with exemplary aspects of the present disclosure Figure 1 Schematic isometric view of a composite airfoil assembly and disk assembly used within a turbine engine.

[0006] Figure 3 According to an exemplary aspect of the present disclosure, there is a Figure 2 Schematic isometric view of the automated fiber placement assembly of the pressure roll of a composite airfoil assembly.

[0007] Figure 4 is a schematic isometric view of a pressure roller positioned along a non-planar portion of a composite airfoil assembly according to an exemplary aspect of the present disclosure.

[0008] Figure 5 is a schematic isometric view of an alternative pressure roller for applying pressure to a fiber tape having an adhesive for use with an automated fiber placement assembly according to an exemplary aspect of the present disclosure.

[0009] Figure 6A is an isometric view of a pressure roll comprising two materials having different material properties for use with an automated fiber placement assembly according to an exemplary aspect of the present disclosure.

[0010] Figure 6B is taken along section VIB-VIB according to an exemplary aspect of the present disclosure Figure 6ACross-sectional view of the pressure roller.

[0011] Figures 7A-7M A cross-sectional view of an alternative exemplary pressure roller suitable for use with an automated fiber placement assembly according to exemplary aspects of the present disclosure is shown.

[0012] Figure 8A is an isometric view of a pressure roll including an internal opening for use with an automated fiber placement assembly according to an exemplary aspect of the present disclosure.

[0013] Figure 8B is taken along section VIIIB-VIIIB according to an exemplary aspect of the present disclosure Figure 8A Cross-sectional view of the pressure roller.

[0014] Figure 8C is a diagram of a device including an aperture in a pressure roller taken along section VIIIC-VIIIC according to an exemplary aspect of the present disclosure Figure 8A Cross-sectional view of the pressure roller.

[0015] Figure 9 is a cross-sectional view of an alternative pressure roller according to an exemplary aspect of the present disclosure, illustrating an alternative arrangement of apertures within the pressure roller.

[0016] Figure 10 is a flow chart depicting a method of forming a part with an automated fiber placement assembly, wherein the part has a substrate with a non-uniform surface, according to an exemplary aspect of the present disclosure. DETAILED DESCRIPTION

[0017] Aspects disclosed herein relate to systems and methods for forming components, such as components for turbine engines, or any other component that can be formed in whole or in part by an automated fiber placement (AFP) assembly or machine. Automated fiber placement machines can be used to lay down successive layers of fiber bundles to build or add to a component. Components can include simple geometries but are often complex, resulting in overhanging bundle ends or undesirable application of fiber bundles due to the complex shape of the component being formed.

[0018] As described herein, an automated fiber placement assembly can be used to form a component or apply fiber bundles during the formation of a component, such as an engine component used in a turbine engine of an aircraft. Such an engine component can be an airfoil, such as an airfoil for a fan blade. It should be understood that the present disclosure can be similarly applied to other components of a turbine engine (such as a combustor liner or disk, in non-limiting examples), as well as non-aircraft, non-turbine, or non-engine components. Although described in terms of components of a turbine engine, it should be understood that the present disclosure can be applied to any component and need not be specific to a turbine engine or aircraft.

[0019] Reference will now be made in detail to the present embodiments of the present disclosure, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in the drawings and the description have been used to refer to like or similar parts of the disclosure.

[0020] The word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any implementation described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other implementations. Furthermore, unless expressly stated otherwise, all embodiments described herein should be considered exemplary.

[0021] As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to indicate the position or importance of each component.

[0022] As used herein, the term "upstream" refers to a direction opposite to the direction of fluid flow, while the term "downstream" refers to a direction in the same direction as the direction of fluid flow. The terms "front" or "in front of" refer to in front of something, and "rear" or "rearward" refer to behind something.

[0023] The term "fluid" may be gas or liquid, or multiple phases.

[0024] As used herein, the terms "complementary" or "supplement" are used herein to indicate that a first aspect of the present invention is shaped relative to another aspect or feature. For example, the concave shape of the pressure roller described herein is complementary to the convex shape of the non-uniform surface, wherein the concave shape is shaped relative to the convex feature such that the concave shape of the pressure roller matches the convex shape of the non-uniform surface.

[0025] As used herein, the term "changed physical configuration" refers to a change in the physical structure of an object, such as the pressure roller described herein. Such a change in physical structure can include a change in the physical structure defined in a direction, such as an axial direction, a radial direction, a circumferential direction, a spanwise direction, a chordwise direction, or a direction specific to the object, such as a direction defined between opposite ends of the object, relative to the rotational axis of the pressure roller, or closer to or further from an interior surface or an exterior surface. The physical structure can change in one of these directions.

[0026] As used herein, the term "varying material configuration" refers to a variation in the material forming an object, such as the pressure roller described herein. In non-limiting examples, such a variation in material can include different materials or utilizing materials with different material properties, such as hardness, elasticity, or yield strength. In one example, different portions of the pressure roller can utilize different materials or materials with different material properties. The variation in material can be defined relative to a direction, such as an axial direction, a radial direction, a circumferential direction, a spanwise direction, a chordwise direction, or a direction specific to the object, such as a direction defined between opposing ends of the object, relative to the axis of rotation of the pressure roller, or a direction closer to or further from an interior surface or an exterior surface.

[0027] Furthermore, as used herein, the term "radial" or "radially" refers to directions away from a common center. For example, in the overall context of a turbine engine, radial refers to directions along a ray extending between the central longitudinal axis of the engine and the engine periphery.

[0028] All directional references as may be used herein (e.g., radial, axial, higher, lower, front, rear, top, bottom, above, upstream, downstream, forward, rearward, etc.) are for identification purposes only to assist the reader in understanding the present disclosure and do not create limitations, particularly with respect to the position, orientation, or use of the disclosed aspects described herein. Connection references (e.g., attach, couple, connect, and engage) are to be interpreted broadly and may include intermediate structural elements between a collection of elements and relative movement between elements, unless otherwise indicated. Therefore, a connection reference does not necessarily mean that the two elements are directly connected and fixed relative to each other. The exemplary figures are for illustration purposes only, and the dimensions, positions, orders, and relative sizes reflected in the accompanying figures may vary.

[0029] Unless the context clearly dictates otherwise, the singular forms "a," "an," and "the" include plural references. Also, as used herein, the term "set" or a "set" of elements can refer to any number of elements, including only one.

[0030] As used herein, the term "non-uniform" may be used to define a shape or surface of a component or substrate that is inhomogeneous, uneven, irregular, or non-constant. Non-uniformity may be defined as extending in one or more directions along the surface of a component or substrate. While a non-uniform surface can be patterned, it is patterned only over a portion of the surface, rather than over the entire surface of the component or substrate.

[0031] As used herein, the term "material property" may be used to define an inherent or intrinsic property of a particular material of an element or feature of the present disclosure, such as an inherent or intrinsic property of the material of a pressure roller. In non-limiting examples, a "material property" as used herein may be elasticity, hardness, or yield strength, which may relate to the amount of deformation a particular material allows under pressure or force, or its resistance to deformation. Such material properties may be defined by the material used to form the element or feature, or by the manufacturing process used to create the element or feature.

[0032] As used herein, the term "elasticity" can be used to define the modulus of elasticity under tension or compression, and can relate to the elasticity of a particular material or structure made from such a material, such as the engine components described herein. Elasticity can be expressed as stress per unit area relative to local strain or its proportional deformation, or can be expressed as a bulk modulus or yield strength, such as the ratio of force to deformation.

[0033] As used herein, the term "hardness" may be used to define a material property that defines resistance to deformation due to indentation or wear. In non-limiting examples, hardness may include scratch hardness, indentation hardness, or rebound hardness. In non-limiting examples, hardness may be measured in Newtons per square millimeter or may be represented by a Brinell hardness number, a Vickers hardness number, or a Rockwell hardness number.

[0034] As used herein, the term "yield strength" may be used to define a material property that defines the limit of elastic behavior and the onset of plastic behavior. A force acting on a material that does not exceed the yield strength limit may cause it to deform while returning to its original shape, while a force exceeding the yield strength limit will begin to cause it to deform without returning to its original shape. In non-limiting examples, yield strength may be defined as the elastic limit or yield point.

[0035] As used herein, the term "composite" refers to a component having two or more materials. A composite can be a combination of at least two or more metals, non-metals, or a combination of metal and non-metal elements or materials. Examples of composite materials include, but are not limited to, polymer matrix composites (PMCs), ceramic matrix composites (CMCs), metal matrix composites (MMCs), carbon fibers, polymer resins, thermoplastic resins, bismaleimide (BMI) materials, polyimide materials, epoxy resins, glass fibers, and silicon matrix materials.

[0036] As used herein, a "composite" component refers to a structure or component comprising any suitable composite material. A composite component, such as a composite airfoil, may include several layers or layups of composite material. The stiffness, material, and dimensions of the layers or layups may vary to achieve a desired composite component or composite portion of a component having a predetermined weight, size, stiffness, and strength.

[0037] In addition, as used herein, a "controller" or "controller module" may include a component that is configured or adapted to provide instructions, control, operation, or any form of communication to an operable component to affect its operation. A controller module may include any known processor, microcontroller, or logic device, including but not limited to: a field programmable gate array (FPGA), an application specific integrated circuit (ASIC), a full authority digital engine control (FADEC), a proportional controller (P), a proportional integral controller (PI), a proportional differential controller (PD), a proportional integral differential controller (PID controller), a hardware accelerated logic controller (e.g., for encoding, decoding, transcoding, etc.), or a combination thereof. Non-limiting examples of controller modules may be configured or adapted to run, operate, or otherwise execute program code to achieve an operation or functional result, including performing various methods, functions, processing tasks, calculations, comparisons, sensing or measurement values, etc., to enable or implement the technical operations or operations described herein. The operation or functional result may be based on one or more inputs, stored data values, sensing or measurement values, true or false indications, etc. Although " program code " is described, the non-limiting examples of operable or executable instruction sets may include routines, programs, objects, components, data structures, algorithms, etc. that have the technical effects of performing specific tasks or implementing specific abstract data types. In another non-limiting example, the controller module may also include a data storage component accessible by the processor, including a memory, whether it is a transient memory, volatile or non-transient memory, or a non-volatile memory. Other non-limiting examples of memory may include random access memory (RAM), read-only memory (ROM), flash memory or one or more different types of portable electronic memories, such as disks, DVDs, CD-ROMs, flash drives, universal serial bus (USB) drives, etc., or any suitable combination of these types of memories. In one example, program code may be stored in a memory in a machine-readable format accessible to the processor. In addition, the memory may store various data, data types, sensed or measured data values, inputs, generated or processed data, etc. that the processor may access when providing instructions, controlling or operating to affect a function or an operational result, as described herein.

[0038] Additionally, as used herein, an element "electrically connected," "electrically coupled," "communicatively coupled," or "in electrical communication," and terms similar thereto, may include electrical transmission, wired or wireless transmission, or the sending, receiving, or communicating of signals to or from such connected or coupled elements. Furthermore, such electrical connection or coupling may include wired or wireless connection, or a combination thereof.

[0039] One or more layers of adhesive may be used to form or join the composite parts. The adhesive may include resins and phenolics, where the adhesive may require curing at elevated temperatures or other hardening techniques.

[0040] As used herein, PMC refers to a class of materials. As an example, PMC materials are defined in part by prepregs, which are reinforcing materials pre-impregnated with a polymer matrix material (e.g., a thermoplastic resin). Non-limiting examples of processes for producing thermoplastic prepregs include: hot melt prepregs, in which fiber reinforcements are pulled through a molten bath of resin; and powder prepregs, in which resin is deposited onto the fiber reinforcement, as a non-limiting example, electrostatically deposited onto the fiber reinforcement, and then adhered to the fibers, as a non-limiting example, in an oven or with the help of heated rollers. Prepregs can be in the form of unidirectional tapes or woven fabrics, which are then stacked on top of each other to create the desired number of plies for a part.

[0041] Multilayer prepreg is stacked to the appropriate thickness and orientation of composite component, and then resin is cured and solidified to provide fiber reinforced composite parts. The resin for PMC matrix material can be generally classified as thermosetting resin or thermoplastic resin. Thermoplastic resin is generally classified as a polymer that can repeatedly soften and flow when heated and can harden due to physical change rather than chemical change when fully cooled. The famous example category of thermoplastic resin includes nylon, thermoplastic polyester, polyaryletherketone and polycarbonate resin. The specific example of the high performance thermoplastic resin envisioned for aerospace application includes polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyetherimide (PEI), polyaryletherketone (PAEK) and polyphenylene sulfide (PPS). On the contrary, once fully cured into hard rigid solid, thermosetting resin will not experience significant softening when heated, but will thermally decompose when fully heated. The famous example of thermosetting resin includes epoxy resin, bismaleimide (BMI) and polyimide resin.

[0042] Instead of using prepreg, in another non-limiting example, woven fabrics can be utilized by using thermoplastic polymers. Woven fabrics may include, but are not limited to, dry carbon fibers woven together with thermoplastic polymer fibers or filaments. Non-prepreg braided architectures can be made in a similar manner. In this way, the fiber volume of a part can be customized by specifying the relative concentrations of the thermoplastic fibers and reinforcing fibers that have been woven or braided together. In addition, different types of reinforcing fibers can be woven or woven together at different concentrations to customize the properties of the part. For example, glass fiber, carbon fiber, and thermoplastic fibers can be woven together at different concentrations to customize the properties of the part. Carbon fiber provides the strength of the system and can be incorporated with glass fiber to enhance impact properties, which is a design feature of parts located near the engine inlet, and thermoplastic fibers provide bonding for the reinforcing fibers.

[0043] In yet another non-limiting example, resin transfer molding (RTM) can be used to form at least a portion of a composite component. Typically, RTM involves applying a dry fiber or matrix material to a mold or cavity. The dry fiber or matrix material can include a prepreg, a braided material, a woven material, or any combination thereof.

[0044] Resin can be pumped or otherwise supplied to the mold or cavity to impregnate the dry fibers or matrix material. The impregnated fibers or matrix material and resin combination is then cured and removed from the mold. Upon removal from the mold, the composite part may require a post-curing process.

[0045] It is contemplated that RTM can be a vacuum-assisted process. That is, the air in the cavity or mold can be removed and replaced with resin before heating or curing. It is further contemplated that the placement of dry fiber or matrix material can be manual or automated.

[0046] The dry fiber or matrix material can be shaped to form the composite part or to guide the resin. Optionally, additional layers or reinforcements of a material different from the dry fiber or matrix material can also be included or added before heating or curing.

[0047] As used herein, CMC refers to a class of materials having reinforcing fibers in a ceramic matrix. Typically, the reinforcing fibers provide structural integrity to the ceramic matrix. Some examples of reinforcing fibers may include, but are not limited to, non-oxide silicon-based materials (e.g., silicon carbide, silicon nitride, or mixtures thereof), non-oxide carbon-based materials (e.g., carbon), oxide ceramics (e.g., silicon oxycarbide, silicon oxynitride, aluminum oxide (Al2O3), silicon dioxide (SiO2), aluminosilicates (such as mullite), or mixtures thereof), or mixtures thereof.

[0048] Some examples of ceramic matrix materials may include, but are not limited to, non-oxide silicon-based materials (e.g., silicon carbide, silicon nitride, or mixtures thereof), oxide ceramics (e.g., silicon oxycarbide, silicon oxynitride, aluminum oxide (Al2O3), silicon dioxide (SiO2), aluminosilicates, or mixtures thereof), or mixtures thereof. Optionally, ceramic particles (e.g., oxides of Si, Al, Zr, Y, and combinations thereof) and inorganic fillers (e.g., pyrophyllite, wollastonite, mica, talc, kyanite, and montmorillonite) may also be included in the ceramic matrix.

[0049] In general, specific CMCs can be referred to by their fiber type / matrix type combination. For example, C / SiC is carbon fiber reinforced silicon carbide, SiC / SiC is silicon carbide fiber reinforced silicon carbide, SiC / SiN is silicon carbide fiber reinforced silicon nitride, SiC / SiC-SiN is a silicon carbide fiber-reinforced silicon carbide / silicon nitride matrix mixture, and so on. In other examples, CMCs can be composed of a matrix comprising oxide-based materials such as aluminum oxide (Al2O3), silicon dioxide (SiO2), aluminosilicates, and mixtures thereof, and reinforcing fibers. Aluminosilicates can include crystalline materials such as mullite (3Al2O3·2SiO2), as well as glassy aluminosilicates.

[0050] In certain non-limiting examples, the reinforcing fibers may be bundled and / or coated prior to inclusion in the ceramic matrix. For example, the fiber bundles may be formed into reinforcement tapes, such as unidirectional reinforcement tapes. Multiple tapes may be stacked together to form a preform component. The fiber bundles may be impregnated with the slurry composition before or after forming the preform. The preform may then be subjected to a heat treatment and subsequent chemical treatment to obtain a component formed of a CMC material having a desired chemical composition. For example, the preform may undergo curing or burnout to produce a high coke residue in the preform and subsequently be melt infiltrated with silicon, or undergo curing or pyrolysis to produce a silicon carbide matrix in the preform and subsequently be chemically vapor infiltrated with silicon carbide. Additional steps may be taken to improve the densification of the preform by injecting the preform with a liquid resin or polymer before or after chemical vapor infiltration, followed by a heat treatment step to fill the voids with silicon carbide. CMC materials as used herein may be formed using any known or later developed method including, but not limited to, melt infiltration, chemical vapor infiltration, polymer infusion pyrolysis (PIP), or any combination thereof.

[0051] Such materials, along with certain monolithic ceramics (i.e., ceramic materials without reinforcements), are particularly well-suited for higher temperature applications. Furthermore, these ceramic materials are lightweight compared to superalloys while still providing strength and durability to components made from them. Consequently, such materials are currently being considered for use in many gas turbine components used in the higher temperature sections of gas turbine engines, such as airfoils (e.g., turbine blades and buckets), combustors, shrouds, and other components, which would benefit from the lighter weight and higher temperature capabilities that these materials can offer.

[0052] The inventors have practiced in the following manner: a system for manufacturing parts (such as airfoils) on a substrate is designed to have improved bundle fiber application, bonding and combining, especially for parts with non-uniform surfaces. The system has been used in the design and creation of several different types of parts (such as Figure 1 The composite components are used in turbine engines as shown, as well as components used in non-aircraft or non-turbine engine applications.

[0053] Figure 1 is a schematic cross-sectional view of a turbine engine 10 for an aircraft. The turbine engine 10 has a generally longitudinally extending axis or engine centerline 12 extending from a front portion 14 to an aft portion 16. The turbine engine 10 includes, in downstream serial flow relationship, a fan section 18 including a fan 20; a compressor section 22 including a supercharger or low-pressure (LP) compressor 24 and a high-pressure (HP) compressor 26; a combustion section 28 including a combustor 30; a turbine section 32 including an HP turbine 34 and an LP turbine 36; and an exhaust section 38.

[0054] The fan section 18 includes a fan case 40 surrounding the fan 20. The fan 20 includes a plurality of fan blades 42 radially arranged about the engine centerline 12. The HP compressor 26, the combustor 30, and the HP turbine 34 form an engine core 44 of the turbine engine 10, which generates combustion gases. The engine core 44 is surrounded by a core case 46, which can be coupled to the fan case 40.

[0055] An HP shaft or spool 48, disposed coaxially about the engine centerline 12 of the turbine engine 10, drivingly connects the HP turbine 34 to the HP compressor 26. An LP shaft or spool 50, disposed coaxially about the engine centerline 12 of the turbine engine 10 within the larger diameter annular HP spool 48, drivingly connects the LP turbine 36 to the LP compressor 24 and the fan 20. The HP and LP spools 48, 50 are rotatable about the engine centerline 12 and are coupled to a plurality of rotatable elements that may collectively define a rotor 51.

[0056] The LP compressor 24 and the HP compressor 26 each include a plurality of compressor stages 52, 54, wherein a set of compressor blades 56, 58 rotate relative to a corresponding set of static compressor vanes 60, 62 to compress or pressurize a fluid flow passing through the stage. In a single compressor stage 52, 54, the plurality of compressor blades 56, 58 may be arranged in a ring and may extend radially outward from a blade platform to a blade tip relative to the engine centerline 12, with the corresponding static compressor vanes 60, 62 positioned upstream and adjacent to the rotating compressor blades 56, 58. Notably, Figure 1 The number of blades, buckets, and compressor stages shown in FIG. 5 are chosen for illustration purposes only, and other numbers are possible.

[0057] Compressor blades 56, 58 for one stage of compressors 24, 26 may be mounted to (or integrated into) a disk 61 mounted to a corresponding one of the HP and LP spools 48, 50. Static compressor vanes 60, 62 for one stage of compressors 24, 26 may be mounted to the core housing 46 in a circumferential arrangement.

[0058] The HP turbine 34 and the LP turbine 36 each include a plurality of turbine stages 64, 66, in which a set of turbine blades 68, 70 rotate relative to a corresponding set of static turbine vanes 72, 74 (also known as nozzles) to extract energy from the fluid flow passing through the stage. In a single turbine stage 64, 66, the plurality of turbine blades 68, 70 may be arranged in a ring and may extend radially outward relative to the engine centerline 12, while the corresponding static turbine vanes 72, 74 are positioned upstream and adjacent to the rotating turbine blades 68, 70. Notably, Figure 1 The number of blades, buckets, and turbine stages shown in FIG. 5 is selected for illustration purposes only; other numbers are possible.

[0059] Turbine blades 68, 70 for a stage of turbines 34, 36 may be mounted to disks 71 mounted to respective ones of HP and LP spools 48, 50. Static turbine buckets 72, 74 for a stage of compressors 24, 26 may be mounted to core housing 46 in a circumferential arrangement.

[0060] Complementing the rotor portion, the stationary portion of the turbine engine 10, such as the static compressor blades 60, 62 and static turbine blades 72, 74 in the compressor section 22 and the turbine section 32, are also individually or collectively referred to as stators 63. Thus, the stator 63 may refer to the combination of non-rotating elements throughout the turbine engine 10.

[0061] In operation, the airflow exiting fan section 18 is split so that a portion of the airflow is directed to LP compressor 24, which then supplies pressurized airflow 76 to HP compressor 26, which further pressurizes the air. The pressurized airflow 76 from HP compressor 26 is mixed with fuel in combustor 30 and ignited, generating combustion gases. HP turbine 34 extracts some work from these gases, which drives HP compressor 26. The combustion gases are exhausted to LP turbine 36, which extracts additional work to drive LP compressor 24, and the exhaust gases are ultimately exhausted from turbine engine 10 via exhaust section 38. The drive of LP turbine 36 drives LP spool 50 to rotate fan 20 and LP compressor 24.

[0062] A portion of the pressurized airflow 76 may be extracted from the compressor section 22 as bleed air 77. The bleed air 77 may be extracted from the pressurized airflow 76 and provided to engine components for cooling. The temperature of the pressurized airflow 76 entering the combustor 30 is significantly increased to a temperature above the bleed air temperature. The bleed air 77 may be used to reduce the temperature of core components downstream of the combustor 30.

[0063] The remaining portion of the pressurized airflow 76 bypasses the LP compressor 24 and the engine core 44 as a bypass airflow 78 and exits the turbine engine 10 through a stationary vane row at the fan exhaust side 84, and more specifically, exits the turbine engine 10 through an outlet guide vane assembly 80 (including a plurality of airfoil guide vanes 82) at the fan exhaust side 84. More specifically, the plurality of airfoil guide vanes 82 may be arranged in a circumferential row of radially extending airfoil guide vanes 82 adjacent to the fan section 18 for use in applying some directional control to the bypass airflow 78.

[0064] Some of the air supplied by the fan 20 may bypass the engine core 44 and be used to cool portions of the turbine engine 10, particularly the hot portion, and / or to cool or power other aspects of the aircraft. In the case of a turbine engine, the hot portion of the engine is typically downstream of the combustor 30, particularly the turbine section 32, with the HP turbine 34 being the hottest portion as it is located directly downstream of the combustion section 28. Other sources of cooling fluid may be, but are not limited to, fluid discharged from the LP compressor 24 or the HP compressor 26.

[0065] Figure 2 Is suitable for Figure 1 Schematic isometric view of a composite airfoil 100 and a disk 102 for use within a turbine engine 10 of FIG. Composite airfoil 100 may define a body 104. Disk 102 is suitable for use as disks 61, 71 ( Figure 1 ) or any other disk, such as but not limited to a turbine engine 10 ( Figure 1 ) of fan section 18 ( Figure 1 )、Compressor section 22( Figure 1 ) or turbine section 32 ( Figure 1 ) within the disk. The composite airfoil 100 may be rotating or non-rotating, such that the composite airfoil 100 may include static compressor blades 60, 62 ( Figure 1 ), the set of compressor blades 56, 58 ( Figure 1 ), static turbine blades 72, 74 ( Figure 1 ), the group of turbine blades 68, 70 ( Figure 1 ) or multiple fan blades 42 ( Figure 1 As a non-limiting example, the composite airfoil 100 may be a composite fan blade.

[0066] Composite airfoil 100 and its body 104 extend between a leading edge 114 and a trailing edge 116 to define a chord-wise direction, and between a root 118 and a tip 120 to define a span-wise direction. Composite airfoil 100 includes a pressure side 122 and a suction side 124.

[0067] The disk 102 may rotate or be stationary about an axis of rotation 106. The axis of rotation 106 may be aligned with the engine centerline 12 ( Figure 1 ) coincident, parallel, or offset. The disk 102 includes a plurality of slots 108 extending axially through a radially outer surface 112 of the disk 102. The plurality of slots 108 are circumferentially spaced about the disk 102 relative to the axis of rotation 106 and allow the composite airfoil 100 to be slidably secured to the disk 102.

[0068] The composite airfoil 100 is coupled to the disk 102 by inserting at least a portion of the composite airfoil 100 into a corresponding slot in the plurality of slots 108. The composite airfoil 100 is held in place by frictional contact with the slot 108 or may be coupled to the slot 108 via any suitable coupling method, such as, but not limited to, welding, bonding, fastening, etc. Although only a single composite airfoil 100 is shown, it should be understood that any number of composite airfoils 100 may be coupled to the disk 102. As a non-limiting example, there may be a number of composite airfoils 100 corresponding to the total number of slots in the plurality of slots 108.

[0069] For ease of reference, a set of relative reference directions and coordinate systems may be applied to the composite airfoil 100 and disk 102. The axial direction (Ad) may extend from front to back and is shown as extending at least partially into the page. The axial direction (Ad) may also be arranged parallel to the rotation axis 106, which may also be arranged parallel to the engine centerline 12 ( Figure 1). The radial direction (Rd) extends perpendicular to the axial direction (Ad), and the radial direction (Rd) may extend perpendicular to the engine centerline 12. The circumferential direction (Cd) may be defined as perpendicular to the radial direction (Rd), and the circumferential direction (Cd) may be defined as a ray extending from or along the curvature of a circle about the axial direction (Ad), may be defined as a ray extending locally from the radial direction (Rd), and / or may be defined relative to the engine centerline 12 ( Figure 1 ) or the axis of rotation 106 along the turbine engine 10 ( Figure 1 ) circumference.

[0070] Figure 3 A schematic perspective view of an automated fiber placement assembly 150 is shown applying a fiber tow band 152 to a component 154, thereby at least partially forming the component 154. In one non-limiting example, the component 154 may be Figure 2 1. The composite airfoil 100 of FIG. 1 is a composite airfoil 100, while other non-airfoil components, composite components, or non-turbine engine components are contemplated. The component 154 may be a substrate 158. The substrate 158 may be defined as the component 154 being formed, for example, having one or more fiber tow tapes 152 already laid up to form the component 154, while alternative substrates (such as a mandrel or workpiece) that do not have laid-up fiber tow tapes 152 are contemplated. The component 154 or substrate 158 has a non-uniform surface 166 on which the fiber tow tapes 152 are placed.

[0071] A pressure roller 160, suspended by a mounting 162, rotates in a rotational direction (ROTD) to apply the fiber band 152 to the component 154. The pressure roller 160 includes an outer surface 164 that contacts the fiber band 152 during application to the component 154. The pressure roller 160 or its outer surface 164 can be shaped to complement the uneven surface 166 on which the fiber band 152 is applied, and will be discussed in greater detail herein. During application, the pressure roller 160 applies pressure to the fiber band 152 against the component 154 to promote adhesion or bonding. In a non-limiting example, the pressure roller 160 can be made of a compliant material (such as one or more of polyurethane, rubber, or a polymer). Multiple layers or stacks of fiber bands 152 can be applied in this manner to form the component 154 on the substrate 158. In a non-limiting example, the pressure roller 160 can be covered with a non-stick coating (such as polytetrafluoroethylene), while alternative anti-adhesion or low-friction materials are contemplated.

[0072] The cutter assembly 168 includes a cutter head 170 coupled to an actuator 172 that actuates the cutter head 170 to cut the fiber tow band 152 against a backing plate 174. For example, the actuator 172 may include a drive such as an electric motor or an air cylinder that reciprocates the cutter head 170 to cut the fiber tow band 152.

[0073] The controller 176 is operatively and communicatively coupled to the pressure roller 160 to control the speed at which the fiber tow band 152 is applied at the pressure roller. Additionally, it is contemplated that the controller 176 is communicatively coupled, operatively coupled, or both communicatively coupled and operatively coupled to additional elements of the automated fiber placement assembly 150, such as the cutter assembly 168, in non-limiting examples. The controller 176 can control the speed or rate at which the fiber tow band 152 is applied by controlling the rotation of the pressure roller 160, such as by controlling a motor 186 that rotates the pressure roller 160, which is operated by the controller 176.

[0074] A heat source 178 may be provided to heat one or both of the component 154 or the surface of the fiber tow band 152 in contact with the component 154, with any positioning being contemplated. The heat source 178 provides heat in addition to the pressure applied by the pressure roller 160 to pre-cure, activate, or otherwise facilitate bonding or application of the fiber tow band 152 to the component 154. For example, a resin provided within the fiber tow band 152 may be activated by the addition of heat, which may cause adhesion to the component 154 or an already laid fiber tow band 152. The heat source 178 may be operatively or communicatively coupled to the controller 176 so that the controller 176 controls one or both of the application of heat and the temperature of the applied heat.

[0075] During operation, rotation of the pressure roller 160 in the direction of rotation (ROTD) lays down the continuous fiber tow band 152 in the placement direction (Pd) to form the component 154 on the substrate 158. The shape of the pressure roller 160 can be defined to complement the non-uniform surface 166, such as by having a shape that is different from the shape of a basic geometric shape (such as the shape of a cylindrical pressure roller), such as having localized peaks or valleys, or other features that complement the non-uniform surface 166, which can provide a varying localized pressure applied by the pressure roller 160 during application to allow the pressure roller 160 to apply pressure evenly or nearly evenly across the fiber tow band 152.

[0076] Figure 4 An isometric view of a pressure roller 160 having a varying physical configuration is shown. Figure 3 The placement direction (Pd) is intercepted at an angle slightly offset from the automatic fiber placement component 150 ( Figure 3) is isolated from the remainder of the non-uniform surface 166. The pressure roller 160 extends between a first end 182 and an opposing second end 184 and rotates about the rotational axis 156 during application. The outer surface 164 of the pressure roller 160 is shaped to complement a portion of the non-uniform surface 166 of the component 154. The pressure roller 160 can be defined as a non-cylindrical shape, having a decreasing and then increasing diameter extending between the first end 182 and the second end 184. The rate at which the diameter increases or decreases between the first end 182 and the second end 184 can define the curvature of the pressure roller 160, such that the curvature is elliptical to complement the spherical or elliptical shape of the non-uniform surface 166. The pressure roller 160 can be substantially cylindrical or have a substantially spherical or circular cross-sectional shape to allow for rolling along the component 154, although the specific shape can vary from a purely cylindrical shape, as defined by different diameters or features of the pressure roller 160. This variation from a cylindrical shape can allow the pressure roller 160 to complement the shape of the non-uniform surface 166. It should be understood that any suitable shape of the pressure roller 160 is contemplated such that the shape complements the non-uniform surface 166 and is capable of applying uniform or substantially uniform pressure to the fiber tow band 152 ( Figure 3 ) is applied to the component 154. Additional non-limiting examples of the shape of the outer surface 164 may include circular, oval, spherical, linear, curvilinear, or combinations thereof, and localized or discrete variations in shape may be used to supplement similar localized or discrete variations in the non-uniform surface 166. In another non-limiting example, the shape of the outer surface 164 of the pressure roller 160 may be a mirror image of the shape of the non-uniform surface 166, such that the outer surface 164 may be rolled over to apply the fiber tow band 152 ( Figure 3 ) matches or complements the non-uniform surface 166.

[0077] In operation, the rotation of the pressure roller 160 pushes the fiber tow band 152 ( Figure 3 ) applies pressure. The geometry of the pressure roller 160 complements the shape of the non-uniform surface 166 to provide the pressure roller 160 with a localized increase or decrease in thickness that is aligned with a similar decrease or increase in diameter of the pressure roller 160 such that an even pressure, or a substantially even pressure, is applied to the component 154 across the entire pressure roller 160 from the first end 182 to the second end 184. In a non-limiting example, such variation may not exceed a 5% variation in the pressure applied across the pressure roller 160. In this manner, the pressure roller 160 may apply even pressure despite the non-uniform shape of the component 154. This even application of pressure along the non-uniform surface 166 provides for improved or increased bonding and holds the fiber tow band 152 ( Figure 3 ) is applied uniformly to component 154.

[0078] Additionally, it is contemplated that the pressure roller 160 may be interchangeable or replaceable during operation. More specifically, the pressure roller 160 may be removable from the mounting member 162 ( Figure 3 ) is removed and replaced with another pressure roller, wherein each pressure roller 160 has a shape that complements a different portion of the non-uniform surface 166 of the component 154. For example, the non-uniform surface 166 may have a non-uniformity that is wider than the pressure roller 160, or a non-uniformity that is larger than the area covered by one rotation of the pressure roller 160. In such an example, multiple pressure rollers 160 may be used to apply the fiber tow band 152 ( Figure 3 ), wherein each pressure roller 160 is shaped to complement a different portion of the non-uniform surface 166. In this manner, the pressure rollers 160 can be removed or interchanged during operation to apply the fiber tow band 152 across the entirety of a component 154 that is larger than a single pressure roller 160 itself. Figure 3 ). In a non-limiting example, the pressure roller 160 can be manually removed or interchanged by a user operating the automated fiber placement assembly 150, or the pressure roller 160 can be interchanged by an automated system, which may or may not be part of the automated fiber placement assembly 150. For example, such interchange can be automated. Combinations of interchange or replacement of the pressure roller 160 by an automated system can include physically removing and replacing the pressure roller 160, such as by utilizing mechanical features, such as a motor and actuator system adapted to secure, remove, and replace one or more pressure rollers 160 within the automated fiber placement assembly 150. In such an example, the automated fiber placement assembly 150, or its user or operator, can select a pressure roller 160 from a set of pressure rollers 160 for forming the part 154, wherein each pressure roller 160 can be shaped relative to a different portion of the non-uniform surface 166. It is contemplated that the automated fiber placement assembly 150 can include a controller, memory, and instructions, such as software or programming instructions for automatically changing the pressure roller 160 to complement the different non-uniform shapes of the underlying part 154 during formation.

[0079] Figure 5 An isometric view of an exemplary pressure roller 200 having a varying physical configuration is shown, the pressure roller 200 extending between a first end 202 and an opposing second end 204 for applying a fiber tow 206 to a component 208 by rotating about an axis of rotation 214. It should be understood that while the component 208 is shown as having a flat or planar exterior surface 210, non-uniform surfaces are also contemplated for the exterior surface 210, similar to Figure 3-4 The non-uniform surface 166.

[0080] During the formation of component 208, adhesive 212 may be used to facilitate bonding of fiber band 206 to component 208. In one example, fiber band 206 may be impregnated with an adhesive (such as a resin), however, a separate adhesive may be applied to fiber band 206. During application, the pressure applied by pressure roller 200 causes at least some adhesive 212 to be squeezed out from between pressure roller 200 and component 208. This squeeze out of adhesive 212 may be exacerbated by the non-uniform surface of exterior surface 210. Using a shaped pressure roller 200, localized increases or decreases in the pressure applied by pressure roller 200 may be defined. Specifically, pressure roller 200 includes an increased diameter near first end 202 and second end 204, thereby defining a localized increased pressure, and a corresponding decrease in diameter and pressure relatively further from first end 202 and second end 204. The increased diameter at first end 202 and second end 204 and the increased localized pressure applied by pressure roller 200 resist squeeze out of adhesive 212, thereby defining a pressure barrier at first end 202 and second end 204. This pressure barrier maintains all, or a relatively greater amount, of adhesive 212 between pressure roller 200 and part 208, such as compared to a cylindrical roller, and reduces or minimizes the amount of adhesive 212 that squeezes out from between pressure roller 200 and part 208. When applied to a non-uniform exterior surface 210, pressure roller 200 may be shaped complementary to non-uniform exterior surface 210, while having a relatively larger diameter or other shape, to achieve a similar pressure barrier at first end 202 and second end 204, despite the non-uniformity of exterior surface 210, thereby maintaining all, or a relatively greater amount, of adhesive 212 between pressure roller 200 and part 208.

[0081] Reducing the squeeze-out of adhesive 212 provides a better, improved, or increased bond between the fiber band 206 and the component 208 due to the greater consistency in the adhesive across the pressure roller 200. The resulting greater consistency in the fiber band 206 results in a reduction or decrease in local variations in the amount or concentration of adhesive 212. This reduction or decrease in local variations also reduces the occurrence of thin spots with relatively small amounts of adhesive 212, reduces areas of excess adhesive 212, or hot spots with relatively larger amounts of adhesive 212, or a combination thereof. The reduction in the amount of squeezed-out adhesive 212 reduces the amount of adhesive 212 applied to or at the fiber band 206, thereby reducing material and waste. Additionally, the amount of finishing or machining required on the component 208 due to adhesive squeeze-out or inconsistent adhesive application can be reduced, further reducing material, handling, and waste while also reducing costs. Additionally, the consistent application of adhesive 212 provides improved or increased consistency in the formation of component 208 , thereby reducing post-processing and overall manufacturing losses that would otherwise occur in areas where the adhesive is relatively heavy or light.

[0082] Figure 6A An exemplary pressure roller 250 having varying material configurations is depicted. The pressure roller 250 has an outer portion 252 and an inner portion 254, with the inner portion 254 being radially surrounded by the outer portion 252 and extending between a first end 256 and an opposing second end 258. While the outer portion 252 and the inner portion 254 are visible at the first end 256, it is contemplated that the outer portion 252 may cover the inner portion 254 at the first end 256 and the second end 258. Figure 3 During the operation of the pressure roller 250 (e.g., the fiber bundle 152 and the component 154), the pressure roller 250 rotates about the rotation axis 264, and the inner portion 254 can intersect the rotation axis 264. The varying material configuration can be defined by different materials for the outer portion 252 and the inner portion 254, which vary in a direction radially outward from the rotation axis 264.

[0083] The outer portion 252 can include a first material, and the inner portion 254 can include a second material different from the first material, wherein each of the first and second materials has its own material properties. In one example, the first material can have a first material property (such as a first hardness, a first elasticity, a first yield strength, or a combination thereof), and the first material property can be different from a second material property, such as a second hardness, a second elasticity, a second yield strength, or a combination thereof. In one non-limiting example, the outer portion 252 and the inner portion 254 can be made of the same material or similar materials, while having different material properties. For example, such different material properties can be the result of manufacturing process differences.

[0084] Figure 6B Shown is a diagram taken along section VIB-VIB. Figure 6A As can be appreciated, the first thickness 260 of the outer portion 252 can be less than the second thickness 262 of the inner portion 254. In a non-limiting example, the first thickness 260 can be 10% of the total thickness of the pressure roller 250 (defined as the combination of the first thickness 260 and the second thickness 262), resulting in the second thickness 262 occupied by the inner portion 254 being 90% of the total thickness. In an alternative non-limiting example, the first thickness 260 of the outer portion 252 can vary from 10% to 90% of the total thickness of the pressure roller 250, and the second thickness 262 of the inner portion 254 can vary from 90% to 10%, respectively.

[0085] Figures 7A-7M Illustrative cross-sectional views of additional exemplary pressure rollers including different portions or features to apply consistent pressure across a non-uniform surface are shown. Figures 7D-7L shows the physical configuration of the changes, Figures 7A-7C 、 Figures 7E-7F 、 Figures 7H-7K and Figure 7M shows varying material configurations, and Figures 7E-7F 、 Figure 7H 、 Figures 7I-7K Varying physical configurations and varying material configurations are shown.

[0086] Figure 7A An alternative cross-sectional view of the pressure roller 268 is shown, wherein the Figure 6B , the outer portion 270 has a relatively greater thickness 272, and wherein the inner portion 274 has a relatively smaller thickness 276 relative to the axis of rotation 277. In non-limiting examples, it is contemplated that the thicknesses in the outer portion 270 and the inner portion 274 can be equal, or that the total mass in the outer portion 270 and the inner portion 274 can be equal, but the thicknesses can be unequal. The outer portion 270 and the inner portion 274 can define varying material configurations, having different materials, or wherein the outer portion 270 has different material properties than the inner portion 274. Such variations are defined in a direction extending radially from the axis of rotation 277.

[0087] Figure 7B Another alternative cross-sectional view of a pressure roller 288 is shown in which an outer portion 280 has a thickness 282 greater than a thickness 286 of an inner portion 284 relative to an axis of rotation 287. In such an example, the inner portion 284 may have 10% of the total thickness and the outer portion 280 may have 90% of the total thickness. The material differences between the outer portion 280 and the inner portion 284 may define a varying material configuration.

[0088] Figure 7C Yet another alternative cross-sectional view of pressure roller 288 is shown, comprising an outer portion 290, a middle portion 292, and an inner portion 294, each of which may comprise a different material, material properties, or combination thereof. It should be understood that any suitable number of portions is contemplated, including one or more, or more than three. In a non-limiting example, it is contemplated that the material properties of each of outer portion 290, middle portion 292, and inner portion 294 may increase or decrease in a direction closer to or farther from axis of rotation 296, thereby defining a gradient of material properties among outer portion 290, middle portion 292, and inner portion 294 in a direction radially inward or radially outward from axis of rotation 296. In a non-limiting example, outer portion 290 may comprise an external coating, such as, in a non-limiting example, a coating used to reduce adhesion. The material differences among two or all of outer portion 290, middle portion 292, and inner portion 294 may define a varying material configuration.

[0089] Additionally, the material properties can vary within one or more of the outer portion 290, the middle portion 292, and the inner portion 294 to complement the non-uniform surface of the component. The material properties can vary the amount of deformation experienced by the pressure roller 288 when applying the fiber band at a specific pressure. This variation in deformation can provide a defined, varying pressure across the pressure roller 288 to complement the non-uniform surface of the component. In this manner, a consistent pressure can be applied across the pressure roller 288 along the non-uniform surface while allowing for the cylindrical shape of the pressure roller 288.

[0090] Figure 7D A cross-section of a pressure roller 300 extending from an axis of rotation 302 is shown, with the pressure roller 300 having opposite ends 304 and a curved, convex outer surface 306. The outer surface 306 can be curved such that the three-dimensional shape of the pressure roller 300 varies from a cylindrical shape, with the diameter increasing toward an axial center 308 in a direction away from either of the opposite ends 304 and decreasing from the axial center 308 in a direction toward the opposite end 304. The pressure roller 300 can be made of a single material and can have consistent material properties across the pressure roller 300, although variable material properties complementary to the non-uniform surface of the component are also contemplated in addition to the curved shape of the outer surface 306. The convex outer surface 306 can define a varying physical configuration of the pressure roller 300.

[0091] Figure 7E A cross section of another exemplary pressure roller 310 is shown, which has a shape similar to that of the pressure roller 310. Figure 7DThe component is shaped like a component, while having two different materials, an inner portion 312 and an outer portion 314, arranged to rotate about an axis of rotation 318. The outer portion 314 includes an outer surface 316 having a convex shape that complements the concave shape of the component's non-uniform surface. In one non-limiting example, the inner portion 312 can have a first material property that is different from a second material property of the outer portion 314. For example, the outer portion 314 can have a greater elasticity or a lower hardness than the inner portion 312, thereby allowing for greater deformation of the outer portion 314 that complements the component's non-uniform shape when the fiber band is applied. In another non-limiting example, the hardness or yield strength of the inner portion 312 can be greater than the hardness or yield strength of the outer portion 314, thereby allowing the inner portion 312 to deform relatively less than the outer portion 314. This arrangement can allow the outer surface 316 to deform to complement the non-uniform shape while the inner portion 312 resists excessive deformation that might otherwise fail to complement the non-uniform surface in a balanced manner. While only two portions or materials are depicted, it should be understood that two or more portions, each having different material properties, are contemplated, while some portions having similar material properties are contemplated. The convex outer surface 316 can define a varying physical configuration of the pressure roller 310, while the material differences in the inner portion 312 and the outer portion 314 can define a varying material configuration.

[0092] Figure 7F A cross section of another exemplary pressure roller 320 is shown, which has a shape similar to Figure 7D and Figure 7E The shape of the device has an inner portion 322 and an outer portion 324 that can rotate around a rotation axis 328. The outer portion 324 has a Figure 7E The thickness of the outer portion 324 is defined as a relatively small thickness perpendicular to the rotation axis 328. The variable thickness of the outer portion 324 can define a variable pressure across the pressure roller 320 by virtue of different materials or different material properties, without requiring complementary shaping between the pressure roller 320 and the non-uniform surface of the component. In one example, the maximum thickness of the inner portion 322 and the outer portion 324 can be located at the axial center 326 of the center of the pressure roller 320 along the rotation axis 328. The convex outer surface can define the varying physical configurations of the pressure roller 310 and each of the inner portion 322 and the outer portion 324. The material differences between the inner portion 322 and the outer portion 324 can define the varying material configurations.

[0093] Figure 7GA cross-sectional view of another exemplary pressure roller 330 is shown, having an axial center 332 centrally located along an axis of rotation 338, opposite ends 334, and a curved, concave outer surface 336. The outer surface 336 can be curved or concave such that the three-dimensional shape of the pressure roller 330 varies from a cylindrical shape, with its diameter decreasing further from the opposite ends 334 toward the axial center 332 and increasing from the axial center 332 toward the opposite ends 334. The pressure roller 330 can be made of a single material and can have consistent material properties across the pressure roller 330, although variable material properties complementary to the non-uniform surface of the component are also contemplated in addition to the curved shape of the outer surface 336. In additional non-limiting examples, different or multiple materials, or materials having different material properties, are contemplated. The concave outer surface 336 can define a varying physical configuration of the pressure roller 330.

[0094] Figure 7H A cross-sectional view of another exemplary pressure roller 340 is shown, which is rotatable about an axis of rotation 346 and is similar in shape to Figure 7G shaped, while having two different materials arranged as an inner portion 342 and an outer portion 344. The material of the inner portion 342 can have different material properties than the outer portion 344, such as a different hardness, a different yield strength, a different elasticity, or a combination thereof. In a non-limiting example, one or both of the hardness or yield strength of the inner portion 342 can be greater than the hardness or yield strength of the outer portion 344, thereby allowing for greater deformation of the outer portion 344 that complements the non-uniform surface of the component. Although only two parts or materials are depicted, it should be understood that two or more parts or materials can be envisioned, each of which has different or similar material properties, shapes, sizes, thicknesses, geometries, or a combination thereof. The concave outer surface can define a varying physical configuration of the pressure roller 340, the outer portion 344, or both. The material differences in the inner portion 342 and the outer portion 344 can define a varying material configuration.

[0095] Figure 7I A cross-sectional view of another exemplary pressure roller 350 is shown having an inner portion 352 and an outer portion 354 rotatable about an axis of rotation 358 and shaped substantially similar to Figure 7G and Figure 7HOuter portion 354 is shaped to have a uniform thickness while having a concave outer surface 356. It is contemplated that the thickness of inner portion 352 may vary in a manner complementary to outer surface 356, thereby allowing for a uniform thickness of outer portion 354 and a concave shape of outer surface 356. In this manner, inner portion 352 can be shaped to complement the non-uniform surface while allowing for a more deformable layer between the laid fiber tow and pressure roller 350 as outer portion 354. This arrangement allows the inner portion 352 to complement the non-uniform surface, while outer portion 354 can deform to provide uniform pressure across the non-uniform surface. In this manner, outer portion 354 can provide uniform pressure across the non-uniform surface while inner portion 352 is sized and shaped to define outer surface 356. For example, such outer portion 354 can provide a complementary deviation of up to 5% between inner portion 352 and the non-uniform surface. Concave outer surface 356 can define a varying physical configuration of pressure roller 350, outer portion 354, inner portion 352, or a combination thereof. The material differences in the inner portion 352 and the outer portion 354 may define a varying material configuration.

[0096] Figure 7J A cross-sectional view of another exemplary pressure roller 360 is shown, comprising an inner portion 362, an outer portion 364, rotatable about an axis of rotation 372, extending between opposite ends 366, and having an outer surface 368. Inner portion 362 has a substantially trapezoidal shape, taken in cross-section, with a long side 370 arranged along axis of rotation 372, a short side 374 positioned at outer portion 364, and opposing edges 376 within outer portion 364 connecting long side 370 to short side 374. Pressure roller 360 can be cylindrical, having a constant thickness and diameter between opposite ends 366, wherein the thickness of outer portion 364 can vary in a manner complementary to the trapezoidal shape of inner portion 362 to maintain a constant thickness. The trapezoidal shape of inner portion 362 can be shaped to complement the uneven surface of a component, while the cylindrical shape of pressure roller 360 formed by outer portion 364 can apply uniform pressure across pressure roller 360 despite the uneven shape of trapezoidal inner portion 362. Although Figure 7J A trapezoidal cross-sectional shape is shown, but additional non-limiting cross-sectional shapes may include square, rectangular, triangular, hexagonal, lattice, circular, oval, elliptical, curved, linear, curvilinear, undefined, or combinations thereof. The shape of inner portion 362 or outer portion 364 may define varying physical configurations of pressure roller 360. The material differences between inner portion 362 and outer portion 364 may define varying material configurations.

[0097] Figure 7KA cross-sectional view of another exemplary pressure roller 380 is shown. Pressure roller 380 has an inner portion 382 and an outer portion 384 extending between opposite ends 386 and rotatable about an axis of rotation 389. The thickness of inner portion 382 can vary uniformly between opposite ends 386 in a direction defined along axis of rotation 389. The varying thickness of the inner portion defines a linear joint 388 between inner portion 382 and outer portion 384, where the distance of linear joint 388 from axis of rotation 389 varies between opposite ends 386. The thickness of inner portion 382 increases in a complementary manner to the decreasing thickness of outer portion 384, and vice versa, to achieve the varying thickness. This allows a cylindrical pressure roller 380 to simultaneously provide varying pressure between opposite ends 386, as determined by the material properties of inner portion 382 and outer portion 384, or the difference between their material properties. The shape of inner portion 382 or outer portion 384 can define the varying physical configuration of pressure roller 380. The material differences in the inner portion 382 and the outer portion 384 may define a varying material configuration.

[0098] Figure 7L A cross-sectional view of another exemplary pressure roller 390 is shown, which is rotatable about an axis of rotation 399 and has an outer surface 392. The outer surface 392 varies in a sinusoidal manner, having a concave portion 394 and a convex portion 396 that meet at an inflection point 398. It should be understood that the outer surface 392 of the pressure roller 390 can include any suitable shape that complements a particular non-uniform surface. The pressure roller 390 can be made of a single material and can have consistent material properties across the pressure roller 390, while variable material properties that complement the non-uniform surface of the component are also contemplated in addition to the shape of the outer surface 392. In one example, the pressure roller 390 can be defined as having a non-uniform radius (and diameter) that can complement the non-uniform surface. The shape of the outer surface 392 can define the varying physical configuration of the pressure roller 390.

[0099] Figure 7MA cross-sectional view of another exemplary pressure roller 400 is shown, comprising an inner portion 402 and an outer portion 404 extending between opposite ends 406 and rotatable about an axis of rotation 410. Inner portion 402 may be made of a material having consistent material properties across the entirety of inner portion 402. Outer portion 404 may comprise a material having variable material properties (such as variable hardness, variable yield strength, variable elasticity, or a combination thereof) along the length of pressure roller 400. Such variable material properties may vary in a consistent or constant manner along the direction extending between opposite ends 406. More specifically, the hardness or yield strength of outer portion 404 may increase as it extends from opposite ends 406 toward axial center 408, with the hardness or yield strength of outer portion 404 being greatest at axial center 408. In this manner, a gradient may be defined for the material properties of outer portion 404, increasing as it approaches axial center 408 and decreasing as it approaches opposite ends 406. In alternative non-limiting examples, it is contemplated that inner portion 402 may have a variable hardness or yield strength, or a material property gradient, or that both inner portion 402 and outer portion 404 may have variable hardness, variable yield strength, or variable material properties. In additional non-limiting examples, it is contemplated that the material properties may vary in a non-uniform manner, such as with localized regions having greater or lesser hardness or yield strength, or with discrete regions having locally varying hardness or a gradient thereof. Material property gradients, whether uniform or non-uniform, or with localized or discrete regions defined by variable material properties, can be tailored to the non-uniform shape of a component while allowing for a cylindrical roller. Alternatively, a non-cylindrical pressure roller with variable material properties is contemplated. While the material property gradient is shown extending between opposite ends 406, it is contemplated that the gradient may vary in any suitable direction, or may vary only within the inner portion of pressure roller 400. In this manner, variable material properties may allow pressure roller 400 to apply greater or lesser localized pressure that complements a specific non-uniform surface of a component, regardless of the shape of pressure roller 400. The gradient, different local material properties, or both can allow the pressure roller 400 to consistently apply pressure without requiring specific geometrical adjustments to the non-uniform surface of the part. The material differences in the inner portion 402 and the outer portion 404 can define a varying material configuration and gradient for the outer portion 404.

[0100] consider Figures 7A-7MIt will be appreciated that the pressure rollers described herein may include a variety of geometries, or geometries defined when the pressure roller is taken in cross-section. Such shapes may include curvatures, such as concave or convex, as well as non-curved or curvilinear shapes, such as linear or geometric shapes, with combinations thereof being contemplated. It will be appreciated that the particular shape or geometry of the pressure roller or its exterior surface may be complementary to or tailored to the shape of the non-uniform surface of the component. The particular material properties of the pressure roller or portions thereof may be used to locally reduce or increase the pressure provided by the pressure roller, thereby complementing local variations in the shape of the non-uniform surface. A smaller local hardness or yield strength results in a greater local deformation of the pressure roller, which may provide greater compliance to resist variations in shape along the component. Similarly, a greater hardness or yield strength results in a smaller deformation under pressure, which translates into increased local pressure applied by the pressure roller. Any suitable geometry or shape for the pressure roller, or any suitable shape for one or more layers or portions thereof forming a complete pressure roller, is contemplated. Additionally, it is contemplated that the pressure rollers from Figures 7A-7M One or more features may be added, removed, or interchanged with other features to define additional embodiments, and the embodiments are not limited to only those examples shown.

[0101] refer to Figure 8A , an exemplary pressure roller 450 includes a body 452 having an exterior surface 454 extending between opposite ends 456. An aperture 458, shown in phantom, through the body 452 is part of a set of apertures 460 that similarly extend through the body 452 between opposite ends 456. Each aperture in the set of apertures 460 can be cylindrical with a widened end 462 at each of the opposite ends 456. In alternative examples, widened end 462 is not contemplated, or alternative non-cylindrical features are contemplated, at any location along each of the set of apertures 460. The set of apertures 460 can define varying physical configurations of the pressure roller 450.

[0102] Figure 8B Shown is a view taken along section VIIIB-VIIIB. Figure 8AFIG4 is a cross-sectional view of a pressure roller 450. An exemplary cross 470, shown in dashed lines, is arranged at the center 472 of the pressure roller 450 and can be used to divide the pressure roller 450 into quadrants 474. It should be understood that the cross 470 is shown only for reference purposes within the visual quadrant 474 and is not a physical feature of the pressure roller 450. The set of apertures 460 is arranged in a first quadrant 474a, while the remaining quadrants 474 do not contain apertures. The set of apertures 460 can also be arranged into groups based on radial distance from the center 472, as radially outer groups 476 and radially inner groups 478, and each aperture in the set of apertures 460 in each of the radially outer groups 476 and radially inner groups 478 can have the same radial distance from the center 472 as another set of apertures 460 within the common radially outer group 476 or radially inner group 478.

[0103] In alternative non-limiting examples, the set of apertures 460 can be arranged in more than one quadrant 474, or can extend in a circular arrangement or pattern, such as with a common radius, across all quadrants 474. In another non-limiting example, each quadrant 474 can have a different arrangement of apertures 460, or two or more quadrants 474 can have the same arrangement, but different from another quadrant 474. While only radially inner and outer groups 476, 478 are shown, any number of groups, each having one or more apertures 460, and each group having a different radius defined from the center 472 for each aperture 460 within each group, is contemplated. It should be understood that any organization or arrangement of apertures 460 is contemplated, with any arrangement also being limited to one or more quadrants 474, or across all quadrants 474. Additionally, the delineation of the pressure roller 450 need not be in quadrants 474, but can be in any suitable fraction (such as one-half, one-third, one-sixth, or one-eighth), and non-uniform or discrete delineations are also contemplated that may be useful based on the non-uniform surface of the component.

[0104] Figure 8C A cross-section taken along section VIIIC-VIIIC and through aperture 458 is shown. Figure 8A It should be understood that for clarity of understanding, this section only shows the cross section of the pressure roller 450. Figure 8A A similar single orifice 458 and a set of orifices 460 ( Figure 8A ) are not shown in section VIIIC-VIIIC. The aperture 458 extends between the opposite ends 456. The aperture 458 includes a widened end 462 at each of the opposite ends 456, wherein the diameter of the aperture 458 increases near the opposite ends 456 to define the widened ends 462, and includes a constant diameter portion 482 extending between the widened ends 462. In additional non-limiting examples, it is contemplated that the aperture 458 or the set of apertures 460 ( Figure 8A ) can have any geometry, including but not limited to cylindrical, annular, oval, circular, elliptical, linear, geometric, stepped, curvilinear, or combinations thereof. In a further non-limiting example, the orifice 458 can have any cross-sectional geometry, including linear, curved, angled, curved, stepped, or combinations thereof.

[0105] refer to Figures 8A-8C It should be understood that the pressure applied by the pressure roller 450 can vary based on the arrangement and shape of the orifices 458 and the rotational position of the pressure roller 450. More specifically, as the pressure roller 450 rotates, different quadrants 474 contact the fiber band based on the relative positions of the pressure roller 450 with the fiber band 152 ( Figure 3 ) applies different pressures to the particular quadrant 474 that contacts the fiber bundle 152. It should be understood that when the first quadrant 474a or any quadrant 474 containing one or more orifices 460 contacts the fiber bundle 152 ( Figure 3 ), a decreasing pressure is applied when the pressure roller 450 is rotated. In this manner, a pressure profile can be defined by the rotation of the pressure roller 450, where the applied pressure varies with the rotational position of the pressure roller and the relative arrangement of the set of apertures 460 within the pressure roller 450. The size, shape, location, number, or orientation of the set of apertures 458 can further define the local pressure along the pressure profile, but in a direction between the opposing ends 456, perpendicular to the rotational direction of the pressure roller 450. In this manner, the pressure applied by the pressure roller 450 can be determined based on the organization of the multiple sets of apertures 460 within the pressure roller 450 and can complement the non-uniform shape of the component, such that the locally applied pressure is increased or decreased by the set of apertures 460. Specifically, because the component defines an increased local thickness due to a non-uniform surface, the arrangement of the set of apertures 460 can complement the non-uniform surface to define a decreased pressure or increased compliance that complements the non-uniform surface. Similarly, fewer or no apertures 460 can be used within the pressure roller 450 to define an increased pressure at areas of the non-uniform surface, thereby complementing the relatively decreased local thickness.

[0106] refer to Figure 9 , similar to Figure 8B , the cross-section of the alternative pressure roller 500 includes a set of apertures 502 in a non-balanced arrangement, and some apertures 502a in the set of apertures 502 have an elliptical cross-sectional shape, while other apertures 502b in the set of apertures 502 have a circular cross-sectional shape. Figure 8B, an exemplary cross 504 is disposed at the center of rotation (shown as center 506) of the pressure roller 500. The cross 504, shown in dashed lines, can be used to understand the division of the pressure roller 500 into a set of quadrants 508. The set of apertures 502 can define a varying physical configuration of the pressure roller 500.

[0107] Most of the set of orifices 502 are arranged in the first quadrant 508a, while one orifice 502c is arranged in the second quadrant 508b. Another orifice 502d is arranged at the junction 510 between the first quadrant 508a and the second quadrant 508b. In this manner, it should be understood that the arrangement of the set of orifices 502 need not be limited to one or more quadrants, or patterned within quadrants, but can be arranged in a non-patterned manner while still applying pressure tailored to the specific shape of the component.

[0108] Figure 10 An automated fiber placement assembly 150 (such as Figure 3 The automatic fiber placement assembly 150) forms a fiber having a non-uniform surface (such as Figure 3-4 components (such as Figure 3-5 Flowchart of method 550 of components 154, 208). Components 154, 208 may be substrates, such as Figure 3 At 552, method 550 may include measuring the non-uniform surface 166, such as with one or more sensors. For example, the non-uniform surface 166 may be measured with a coordinate measuring machine (CMM), such as a laser CMM, to determine the geometry of the non-uniform surface 166. Alternatively, the measurement of the non-uniform surface 166 may be derived from the geometry of the part 154, 208, or the geometry of the substrate 158 or mandrel on which the part 154, 208 is formed, without directly measuring the non-uniform surface 166 itself.

[0109] At 554, method 550 may include selecting a pressure roller, such as Figure 3-9 The pressure rollers 160, 200, 250, 268, 278, 288, 300, 310, 320, 330, 340, 350, 360, 380, 390, 400, 450, 500 are selected. The selected pressure rollers can have one or both of a varying physical configuration or a varying material configuration. The selected pressure rollers include a varying physical configuration or a varying material configuration that complements the non-uniform surface 166 so as to provide a balanced or uniform pressure across the non-uniform surface 166. In the event that multiple pressure rollers are required to cover the non-uniform surface 166, selecting the pressure rollers can include selecting multiple pressure rollers as needed to cover the non-uniform surface 166.

[0110] At 556, method 550 may include attaching a pressure roller to the automated fiber placement assembly 150 ( Figure 3 At 558, method 550 may include applying a pressure roller along the non-uniform surface 166 ( Figure 3 ) will be fiber bundles (such as Figure 3 and Figure 5 Fiber bands 152, 206) are applied to the substrate 158 ( Figure 3 The pressure roller may apply an even pressure across the fiber tow band 152, 206 complementary to the non-uniform surface 166. In one example, the pressure may vary by no more than 5% across the pressure roller along the non-uniform surface.

[0111] Where multiple pressure rollers are utilized, at 560, method 550 may further include changing the pressure roller from the first pressure roller to a second, different pressure roller that complements a different portion of the non-uniform surface 166 and attaching the second pressure roller to the automated fiber placement assembly 150. After changing the pressure roller, at 562, method 550 may return to applying another fiber tow at 558, and the process cycle may be repeated until formation of the part is complete.

[0112] In an alternative example, the method 550 may be specific to a particular component (such as Figure 2 In the event that method 550 is specific to a particular component, it may not be necessary to measure the non-uniform surface at 552 or select a specific pressure roller at 554, as the particular component may be pre-measured and have a specific pressure roller or set of pressure rollers configured for forming the particular component. Therefore, it should be understood that method 550 may include steps 556, 558, and 560, including attaching a pressure roller to the automated fiber placement assembly 150, applying the fiber tow tape 152, 206, and changing the pressure roller to apply additional fiber tow tapes 152, 206 to additional areas of the non-uniform surface 166. Furthermore, it is contemplated that one or more pressure rollers may be pre-attached to the automated fiber placement assembly 150, such that method 550 need not include attaching a pressure roller to the automated fiber placement assembly 150 at 556. Furthermore, method 550 may include, at 556, attaching the pressure roller includes attaching a set of multiple pressure rollers, without replacing a single pressure roller and selecting another attached pressure roller to apply the fiber tow tape 152, 206. In such an example, changing the pressure roller at 560 may include selecting a different pressure roller from a set of pressure rollers already attached to automated fiber placement assembly 150 .

[0113] The method 550 described herein provides for creating a component on a substrate having a non-uniform surface and improving the manufacture of such a component by applying uniform pressure across the non-uniform surface using a pressure roller shaped to complement the non-uniform surface. Applying a fiber band to the non-uniform surface using a pressure roller shaped to complement the non-uniform surface provides improved application of the fiber band, such as improved bonding and bonding, which results in greater consistency in the material forming the component. This greater consistency reduces manufacturing costs and the required finishing and post-production compared to typical application of material to form the component without considering the non-uniform surface of the component.

[0114] Benefits can be realized using rollers for an automated fiber placement assembly where the rollers are shaped to complement a component, particularly when the component includes a non-uniform surface. Pressure rollers that complement the non-uniform surface result in better uniformity of pressure applied to the fiber band placed on the component compared to pressure rollers that are not customized for the component. The better uniformity of pressure can provide better or improved bonding between the fiber band and the underlying component, as well as reduced squeeze-out of the adhesive. The pressure rollers can include various materials, material properties, shapes, orifices, geometries, or other arrangements to define a variable pressure across the pressure rollers that are shaped to complement the shape of the non-uniform surface of the component. The improved application of pressure improves overall manufacturing, reduces finishing and associated costs, as well as required maintenance, and can extend component life.

[0115] This written description uses examples to disclose the present disclosure, including the best mode, and also to enable any person skilled in the art to practice the present disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the present disclosure is defined by the claims and may include other examples that occur to those skilled in the art. If such other examples include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims, such other examples are intended to be within the scope of the claims.

[0116] Further aspects are provided by the subject matter of the following clauses:

[0117] An automated fiber placement assembly for forming a component by applying a fiber tow band, the automated fiber placement assembly comprising: a substrate comprising a non-uniform surface; a pressure roller for applying the fiber tow band to the substrate, the pressure roller comprising an outer surface defining an axis of rotation and extending between a first end and an opposite second end; wherein the outer surface of the pressure roller is complementary to the non-uniform surface of the substrate.

[0118] The automated fiber placement assembly of any preceding clause, wherein the exterior surface is non-cylindrical.

[0119] The automated fiber placement assembly of any preceding clause, wherein at least a portion of the exterior surface is concave or convex.

[0120] The automated fiber placement assembly of any preceding clause, wherein the pressure roller comprises a variable diameter extending between the first end and the second end to complement the exterior surface.

[0121] The automated fiber placement assembly of any preceding clause, wherein the variable diameter of the pressure roller is larger at the first and second ends than at a diameter of the pressure roller spaced from the first and second ends.

[0122] The automated fiber placement assembly of any preceding clause, wherein the larger diameters at the first and second ends reduce squeeze-out of an adhesive bonding the fiber tow band to the substrate.

[0123] The automated fiber placement assembly of any preceding clause, wherein the variable diameter varies uniformly between the first end and the second end.

[0124] The automated fiber placement assembly of any preceding clause, wherein the pressure roller further comprises an inner portion and an outer portion.

[0125] The automated fiber placement assembly of any preceding clause, wherein the exterior surface of the outer portion is non-cylindrical and the inner portion is cylindrical.

[0126] The automated fiber placement assembly of any preceding clause, wherein the roller has a non-uniform radius complementary to the non-uniform surface.

[0127] The automated fiber placement assembly of any preceding clause, wherein the exterior surface is one of circular, elliptical, spherical, curved, linear, curvilinear, concave, convex, stepped, sinusoidal, or combinations thereof.

[0128] The automated fiber placement assembly of any preceding clause, wherein the inner portion comprises a first material property defining a first stiffness or a first yield strength, and the outer portion comprises a second material property defining a second stiffness or a second yield strength, and wherein the first stiffness or the first yield strength of the first material property is greater than the second stiffness or the second yield strength of the second material property.

[0129] An automatic fiber placement assembly for forming a component by applying a fiber bundle, the automatic fiber placement assembly comprising: a substrate having a non-uniform surface; and a pressure roller extending between a first end and an opposite second end and defining a rotation axis, the pressure roller comprising an inner portion and an outer portion located outside the inner portion, wherein the outer portion defines a cylindrical outer surface; wherein at least one of the inner portion or the outer portion is complementary to the non-uniform surface to provide uniform pressure to the non-uniform surface across the pressure roller from the first end to the second end.

[0130] The automated fiber placement assembly of any preceding clause, wherein the equalization pressure varies by less than 5% across the exterior surface.

[0131] The automated fiber placement assembly of claim 10, wherein one of the inner portion or the outer portion has material properties complementary to the non-uniform surface.

[0132] An automated fiber placement assembly as claimed in any preceding clause, wherein the material properties include a variable hardness or variable yield strength across the pressure roller complementary to the non-uniform surface.

[0133] The automated fiber placement assembly of any preceding clause, wherein the material property comprises the variable hardness, and wherein the variable hardness defines a hardness gradient between the first end and the second end.

[0134] The automated fiber placement assembly of any preceding clause, wherein at least one of the first portion or the second portion comprises a variable diameter extending at least partially between the first end and the second end.

[0135] The automated fiber placement assembly of any preceding clause, wherein one of the inner portion or the outer portion comprises 10% of the thickness of the pressure roller and the other of the inner portion or the outer portion comprises 90% of the thickness of the pressure roller.

[0136] The automated fiber placement assembly of any preceding clause, wherein the pressure roller further comprises an intermediate portion between the inner portion and the outer portion, and wherein the intermediate portion comprises one of a material property complementary to the non-uniform surface or a variable diameter.

[0137] The automated fiber placement assembly of any preceding clause, wherein the inner portion is cylindrical and the outer portion includes a concave exterior surface.

[0138] The automated fiber placement assembly of any preceding clause, wherein the outer portion comprises a constant thickness defined extending between the first end and the second end.

[0139] The automated fiber placement assembly of any preceding clause, wherein the inner portion comprises a constant thickness defined extending between the first end and the second end.

[0140] The automated fiber placement assembly of any preceding clause, wherein the inner portion and the outer portion include a variable thickness defined extending between the first end and the second end.

[0141] The automated fiber placement assembly of any preceding clause, wherein one of the inner portion or the outer portion comprises a trapezoidal cross-sectional profile.

[0142] The automated fiber placement assembly of any preceding clause, wherein one of the inner portion or the outer portion comprises a cross-sectional profile that is one of square, circular, rectangular, trapezoidal, hexagonal, oval, elliptical, curved, linear, curvilinear, or combinations thereof.

[0143] A pressure roller for an automatic fiber placement assembly for forming a component on a substrate by applying a fiber bundle, wherein the substrate has a non-uniform surface, the pressure roller comprising: a body, the body including an outer surface, defining an axis of rotation, and extending between a first end and an opposite second end; and an orifice, the orifice extending at least partially through the body between the first end and the second end; wherein the orifice is arranged in the body to provide uniform pressure across the outer surface complementary to the non-uniform surface of the substrate.

[0144] A pressure roller as described in any preceding clause, wherein the body is cylindrical.

[0145] A pressure roller according to any preceding clause, wherein the aperture extends fully between the first end and the second end.

[0146] A pressure roller as in any preceding clause, wherein at least a portion of the aperture comprises a variable diameter defined in a direction extending between the first end and the second end.

[0147] A pressure roller as in any preceding clause, wherein at least a portion of the aperture comprises a constant diameter defined in the direction extending between the first end and the second end.

[0148] A pressure roller as claimed in any preceding clause, wherein the pressure roller is separable into a set of quadrants and the at least one aperture is arranged in one of the set of quadrants.

[0149] A pressure roller as in any preceding clause, wherein the apertures are part of a group of apertures, and wherein the group of apertures is arranged in a radially outer group and a radially inner group.

[0150] A pressure roller according to any preceding clause, further comprising a second aperture, and wherein the aperture and the second aperture are spaced at different radial distances from the axis of rotation.

[0151] A pressure roller as in any preceding clause, wherein the aperture and the second aperture have different shapes.

[0152] A pressure roller as claimed in any preceding clause, wherein the pressure roller is interchangeable.

[0153] A method of forming a component with an automated fiber placement assembly, the component comprising a substrate having a non-uniform surface, the method comprising: applying a fiber tow band to the substrate with a pressure roller; wherein the pressure roller is shaped to complement the non-uniform surface to apply an even pressure to the non-uniform surface across the pressure roller.

[0154] A method as in any preceding clause, further comprising measuring the non-uniform surface.

[0155] A method as in any preceding clause, further comprising selecting the pressure roller to be shaped complementary to the measured non-uniform surface.

[0156] The method of any preceding clause, further comprising attaching the selected pressure roller to the automated fiber placement assembly.

[0157] A method as in any preceding clause, further comprising changing the pressure roller from a first pressure roller to a second pressure roller.

[0158] The method of any preceding clause, wherein the first pressure roller is shaped complementary to a first portion of the non-uniform surface, and wherein the second pressure roller is shaped complementary to a second portion of the non-uniform surface different from the first portion.

[0159] A method as in any preceding clause, wherein the first portion of the non-uniform surface comprises a different surface than the second portion of the non-uniform surface.

[0160] A method according to any preceding clause, wherein the pressure roller is formed to be complementary to the non-uniform surface by one or more of the following: the shape of the pressure roller is defined to be complementary to the non-uniform surface, the diameter of the pressure roller is defined to be complementary to the non-uniform surface, or the material properties of the pressure roller are defined to be complementary to the non-uniform surface.

[0161] An automatic fiber placement assembly for forming a component by applying a fiber bundle, the automatic fiber placement assembly comprising: a substrate, the substrate comprising a non-uniform surface; and a pressure roller, the pressure roller extending axially between a first end and an opposite second end, and having a body, the body having an external surface for applying pressure to the fiber bundle against the non-uniform surface of the substrate when the pressure roller rotates about a rotational axis; wherein the pressure roller has a design structure, the design structure being a varying physical structure, a varying material property structure, or both, and wherein the design structure enables the pressure roller to apply the pressure uniformly to the fiber bundle in a manner complementary to the non-uniform surface.

[0162] The automated fiber placement assembly of any preceding clause, wherein the designed configuration is a varied physical configuration in which the exterior surface is shaped to complement the shape of the non-uniform surface.

[0163] The automated fiber placement assembly of any preceding clause, wherein at least a portion of the exterior surface is concave or convex.

[0164] The automated fiber placement assembly of any preceding clause, the pressure roller having a diameter at the first and second ends that is larger than a diameter of the pressure roller spaced from the first and second ends.

[0165] The automated fiber placement assembly of any preceding clause, wherein the body further comprises an inner portion and an outer portion, the outer portion being located exterior to the inner portion and defining the exterior surface.

[0166] The automated fiber placement assembly of any preceding clause, wherein the exterior surface is cylindrical.

[0167] The automated fiber placement assembly of any preceding clause, wherein the variable diameter varies uniformly between the first end and the second end.

[0168] An automated fiber placement assembly according to any preceding clause, wherein the design configuration is the varied physical configuration and the varied material property configuration, wherein the material properties of the body vary axially, radially, or axially and radially for the varied material property configuration.

[0169] An automated fiber placement assembly according to any preceding clause, wherein the body further comprises an inner portion and an outer portion, the outer portion being located outside the inner portion and defining the outer surface, wherein the inner portion has a first material property and the outer portion has a second material property different from the first material property.

[0170] The automated fiber placement assembly of any preceding clause, wherein the exterior surface is cylindrical.

[0171] The automated fiber placement assembly of any preceding clause, wherein the material property is one or more of hardness or yield strength.

[0172] An automated fiber placement assembly as defined in any preceding clause, wherein the material properties include the hardness defining a hardness gradient in a direction extending between the first end and the second end.

[0173] The automated fiber placement assembly of any preceding clause, wherein the pressure roller further comprises an inner portion and an outer portion, wherein at least one of the inner portion or the outer portion comprises the varying material configuration.

[0174] The automated fiber placement assembly of any preceding clause, wherein at least one of the inner portion or the outer portion is non-cylindrical.

[0175] The automated fiber placement assembly of any preceding clause, wherein the pressure roller further comprises an intermediate portion between the inner portion and the outer portion, and wherein at least one of the inner portion, the outer portion, or the intermediate portion comprises the varied material configuration.

[0176] The automated fiber placement assembly of any preceding clause, wherein the designed configuration is a varied physical configuration, wherein the pressure roller includes one or more apertures extending axially through the body at least partially between the first end and the second end.

[0177] The automated fiber placement assembly of any preceding clause, wherein the aperture extends fully between the first end and the second end.

[0178] The automated fiber placement assembly of any preceding clause, wherein at least a portion of the aperture comprises a variable diameter defined in a direction extending between the first end and the second end.

[0179] The automated fiber placement assembly of any preceding clause, wherein at least a portion of the aperture comprises a constant diameter defined in the direction extending between the first end and the second end.

[0180] An automated fiber placement assembly as claimed in any preceding clause, wherein the pressure roller is separable into a set of quadrants and the aperture is arranged in one of the set of quadrants.

[0181] An automated fiber placement assembly according to any preceding clause, wherein the design configuration is a varying material configuration in which material properties of the body vary axially, radially, or axially and radially in a manner complementary to the non-uniform surface.

[0182] An automated fiber placement assembly according to any preceding clause, wherein the body further comprises an inner portion and an outer portion, the outer portion being located outside the inner portion and defining the outer surface, wherein the inner portion has a first material property and the outer portion has a second material property different from the first material property.

[0183] The automated fiber placement assembly of any preceding clause, wherein the outer portion defines the exterior surface of the pressure roller, and wherein the exterior surface is cylindrical.

Claims

1. An automated fiber placement assembly for forming a component by applying a fiber tow tape, characterized in that The automated fiber placement assembly comprises: a substrate comprising a non-uniform surface; and a pressure roller extending axially between a first end and an opposite second end and having a body with an exterior surface for applying pressure to the fiber tow band against the non-uniform surface of the substrate as the pressure roller rotates about an axis of rotation; wherein the pressure roller has a design configuration that is a varying physical configuration, a varying material property configuration, or both, and wherein the design configuration enables the pressure roller to uniformly apply the pressure to the fiber tow band in a manner that is complementary to the non-uniform surface.

2. The automatic fiber placement assembly according to claim 1, characterized in that in, The designed configuration is a varied physical configuration in which the exterior surface is shaped to complement the shape of the non-uniform surface.

3. The automatic fiber placement assembly according to claim 2, characterized in that in, At least a portion of the exterior surface is concave or convex.

4. The automatic fiber placement assembly according to claim 2, characterized in that The diameter of the pressure roller at the first end and the second end is larger than the diameter of the pressure roller spaced apart from the first end and the second end.

5. The automatic fiber placement assembly according to claim 2, characterized in that in, The body further includes an inner portion and an outer portion, the outer portion being located outside the inner portion and defining the exterior surface.

6. The automatic fiber placement assembly according to claim 5, characterized in that in, At least one of the inner portion and the outer portion includes a variable diameter.

7. The automatic fiber placement assembly according to claim 6, characterized in that in, The variable diameter varies uniformly between the first end and the second end.

8. The automatic fiber placement assembly according to claim 2, characterized in that in, The design configuration is the varied physical configuration and the varied material property configuration, wherein for the varied material property configuration, the material properties of the body vary axially, radially, or axially and radially in a manner complementary to the non-uniform surface.

9. The automatic fiber placement assembly according to claim 8, characterized in that in, The material property is one or more of hardness or yield strength.

10. The automated fiber placement assembly of claim 9, wherein: in, The material properties include the hardness defining a hardness gradient in a direction extending between the first end and the second end.

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