Spiral winding systems for manufacturing composite fan bypass ducts and other like components

Abstract

Spiral winding systems for manufacturing a contoured composite component including a creel for holding a triaxial material having a width and keeping the material straight to provide uniform overlaps during winding; a tensioning device for receiving the width of material from the creel and providing tension to the material during winding; a contoured curing mandrel for receiving the material from the tensioning device to produce a spirally wound contoured composite component preform; and a traversing screw for spirally winding the material from the tensioning device about the contoured curing mandrel such that each subsequent layer of the material overlaps by about half of the width where the contoured composite component comprises a cylindrical shape and non-crimp or braided material; a conical shape and non-crimp or braided material void of hoop fibers; or a combination thereof.

1 . A spiral winding system for manufacturing a contoured composite component comprising:
 a creel for holding a triaxial material having a width and keeping the material straight to provide uniform overlaps during winding;   a tensioning device for receiving the width of material from the creel and providing tension to the material during winding;   a contoured curing mandrel for receiving the material from the tensioning device to produce a spirally wound contoured composite component preform; and   a traversing screw for spirally winding the material from the tensioning device about the contoured curing mandrel such that each subsequent layer of the material overlaps by about half of the width   
     wherein the contoured composite component comprises a cylindrical shape and non-crimp or braided material; a conical shape and non-crimp or braided material void of hoop fibers; or a combination thereof. 
   
   
       2 . The system of  claim 1  wherein the triaxial material comprises fibers selected from the group consisting of carbon fiber, glass fiber, ceramic fiber, graphite fiber, aramid fiber, and combinations thereof. 
   
   
       3 . The system of  claim 2  wherein the material width is from about 4 inches (about 10.2 cm) to about 8 inches (about 20.3 cm). 
   
   
       4 . The system of  claim 3  wherein the tensioning device is a magnetic break or a friction break. 
   
   
       5 . The system  claim 4  wherein the curing mandrel comprises a length and the traversing screw is positioned to lie along the length of the contoured curing mandrel. 
   
   
       6 . The system of  claim 5  wherein the tensioning device moves laterally along the traversing screw to produce a spirally wound contoured composite component preform about the contoured curing mandrel. 
   
   
       7 . The system of  claim 6  wherein each subsequent layer of the material overlaps by about 2 inches (about 5.1 cm). 
   
   
       8 . The system of  claim 7  wherein the contoured composite component preform is treated with a resin and subsequently cured to produce the contoured composite component. 
   
   
       9 . The system of  claim 8  wherein the contoured composite component comprises a fan bypass duct or a containment casing. 
   
   
       10 . A spiral winding system for manufacturing a contoured composite component comprising:
 a creel for holding a triaxial material having a width and keeping the material straight to provide uniform overlaps during winding;   a tensioning device for receiving the width of material from the creel and providing tension to the material during winding;   a cylindrically shaped curing mandrel for receiving the material from the tensioning device to produce a spirally wound contoured composite component preform; and   a traversing screw for spirally winding the material from the tensioning device about the cylindrically shaped curing mandrel such that each subsequent layer of the material overlaps by about half of the width   
     wherein the triaxial material comprises fibers selected from the group consisting of carbon fiber, glass fiber, ceramic fiber, graphite fiber, aramid fiber, and combinations thereof. 
   
   
       11 . The system of  claim 10  wherein the material width is from about 4 inches (about 10.2 cm) to about 8 inches (about 20.3 cm) and wherein each subsequent layer of the material overlaps by about 2 inches (about 5.1 cm). 
   
   
       12 . The system  claim 11  wherein the cylindrically shaped curing mandrel comprises a length and the traversing screw is positioned to lie along the length of the cylindrically shaped curing mandrel. 
   
   
       13 . The system of  claim 12  wherein the tensioning device moves laterally along the traversing screw to produce a spirally wound contoured composite component preform about the cylindrically shaped curing mandrel. 
   
   
       14 . The system of  claim 13  wherein the contoured composite component comprises a fan bypass duct or a containment casing. 
   
   
       15 . A spiral winding system for manufacturing a contoured composite component comprising:
 a creel for holding a triaxial material void of hoop fibers having a width and keeping the material straight to provide uniform overlaps during winding;   a tensioning device for receiving the width of material from the creel and providing tension to the material during winding;   a conically shaped curing mandrel for receiving the material from the tensioning device to produce a spirally wound contoured composite component preform; and   a traversing screw for spirally winding the material from the tensioning device about the conically shaped curing mandrel such that each subsequent layer of the material overlaps by about half of the width.   
   
   
       16 . The system of  claim 15  wherein the triaxial material comprises fibers selected from the group consisting of carbon fiber, glass fiber, ceramic fiber, graphite fiber, aramid fiber, and combinations thereof. 
   
   
       17 . The system of  claim 16  wherein the material width is from about 4 inches (about 10.2 cm) to about 8 inches (about 20.3 cm) and wherein each subsequent layer of the material overlaps by about 2 inches (about 5.1 cm). 
   
   
       18 . The system  claim 17  wherein the conically shaped curing mandrel comprises a length and the traversing screw is positioned to lie along the length of the conically shaped curing mandrel. 
   
   
       19 . The system of  claim 18  wherein the tensioning device moves laterally along the traversing screw to produce a spirally wound contoured composite component preform about the conically shaped curing mandrel. 
   
   
       20 . The system of  claim 19  wherein the contoured composite component comprises a fan bypass duct or a containment casing.