An assembly to connect together first and second sheet members. The assembly includes a pressure device that applies pressure to the sheet members while the sheet members are in an overlapping arrangement and positioned on a support platform. A sensing system that includes one or more thin film pressure sensors detects the positions of the leading and trailing edges. A connection device connects the members together in an overlapping arrangement.

A system for manufacturing a rotor blade comprises a first tooling, positioned at a factory location and configured to assemble a first blade module, comprising a first-module skin and a first-module spar, each comprising a first thermoplastic polymer and a first reinforcement material. The system also comprises a second tooling, configured to assemble a second blade module, comprising a second-module skin and a second-module spar, each comprising a second thermoplastic polymer and a second reinforcement material. The system further comprises a first support, positioned at a field location and configured to receive the first blade module, and a second support, positioned at the field location and configured to receive the second blade module. The system also comprises a spar welding assembly, positioned at the field location and configured to join the first-module spar with the second-module spar.

A system for manufacturing a rotor blade comprises a first tooling, positioned at a factory location and configured to assemble a first blade module, comprising a first-module skin and a first-module spar, each comprising a first thermoplastic polymer and a first reinforcement material. The system also comprises a second tooling, configured to assemble a second blade module, comprising a second-module skin and a second-module spar, each comprising a second thermoplastic polymer and a second reinforcement material. The system further comprises a first support, positioned at a field location and configured to receive the first blade module, and a second support, positioned at the field location and configured to receive the second blade module. The system also comprises a spar welding assembly, positioned at the field location and configured to join the first-module spar with the second-module spar.

This invention relates to an assembly of regions (10a, 10b) of composite parts (2a, 2b) with thermoplastic matrix, including a plurality of riveting points along regions (10a, 10) of the parts that overlap through the superposition of two faces (12a, 12b) of these regions (10a, 10b) which are positioned facing one another, each region (10a, 10b) having another, opposite, face (11a, 11b) which remains visible with the part (2a, 2b). The riveting is performed using assembly ties (6) made of thermoplastic resin-based composite material compatible with the material of the parts (2a, 2b). These ties (6), which are made up at least in part of a stitch of backstitch produced using a filament of a material selected from a fiber coated with aramid resin, a carbon fiber and a glass fiber, are embedded in said regions (10a, 10b) and passing right through the same with an orientation comprised between 30 and 90 with respect to their faces (11a, 11b; 12a, 12b).

This invention relates to an assembly of regions (10a, 10b) of composite parts (2a, 2b) with thermoplastic matrix, including a plurality of riveting points along regions (10a, 10) of the parts that overlap through the superposition of two faces (12a, 12b) of these regions (10a, 10b) which are positioned facing one another, each region (10a, 10b) having another, opposite, face (11a, 11b) which remains visible with the part (2a, 2b). The riveting is performed using assembly ties (6) made of thermoplastic resin-based composite material compatible with the material of the parts (2a, 2b). These ties (6), which are made up at least in part of a stitch of backstitch produced using a filament of a material selected from a fiber coated with aramid resin, a carbon fiber and a glass fiber, are embedded in said regions (10a, 10b) and passing right through the same with an orientation comprised between 30 and 90 with respect to their faces (11a, 11b; 12a, 12b).

A method is provided in one example embodiment and may include assembling a first component and a second component together using, at least in part, a first adhesive film on the first component and a second adhesive film on the second component, wherein the first component and the second component are fully cured and the first adhesive film and the second adhesive film are at least partially uncured; and curing the first adhesive film and the second adhesive film to form a bonded structure.

A method is provided in one example embodiment and may include assembling a first component and a second component together using, at least in part, a first adhesive film on the first component and a second adhesive film on the second component, wherein the first component and the second component are fully cured and the first adhesive film and the second adhesive film are at least partially uncured; and curing the first adhesive film and the second adhesive film to form a bonded structure.

A preform-charge fixture creates a preform charge, which is a partially consolidated assemblage of preforms that can be efficiently transferred to a mold to create a finished part in a molding process, such as compression molding. In the illustrative embodiment, the preform-charge fixture includes peripheral cleats that are movable towards a central cleat to create a small gap therebetween that receives and constrains preforms in a desired position. The fixture also includes clamps, which are operable to engage an uppermost layer of preforms in the gap and apply a slight amount of downward pressure thereto to assure that the preforms are properly seated. The fixture also accommodates an energy source that heats the preforms so that, in conjunction with downforce applied by the clamps and/or gravity, the preforms can be tacked together, forming the preform charge.

A preform-charge fixture creates a preform charge, which is a partially consolidated assemblage of preforms that can be efficiently transferred to a mold to create a finished part in a molding process, such as compression molding. In the illustrative embodiment, the preform-charge fixture includes peripheral cleats that are movable towards a central cleat to create a small gap therebetween that receives and constrains preforms in a desired position. The fixture also includes clamps, which are operable to engage an uppermost layer of preforms in the gap and apply a slight amount of downward pressure thereto to assure that the preforms are properly seated. The fixture also accommodates an energy source that heats the preforms so that, in conjunction with downforce applied by the clamps and/or gravity, the preforms can be tacked together, forming the preform charge.

A method for fusing thermoplastic composite structures includes placing a substructure on an inner surface of a skin that is laid up on a shaping surface of a tool configured to maintain the shape of an outer mold line. The method further includes applying at least one insulation layer over a flange of the substructure and over exposed portions of the inner surface of the skin not in contact with the substructure, and applying a vacuum bag to at least partly enclose the skin and the substructure. The method yet still further includes applying heat to the shaping surface to fuse the substructure to the skin such that the skin exceeds its melting point and at least a portion of a raised segment of the substructure does not exceed its melting point.