Abstract A simplified layup mandrel with no contour or twist is utilized by the method of this invention for forming the spar member of an aerodynamic rotor blade. A fiber glass tape is wrapped (laid-up) to a desired thickness onto the simplified mandrel to form a strap as the initial step. Because of the simple design of the mandrel, the laid-up strap when removed from the mandrel has a basic U-shaped configuration with straight extending legs having substantially parallel vertically oriented faces. This strap is then placed on a forming mandrel and contoured to the desired shape either by hand or by coining in a forming die. The contoured strap is then utilized in any of the various subassemblies or final assembly of the composite aerodynamic rotor blade.
A method of forming a spar layup for an aerodynamic rotor blade including the steps of: a. laying-up a continuous tape strand onto an elongated mandrel to form a generally U-shaped strap of a given thickness, with leg portions having parallel generally vertically disposed faces; b. removing the strap from the mandrel; c. contouring the leg portions of the strap to a desired airfoil portion; d. repeating steps a-c to form a further generally U-shaped contoured strap; and e. mounting both straps onto an assembly mandrel to form complementary portions of the spar layup.
Claim 2
Independent Claim
94 words
A method of forming a spar layup for an aerodynamic rotor blade including the steps of: a. laying-up a continuous tape strand onto an elongated mandrel to form a generally U-shaped strap of a given thickness, with leg portions having parallel generally vertically disposed faces; b. removing the strap from the mandrel; c. contouring the leg portions of the strap to a desired airfoil portion; d. repeating steps a-c to form a further generally U-shaped contoured strap; and e. mounting both straps onto an assembly mandrel to form complementary portions of the spar layup.
Claim 3
Dependent Claim
23 words
The method as defined in claim 1, wherein each strap is contoured to the desired airfoil shape by hand on a forming mandrel.
Claim 4
Dependent Claim
23 words
The method as defined in claim 1, wherein each strap is contoured to the desired airfoil shape by coining in a forming die.
Claim 5
Dependent Claim
52 words
The method as defined in claim 1, further including the steps of: f. surrounding the mandrel on which the strap is formed with a correspondingly U-shaped removable strip against which the continuous tape strand is layed-up; g. removing the removable strip from the mandrel and formed strap prior to removing the strap.