Multi orientation composite material impregnated with non-liquid resin

Abstract

A composite material made of multiple filament bands is disclosed. The filament bands are wound to create a composite material. The filament bands may be impregnated with a solid or semi-solid resin. The filament bands are wound in multiple orientations to form a sheet of composite material. Additionally, the composite material may be made to have a varying number of layer and fiber orientations throughout the sheet of composite material. In another embodiment, a composite component requiring multiple layers and fiber orientations may be substantially manufactured during a filament winding process.

Description

[0001] This application is a continuation-in-part of co-pending patent application Ser. No. 09 / 443,227 filed Nov. 18, 1999 and entitled PRESSURE-CYCLED, PACKET-TRANSFERRED INFUSION OF RESIN-STITCHED PREFORMS and is incorporated herein by reference.[0002] 1. Field of the Invention[0003] The present invention relates to composite materials. More particularly, the present invention relates to a composite material having multiple resin impregnated filament bands.[0004] 2. Technical Background[0005] Filament winding and composite materials have been a desirable substitute for metals and other materials in manufacturing applications. Composite materials have the advantages of being high strength, lightweight, and easily formable. Composite materials are comprised of a fiber, typically carbon, that is impregnated with a curable resin. Composite materials are often drapable like a fabric, allowing the uncured composite material to be formed into various shapes. Once the composite material i...

AI Technical Summary

Benefits of technology

[0018] Multiple layers and orientations of the filament bands may exist in a composite material according to load requirements for a selected part or component, where the composite material is a pre-form. A pre-form is a part made of composite material where the features of the part are created during the winding process, thus eliminating laying up multiple layers of composite sheets. Different features in different locations of the parts may be created by varying the orientation and number of layers of the filament bands.

Problems solved by technology

Despite the many positive characteristics of composite materials, the overall cost of composite materials often makes their use impractical.

Various factors affect the cost of composite materials.

Often manufacturing a composite material and forming the composite material into the desired shape requires multiple machines and extensive hand labor.

Weaving large sheets of carbon fibers can require expensive machines and can be a time intensive process.

These additional steps can involve impregnating entire sheets of composite materials with resins, creating difficulties in uniformly applying a resin to a large sheet of composite material.

Additionally, these impregnating processes are often performed by different manufacturers at different locations, adding manufacturing and shipping costs at each step.

As a result, the overall price of the composite materials for the end user can be high.

The process of laying up and orienting individual sheets of composite material can add further expense and time to the already expensive and time-consuming manufacturing process.

Yet another problem with current composite materials is the handling of the resin impregnated composite material.

While low viscosity resin allows for better permeation of the composite material, a low viscosity of liquid resin creates undesirable handling characteristics.

Furthermore, the low viscosity resin does not effectively maintain the lay up of the composite sheet.

Thus, the fibers may separate and fall apart when being handled or transported.

Also, a low viscosity resin may flow away from certain sections of the composite material while being cured, leaving some areas with insufficient resin.

Images