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

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

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