Resin impregnated multi orientation composite material

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 divisional of U.S. application Ser. No. 10 / 175,964 filed Jun. 20,2002, entitled RESIN IMPREGNATED MULTI-ORIENTATION COMPOSITE MATERIAL which 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 m...

AI Technical Summary

Benefits of technology

"The present invention relates to a composite material that has multiple resin-impregnated filament bands. The composite material is made up of layers of filament bands that are wound onto a sheet of composite material. The layers of filament bands are impregnated with a solid or semi-solid resin that is a low viscosity liquid at ambient temperatures. The resin may be heated to a viscous state to impregnate the filament bands. The composite material has the advantage of being formable and easily manufactured. It also requires less manual labor to assemble and has improved handling characteristics. The invention aims to provide an inexpensive composite material that can be rapidly manufactured and used in various applications."

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.

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