3D Woven Composite Preform with Shape Memory Alloy Wires
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current composite materials with high strength-to-weight ratios, used in aerospace and automotive applications, suffer from poor impact resistance and inter-laminar properties, requiring improved materials for complex 3D structures.
Innovation Solution
A composite material is developed using a polymer matrix with a 3D-preform embedded within, where the 3D-preform consists of reinforcing fibers and shape memory alloy (SMA) wires, formed through methods like weaving, braiding, knitting, stitching, tufting, or z-pinning, to enhance structural integrity and resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional composite materials are made by layering pre-impregnated plies of fibres, then high strength to weight ratio is achieved, but impact resistance and inter-laminar properties deteriorate
Solution Approach 1:
The patent transitions from conventional 2D layered composite structures to 3D woven composite structures. The fibres are arranged in three-dimensional interlaced patterns that provide through-thickness reinforcement, enabling the material to resist impact loads and delamination forces that act perpendicular to the laminate surface, thereby resolving the contradiction between maintaining high strength-to-weight ratio and improving impact resistance.
Solution Approach 2:
The patent employs a hybrid composite structure combining organic fibres (such as carbon, glass, or aramid) with inorganic reinforcement elements (such as metal wires or ceramic fibres) within the 3D woven architecture. This composite-of-composites approach enhances both the strength-to-weight ratio and the toughness/impact resistance by leveraging the complementary properties of different material systems.
2Strength
If conventional composite materials are made by layering pre-impregnated plies of fibres, then high strength to weight ratio is achieved, but inter-laminar properties and resistance to delamination deteriorate
Solution Approach 1:
The 3D woven architecture introduces through-thickness fibre pathways that physically interlock multiple layers, creating inherent resistance to delamination. The interlaced structure ensures that fibres continue across layer boundaries, maintaining structural integrity and preventing separation under inter-laminar stresses, thereby resolving the contradiction between maintaining high strength-to-weight ratio and improving inter-laminar stability.
3Ease of manufacture
If thin sheets are used to make composite materials, then manufacturing is simplified, but the ability to create complex 3D structures deteriorates
Solution Approach 1:
The 3D woven preform technology enables direct fabrication of complex three-dimensional structures with varying fibre orientations and densities throughout the volume. The weaving process can accommodate curved surfaces, hollow sections, and geometrically complex shapes in a single manufacturing step, eliminating the need to assemble multiple thin sheets and providing superior adaptability while maintaining manufacturing efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides improved impact performance, inter-laminar strength, and the ability to create complex 3D structures in a single piece, reducing resin infusion time and minimizing fiber crimping, thus addressing the limitations of existing composite materials.
Implementation Method 1
3D-preforms including reinforcing fibres and shape memory alloy (SMA) wires
Data Source
AI summary
Some embodiments are directed to a three-dimensional (3D) preform including reinforcing fibres and shape memory alloys (SMA) wires and a composite material including a polymer matrix with a 3D-preform embedded therein, wherein the 3D-preform includes reinforcing fibres and shape memory alloy (SMA) wires.