Composite Bonding with Multi-Directional Protruding Members
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Solution Overview
Problem
Existing methods for bonding composite materials, such as those used in aircraft components, face challenges in suppressing delamination between layers, particularly when pins inserted to enhance strength can fall out.
Innovation Solution
A method involving the placement of protruding members with protrusions in different directions on the surface of composite materials, which are then introduced into the layers to bond them together, using a thermoplastic resin that is heated and cooled to cure and secure the bond.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If pins are inserted through prepreg layers to increase strength along lamination direction, then delamination is suppressed, but the pins may fall out from the composite material layers
Solution Approach 1:
The invention transitions from simple pin insertion to a three-dimensional protruding structure with multiple protrusions extending in different directions. This dimensional complexity prevents the fastening element from falling out by creating mechanical interlocking in multiple directions rather than a single linear path
Solution Approach 2:
The protruding member is formed as a composite structure combining resin and reinforcing fibers, creating a material that is both strong and capable of bonding with the composite material layers. This composite construction enhances both the strength along lamination direction and the reliability of retention
2Reliability
If multiple protrusions are added to protruding members to prevent falling out, then retention is improved, but the complexity of the protruding member structure increases
Solution Approach 1:
The invention merges multiple protrusions into a single integrated protruding member formed from one piece of composite material. This combining approach achieves the retention benefits of multiple protrusions while avoiding the complexity of assembling separate components, as the entire structure is formed as a unified element
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
This approach effectively suppresses delamination by physically fastening the composite materials with protruding members, enhancing adhesion and maintaining the bond strength.
Implementation Method 1
the introduction step includes heating and melting the resin with which the first composite material and the second composite material are each impregnated to introduce the protruding members into the interiors of the first composite material and the second composite material
Implementation Method 2
the bonding step includes cooling the resin with which the first composite material and the second composite material are each impregnated to cure the resin
Data Source
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AI summary
A method for bonding a composite material (10), in which resin is impregnated in a reinforcing fiber-containing first composite material (12) and a second composite material (14) to bond the same, comprises: a protruding member placement step for disposing multiple protruding members (16), which have multiple protrusions that protrude in mutually different directions, on the surface (12A) of the first composite material (12); a second composite material placement step for disposing the second composite material (14) on a site of the surface (12A) of the first composite material (12) where the protruding members (16) have been disposed; an introduction step for introducing the protruding members (16) into the first composite material (12) and into the second composite material (14) while bringing the first composite material (12) into contact with the second composite material (14); and a bonding step for bonding the first composite material (12) to the second composite material (14) with the protruding members (16) introduced therein by curing the resin impregnated in the first composite material (12) and the second composite material (14).