Composite Material Damping Layer Adhesion
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Solution Overview
Problem
Fibre reinforced composite materials, particularly in aerospace applications, face challenges with high stiffness and low inherent damping qualities, leading to increased costs and weight from conventional noise and vibration damping methods, and existing viscoelastic damping materials are not compatible with automated lay-up processes due to deformation under high tensions.
Innovation Solution
A composite material and method incorporating a viscoelastic damping layer with a thermosetting resin bonding material to enhance adhesion between the damping and structural layers, reducing deformation and tension, and using a surface layer of thermosetting resin film to improve adhesion and compatibility with automated tape lay-up systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If viscoelastic damping material is applied to structural layers using conventional means (consolidating roller), then damping properties are achieved, but the material deforms significantly and causes unacceptable distortion of the structural layer
Solution Approach 1:
A bonding material layer is introduced as an intermediary between the viscoelastic damping material and the structural layer. This bonding material has higher adhesion to both layers, allowing the consolidating roller to apply sufficient force for bonding without causing excessive deformation of the viscoelastic material that would distort the structural layer.
Solution Approach 2:
The adhesion parameters of the bonding material are specifically optimized to be higher than both the structural layer and damping material. This parameter change in adhesion strength allows the system to withstand the forces applied during consolidation without causing distortion, while still achieving proper bonding.
2Reliability
If damping material is made highly deformable to achieve required damping properties at service temperature, then damping performance is improved, but the material is not compatible with high tensions used in ATL layup
Solution Approach 1:
The bonding material serves as a mediator that protects the highly deformable viscoelastic damping material from the high tensions applied during ATL layup. The bonding material layer absorbs and distributes the tensile forces, preventing them from acting directly on the damping material which remains highly deformable for optimal damping performance.
Solution Approach 2:
The bonding material provides beforehand cushioning by being applied to the structural layer prior to placing the damping material. This protective layer is in place before the ATL process begins, cushioning the damping material against the high tensions and preventing incompatibility issues during layup.
3Force
If bonding material with higher adhesion is used between damping material and structural layer, then force required for application is reduced and deformation is minimized, but material complexity increases
Solution Approach 1:
A bonding material layer is introduced as an intermediary between the viscoelastic damping material and the structural layer. This bonding material has higher adhesion to both layers, allowing the consolidating roller to apply sufficient force for bonding without causing excessive deformation of the viscoelastic material that would distort the structural layer.
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 effectively reduces the force required for damping material application, minimizes distortion of structural layers, and enhances noise attenuation while maintaining compatibility with automated lay-up processes, thereby reducing material costs and weight.
Implementation Method 1
the bonding material consist of a thermosetting resin film with areal weight of 1 to 50g/m2
Implementation Method 2
the damping material comprises a viscoelastic material
Implementation Method 3
damping material and a bonding material and a structural layer which comprises fibres and a structural resin material
Data Source
Figure 1~2
Figure 3~4
AI summary
A damped composite material comprising a damping material, a bonding material structural layer which comprises fibres and a structural resin material.