Composite Component with Kinked Strips for Delamination Resistance
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Solution Overview
Problem
Conventional composite components with sandwich structures face limitations in mechanical performance due to delamination issues and low pressure and shear stability, particularly with honeycomb and foam cores, which are often adhesive-bonded to cover layers, and textile spacer structures that are susceptible to kinking.
Innovation Solution
A composite component with a form-fitting, fiber-based connection using kinked strips between two cover layers, where the strips are woven into the fabric layers, providing a core layer with high flexural rigidity and adjustable orientation for isotropic or anisotropic properties, and a method for producing this component using a weaving device to integrate the kinked bands into the fabric layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If honeycomb and folded cores are used with adhesive bonding to cover layers, then core stability is improved, but delamination occurs and mechanical performance is limited
Solution Approach 1:
The invention extracts the adhesive bonding method from the connection system and replaces it with a mechanical interlocking mechanism. The core layer is formed from three-dimensional tapes that are directly integrated into the cover layers through weaving, eliminating the need for adhesive and preventing delamination while maintaining core stability.
Solution Approach 2:
The invention merges the core layer and cover layers into a single integrated structure through the weaving process. The three-dimensional tapes of the core layer are woven together with the cover layers, creating a unified composite structure that eliminates the interface between core and cover layers, thereby preventing delamination.
2Strength
If adhesive bonding is used to connect core and cover layers, then connection strength is improved, but manufacturing complexity and quality control difficulty increase
Solution Approach 1:
The invention replaces the adhesive bonding mechanism with a mechanical interlocking system. The three-dimensional tapes are woven into the cover layers through a weaving device, creating physical interlocking that provides connection strength without requiring adhesive application, thereby simplifying the manufacturing process and improving quality control.
3Stability of the object's composition
If spacer threads are used in textile structures, then cover layer connection is improved, but pressure stability decreases due to kinking
Solution Approach 1:
The invention changes the geometric parameters of the core layer structure by using three-dimensional tapes with specific cross-sectional shapes (flat, triangular, trapezoidal) that maintain their shape and provide pressure stability. The weaving process integrates these tapes into the cover layers, creating a structure that resists kinking and maintains mechanical properties under load.
4Device complexity
If wire mesh is used as core layer, then structural simplicity is improved, but flexural rigidity and shear stability decrease
Solution Approach 1:
The invention uses composite material structures where three-dimensional tapes made from fibrous materials are integrated with cover layers through weaving. This composite construction provides both structural simplicity and high flexural rigidity, as the tapes maintain their geometric shape and the weaving process creates a rigid integrated structure that resists bending and shear forces.
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
According to various embodiments, a composite component (100) can have the following: a first cover layer comprising a first fabric (102g); a second cover layer (112) comprising a second fabric (112g), wherein the first fabric (102g) and the second fabric (112g) define a warp direction (101k) and a weft direction (101s); several strips (124) arranged between the two cover layers (102, 112), each of the several strips (124) being arranged along the warp direction (101k) and connected to the respective fabric (102g, 112g) of the first cover layer (102) and the second cover layer (112), each of the several strips (124) being folded multiple times and the fold edges (124k) extending obliquely to the warp direction (101k) and/or obliquely to the weft direction (101s).