Composite Laminate Filament Network for Notch Toughness
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Solution Overview
Problem
Current methods to improve the notch toughness of composite laminates often compromise the resistance to undesired inconsistencies, such as cracks and delamination, and limit the infusion of resin between fibers.
Innovation Solution
A method and apparatus that incorporate a filament network with discontinuous filaments and a binding material to fill spaces between and around fiber bundles, enhancing notch toughness and resistance to inconsistencies while allowing easy resin infusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If discontinuous fibers are laid up between composite layers to improve notch toughness, then the notch toughness is improved, but the resistance to formation of undesired inconsistencies is reduced
Solution Approach 1:
The patent applies composite materials by combining continuous fiber bundles with discontinuous filament networks to create a hybrid reinforcement structure. The continuous fibers provide structural integrity and resistance to inconsistencies, while the discontinuous filaments improve notch toughness by filling voids and creating a more uniform stress distribution throughout the composite laminate.
Solution Approach 2:
The patent implements local quality by placing discontinuous filaments specifically in the spaces between continuous fiber bundles rather than uniformly throughout. This localized placement targets the void regions that contribute to poor notch toughness without compromising the overall structural integrity provided by the continuous fibers, thus improving notch toughness while maintaining resistance to undesired inconsistencies.
2Strength
If Z-pinning, stitching, or tufting is used to improve notch toughness, then the notch toughness is improved, but the resistance to formation of undesired inconsistencies is reduced and fiber damage may occur
Solution Approach 1:
The patent utilizes porous materials by employing a discontinuous filament network that fills the void spaces between continuous fiber bundles. This filament network acts as a porous filler that improves notch toughness by providing additional load paths and energy absorption mechanisms without the need for invasive Z-pins or stitching that could damage fibers or create stress concentration points.
3Strength
If methods are used to improve notch toughness, then the notch toughness is improved, but resin infusion efficiency is reduced
Solution Approach 1:
The patent applies preliminary action by pre-positioning the discontinuous filament network within the mold cavity before resin infusion. The filaments are laid up to fill void spaces between fiber bundles in advance, creating a prepared reinforcement structure that guides resin flow and ensures complete saturation without requiring additional processing steps or compromising infusion efficiency.
Data Source
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AI summary
A method and apparatus for forming a composite structure. The apparatus comprises a fiber layer. The fiber layer comprises a plurality of fiber bundles (238) and a number of filler portions (236). The plurality of fiber bundles has a number of spaces between the plurality of fiber bundles. A number of filler is comprised of discontinuous filaments that substantially fill the number of spaces between the plurality of fiber bundles.