Composite Laminate Test System for Controlled Out-of-Plane Fiber Distortion
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Solution Overview
Problem
Current methods for creating controlled and repeatable out-of-plane fiber distortion in composite structures, such as composite laminates, on a sub-scale level are costly, labor-intensive, and time-consuming, especially when manufacturing cylindrical or curved parts, and fail to accurately replicate full-scale size part distortions.
Innovation Solution
A test system comprising a layup tool with fairing bars and fiber distortion initiators, which restricts ply expansion and creates pressure differential regions during a pressurized cure process with vacuum compaction, allowing for controlled and repeatable out-of-plane fiber distortion in composite laminates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If full scale size parts are fabricated multiple times to create representative out-of-plane fiber distortion, then the accuracy of representing full-scale distortions is improved, but the cost, labor intensity, and time consumption increase significantly
Solution Approach 1:
The patent creates sub-scale test parts that are simplified copies of full-scale parts, maintaining the essential geometric features and distortion characteristics while reducing size. This allows representative out-of-plane fiber distortion to be created on sub-scale levels, avoiding the need to fabricate multiple full-scale parts.
Solution Approach 2:
The patent employs disposable, low-cost sub-scale test parts made from readily available materials like foam blocks and cardboard. These inexpensive models can be rapidly fabricated and discarded after testing, eliminating the high cost and time associated with creating multiple full-scale parts.
2Productivity
If sub-scale level testing is performed to reduce costs and time, then the productivity is improved, but the ability to create repeatable representative out-of-plane fiber distortion deteriorates
Solution Approach 1:
The patent incorporates pre-formed distortion features directly into the sub-scale test part fabrication process. By intentionally creating out-of-plane fiber distortion during the molding or fabrication of sub-scale parts, the distortion is built-in from the beginning, ensuring repeatable results without requiring multiple full-scale fabrications.
Solution Approach 2:
The patent applies localized distortion features at specific locations on sub-scale test parts, rather than requiring uniform distortion throughout entire full-scale parts. This localized approach maintains the essential distortion characteristics needed for testing while working within the constraints of sub-scale modeling.
3Ease of manufacture
If traditional vacuum bagging and compaction are used during cure, then the debulking process is simplified, but out-of-plane fiber distortion occurs in top-most plies due to excessive compaction
Solution Approach 1:
The patent pre-positions spacers or support structures within the mold before laying up the composite plies. These pre-installed features control the thickness and prevent excessive compaction of top-most plies during the subsequent vacuum bagging and compaction process, eliminating out-of-plane fiber distortion while maintaining process simplicity.
Solution Approach 2:
The patent introduces intermediary elements such as spacers, bucking bars, or thickness control features between the mold surface and the composite laminate. These intermediaries distribute the compaction pressure uniformly and prevent localized excessive compression that causes fiber distortion in top plies.
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 enables the creation of controlled and repeatable out-of-plane fiber distortion at a sub-scale level, reducing costs and time while accurately representing full-scale distortions, facilitating testing and process improvements for composite manufacturing.
Implementation Method 1
a pressurized cure process with a vacuum compaction
Implementation Method 2
create a pressure differential region with a relative pressure change between a low pressure area and a high pressure area
Data Source
Figure 1
Figure 2A~2B
Figure 2C
AI summary
In one version there is provided a test system (10) including a layup tool (20) having a layup surface (26), and two fairing bars (40) attached to the layup surface (26). The test system (10) includes the composite laminate (14) having a plurality of stacked plies (64), and positioned between the two fairing bars (40). The test system (10) includes fiber distortion initiators (90) positioned at one or more locations under, and adjacent to, one or more plies of the plurality of stacked plies (64). The test system (10) includes two caul plates with a gap (122) in between, and positioned over the composite laminate (14). When the test system (10) undergoes a pressurized cure process (140) with a vacuum compaction (144), a restricted outward expansion (148) of the plurality of stacked plies (64) by the fairing bars (40), and a pressure differential region (114) formed by the one or more fiber distortion initiators (90) at the one or more locations (92), create the controlled and repeatable out-of-plane fiber distortion (12b) in the composite laminate (14).