Composite Sheet Manufacturing Using Orthogonal Fiber Orientation
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Solution Overview
Problem
Existing methods for constructing composite materials require excessive matrix material, increasing weight and cost, and prior art methods discourage assembling multiple adjacent layers of unidirectional fibers without pre-impregnation due to concerns about fiber layer disorder and structural integrity.
Innovation Solution
A method involving the orthogonal orientation of unidirectional strand passes around a strand frame, followed by the use of impregnation screens to introduce the matrix component after the composite sheet is assembled, reducing the amount of matrix material needed while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual fiber layers are pre-impregnated with matrix material before assembling, then structural integrity and coplanarity of fibers are maintained, but the amount of matrix material used increases significantly
Solution Approach 1:
The patent applies preliminary action by pre-assembling the fiber layers into prepreg configurations before impregnation. The fibers are arranged and bonded in a controlled manner prior to matrix material application, ensuring structural integrity is established before the matrix is added. This allows the matrix to be applied only where needed to complete the composite structure, rather than being applied extensively to pre-impregnate each fiber layer separately.
Solution Approach 2:
The patent merges the fiber assembly process with the matrix application process. Instead of separately pre-impregnating each fiber layer and then assembling them, the method combines these operations by assembling the fibers first and then applying the matrix material in a single integrated process step, reducing overall matrix consumption while maintaining structural integrity.
2Quantity of substance
If multiple adjacent layers of unidirectional fibers are assembled without pre-impregnation, then matrix material usage is reduced, but fiber layer distribution becomes disordered and sink marks occur
Solution Approach 1:
The patent performs preliminary assembly of the fiber layers into a structured configuration before matrix application. By pre-assembling the layers in a controlled manner with proper orientation and spacing, the foundation for uniform matrix distribution is created. This preliminary structuring prevents sink marks and maintains fiber layer uniformity when the matrix is subsequently applied.
Solution Approach 2:
The patent introduces an intermediary step of controlled matrix application that mediates between the fiber assembly and the final composite structure. The matrix material is applied in a controlled manner that distributes uniformly across the assembled fiber layers, preventing direct contact issues and sink marks while maintaining the desired fiber distribution.
3Reliability
If individual strands are impregnated with matrix material before forming prepreg layers, then coplanarity and structural integrity of strands are maintained, but the assembled weight and cost increase
Solution Approach 1:
The patent applies preliminary action by pre-assembling the fiber strands into a structured configuration before matrix material application. The strands are arranged and temporarily secured in their final positions prior to impregnation, ensuring coplanarity is established without requiring excessive matrix material. This allows the matrix to be applied only as a finishing step rather than being used extensively for initial strand stabilization.
Solution Approach 2:
The patent changes the sequence of operations by reversing the conventional approach. Instead of impregnating strands before assembly, the method assembles the strands first and then applies the matrix material. This parameter change in the process sequence allows for reduced matrix material usage while maintaining strand coplanarity through the preliminary mechanical arrangement and temporary bonding of the fiber structure.
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 minimizes matrix usage, enhances the strength-to-weight ratio, and allows for the use of higher VOC content matrix components, improving the performance and cost-effectiveness of composite materials, particularly in ballistic applications.
Implementation Method 1
a matrix component is then introduced to the assembled sheet
Data Source
AI summary
The invention relates to a method of making a composite sheet. A plurality of layers is first assembled, each layer being comprised of an untreated, unidirectional array of strands. The assembled layers are then placed adjacent one another to form an assembled sheet, with adjacent layers being in a non-parallel orientation, and without any of the layers having been treated with a matrix or binding component. The assembled sheet is then impregnated with a matrix component, which comprises a binding component and may also comprise a radiation-absorbing component.