Composite Sub-Laminate Module for Thinner Laminates
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Solution Overview
Problem
Conventional composite laminate structures face inefficiencies due to their discrete nature and self-imposed constraints, leading to thick sub-laminates, delamination issues, and complexity in manufacturing, which limits their application in thin structures and requires excessive plies for desired material characteristics.
Innovation Solution
The introduction of a sub-laminate module with a continuous field of ply angles, allowing for thinner laminates with natural symmetry, enabling single-ply drops and simplifying blending and optimization, while maintaining mid-plane symmetry and reducing the minimum gauge requirement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional composite laminate structures use discrete sub-laminates with mid-plane symmetry, then structural strength is improved, but laminate thickness increases significantly
Solution Approach 1:
The laminate is divided into sub-laminates with continuous fiber fields instead of discrete ply orientations. This segmentation allows each sub-laminate to be optimized independently while maintaining overall structural integrity, reducing the need for excessive thickness to achieve strength requirements.
Solution Approach 2:
The invention changes the parameter of fiber orientation from discrete fixed angles (0, 45, 90 degrees) to continuous variable angles throughout the sub-laminate. This parameter change enables optimization of strength characteristics with fewer plies, thereby reducing laminate thickness while maintaining required strength.
2Ease of manufacture
If conventional composite laminate structures use thick sub-laminates, then manufacturing complexity is reduced, but delamination and failure modes increase
Solution Approach 1:
The invention introduces dynamic variation in fiber orientation angles within continuous fields throughout the sub-laminate structure. This dynamic approach allows optimization of stress distribution and failure mode prevention without requiring uniformly thick sub-laminates, improving reliability while maintaining manufacturing feasibility.
Solution Approach 2:
The invention uses composite sub-laminates with continuously varying fiber orientations rather than discrete plies. This composite approach creates more uniform stress distribution and reduces delamination-prone interfaces, improving reliability without significantly increasing manufacturing complexity.
3Adaptability or versatility
If conventional composite laminate structures use discrete ply orientations, then material characteristics are simplified, but optimization capability is limited
Solution Approach 1:
The invention employs dynamic, continuous variation of fiber orientation angles within sub-laminates rather than fixed discrete orientations. This enables adaptive optimization of material characteristics for specific loading conditions while maintaining manageable complexity through the sub-laminate modular structure.
Solution Approach 2:
The invention changes fiber orientation from discrete fixed parameters to continuous variable parameters within sub-laminates. This parameter change dramatically increases optimization capability, allowing tailoring of material characteristics to match specific structural requirements without excessive complexity.
4Stability of the object's composition
If conventional composite laminate structures require mid-plane symmetry, then warping is prevented, but minimum gauge requirements increase
Solution Approach 1:
The invention segments the laminate into multiple sub-laminates, each with continuous fiber fields. This segmentation allows warping resistance to be achieved through the collective behavior of multiple thinner sub-laminates rather than requiring a single thick symmetric laminate, reducing minimum gauge requirements.
Solution Approach 2:
The invention uses composite sub-laminates with continuous fiber orientation fields that can inherently resist warping through optimized fiber distribution. This composite approach achieves stability with thinner overall laminates compared to conventional discrete ply structures requiring mid-plane symmetry.
Data Source
Figure 1A~1B
Figure 1C
Figure 2A~2B
AI summary
Disclosed is a sub-laminate module for use in forming a composite laminate structure. The sub-laminate module comprises: a first ply set containing a first ply layer oriented at a first angle and a second ply layer oriented at a second angle, the second angle being equal and opposite the first angle; a second ply set containing a third ply layer oriented at a third angle and a fourth ply layer oriented at a fourth angle, the fourth angle being equal and opposite the third angle; and an acute angle defined by a difference between the first angle and the third angle, wherein the second ply layer is positioned adjacent the third ply layer and the second and third ply layers are both positioned intermediate the first and fourth ply layers, so as to define a double-double helix arrangement. Associated composite laminate structures and methods are also disclosed.