Composite Tape Wind Stacking for Thermal Stability
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Solution Overview
Problem
Conventional composite manufacturing processes face issues with structural instability due to thermal cycling, high manufacturing costs, and the need for oven curing, which sacrifices stress capacity and control over fiber orientation.
Innovation Solution
The method involves forming composite structures using a stacked configuration of tape winds with a bonding material that cures in less than 1 second, applied at high speeds without subsequent curing, allowing precise control over fiber orientation and density, and using a different matrix material between layers to achieve cost advantages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional thermosetting cure processes are used to cure the entire structure after wet assembly, then strong interfaces between plies are achieved, but the entire core of the tape requires re-liquifaction during bonding producing parts whose shape is inherently unstable under subsequent thermal cycling
Solution Approach 1:
The patent divides the curing process into two stages: first curing only the bonding material at the interface between plies, then separately curing the matrix material in the core of the tape. This segmentation allows the bonding material to provide immediate interface strength while the core matrix can be cured later without causing shape instability, resolving the contradiction between achieving strong interfaces and maintaining shape stability during thermal cycling.
Solution Approach 2:
The bonding material is applied and cured in advance before the final matrix curing step. By performing the bonding action preliminarily, the interface strength is established early while the core matrix remains uncured and flexible, preventing shape instability during subsequent thermal cycling. The final matrix curing then completes the structure without compromising the already-established interface bonds.
2Strength
If conventional wet assembly processes are used to form layers with controlled fiber orientation, then superior strength parts are produced, but manufacturing costs and capital costs for tooling remain high
Solution Approach 1:
The patent extracts and separates the bonding material from the bulk matrix material, applying it only where needed at the interface between plies rather than throughout the entire structure. This extraction reduces the amount of expensive matrix material required, lowering manufacturing costs while maintaining the controlled fiber orientation and strength benefits in the bonding regions.
Solution Approach 2:
Instead of using matrix material uniformly throughout the entire tape and structure, the patent applies matrix material locally only at the bonding interfaces between plies. This local quality approach reduces material costs and simplifies manufacturing while maintaining the critical bonding strength and controlled fiber orientation where it matters most, without the high costs associated with conventional wet assembly processes.
3Strength
If conventional processes cure the entire part after wet assembly, then strong interfaces are formed, but the cost of oven curing the entire structure increases manufacturing cost
Solution Approach 1:
The curing process is segmented to cure only the bonding material at interfaces rather than the entire structure. This reduces the volume of material requiring thermal curing, thereby decreasing energy consumption and manufacturing cost while maintaining strong interfaces between plies through targeted curing of the bonding material layers.
Solution Approach 2:
Instead of curing the entire structure excessively, the patent applies curing only to the necessary bonding interfaces. This partial action approach reduces energy costs associated with oven curing while still achieving the required interface strength, avoiding the waste of energy on regions that do not require curing.
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 results in composite structures with superior strength, lower manufacturing costs, minimal capital costs for tooling, and eliminates the need for oven curing, while maintaining high precision and strength performance.
Implementation Method 1
a bonding material that cures in less than 1 second
Data Source
AI summary
An article of manufacture according to one embodiment includes a plurality of plies in a stacked configuration, where each ply includes a plurality of tape winds having edges. A distance between the edges of adjacent tape winds in the same ply is about constant along a length of the wind. Each tape wind comprises elongated fibers and a matrix, axes of the fibers being oriented about parallel to a longitudinal axis of the tape wind. Additional systems, methods and articles of manufacture are also presented.