Continuous Bias Pattern Fabric for Aerospace Composites
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Solution Overview
Problem
The conventional method of forming a reel of ±45° prepreg is impractical for certain aerospace applications due to stitching contaminants causing undesirable material behavior, such as fracture or tear, and results in significant waste and poor uniformity.
Innovation Solution
Creating a continuous bias pattern fabric with carbon fibers oriented diagonally, which is then impregnated with resin and cut lengthwise to form long bias tapes with minimal seams, thereby reducing waste and improving uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional 0°/90° prepreg is cut at 45° angle and stitched together to form ±45° prepreg reel, then the prepreg can be formed for aerospace applications, but the stitching creates contaminants that cause fracture or tear and make the composite behave in undesired manner
Solution Approach 1:
The invention extracts and eliminates the stitching operation from the manufacturing process. Instead of cutting 0°/90° prepreg at 45° and stitching the pieces together, the method uses pre-manufactured ±45° bias pattern fabric that already has the correct fiber orientation without requiring any stitching. This removes the harmful stitching contaminant entirely from the process.
Solution Approach 2:
The invention performs the bias pattern formation in advance during fabric manufacturing rather than during prepreg fabrication. The ±45° bias pattern fabric is pre-manufactured with carbon fibers oriented at the required angles through weaving or knitting processes, so when the prepreg is later formed by impregnating this pre-configured fabric with resin, the correct fiber orientation is already established without requiring cutting or stitching operations.
2Length of moving object
If the ends of ±45° plies are stitched together to form longer sections, then the reel can be formed, but the stitched areas are relatively long and more prone to causing undesirable effects
Solution Approach 1:
The invention completely removes the stitching operation from the process. The ±45° bias pattern fabric is manufactured as a continuous material with the correct fiber orientation already established through weaving or knitting. This eliminates the need to stitch plies together to achieve the required length, thereby removing the source of stitching contaminants entirely.
3Shape
If 0°/90° prepreg is cut at 45° angle to form ±45° plies, then the bias pattern can be achieved, but significant waste is created and uniformity is poor
Solution Approach 1:
The invention performs the bias pattern formation in advance during fabric manufacturing through weaving or knitting processes that directly create ±45° fiber orientations. When the prepreg is later formed by impregnating this pre-configured bias pattern fabric with resin, the correct fiber orientation is already established without requiring cutting operations, thereby eliminating the material waste that would otherwise be generated.
4Duration of action of stationary object
If stitching is used to join ±45° plies, then continuous prepreg sections can be formed, but the seams are long and cause poor uniformity
Solution Approach 1:
The invention completely eliminates the stitching operation from the manufacturing process. The ±45° bias pattern fabric is manufactured as a continuous material with the correct fiber orientation already established through weaving or knitting processes. This removes the need to stitch plies together to achieve continuity, thereby eliminating the source of seam uniformity problems entirely.
Data Source
AI summary
Techniques are directed to providing a carbon composite product. Such techniques involve providing a bias pattern fabric that extends from a starting side along a run direction, the bias pattern fabric including carbon fiber threads oriented diagonally relative to the run direction. Such techniques further involve impregnating the bias pattern fabric with resinous material to form a run of prepreg material. Such techniques further involve cutting the run of prepreg material lengthwise to the run direction to form multiple tapes.