Textile Substrate with Core/Sheath Transverse Threads
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Solution Overview
Problem
Existing textile substrates for composite material preforms lack sufficient stability and drapeability, especially during the infiltration of matrix resins and under pressure, which affects the production of parts with high strength and impact resistance.
Innovation Solution
A textile substrate comprising a unidirectional composite with multifilament reinforcing yarns joined by transverse threads having a core/sheath structure, where the first component is a fusible thermoplastic polymer with a lower melting point and the second component has a higher melting point, providing adhesive bonding and stabilization, along with a nonwoven of thermoplastic polymer material for enhanced stability and permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a unidirectional composite with multifilament reinforcing yarns joined by transverse threads is used, then manufacturing precision and structural stability are improved, but device complexity increases due to the core/sheath structure requirement
Solution Approach 1:
The transverse threads are segmented into two functional components: a fusible thermoplastic polymer sheath (first component) that melts during resin infiltration to facilitate matrix penetration, and a higher melting point core (second component) that maintains structural integrity. This segmentation allows each component to perform its specific function independently, resolving the contradiction between achieving dimensional stability and managing structural complexity.
Solution Approach 2:
The transverse threads are constructed as composite structures with a core/sheath configuration, combining materials with different melting points and properties. The sheath material (first component) is selected to be fusible at resin infiltration temperatures, while the core material (second component) maintains higher thermal stability. This composite approach enables the thread to provide both structural support and facilitate resin flow, simultaneously improving dimensional stability without excessive complexity.
2Reliability
If a nonwoven of thermoplastic polymer material is adhesively bonded to the flat layer of multifilament reinforcing yarns, then stability during resin infiltration is improved, but manufacturing complexity increases
Solution Approach 1:
The nonwoven thermoplastic polymer material is adhesively bonded to the flat layer of multifilament reinforcing yarns, merging the functions of structural reinforcement and resin infiltration stability into a single integrated substrate. This combination eliminates the need for separate stabilization measures during resin infiltration, improving reliability while maintaining manufacturing feasibility through a unified structure.
3Quantity of substance
If the first component of transverse threads has a lower melting point than the second component, then permeability during resin infiltration is improved, but structural strength at high temperature decreases
Solution Approach 1:
The transverse threads exhibit local quality differentiation through their core/sheath structure: the sheath (first component) has lower melting point properties optimized for resin infiltration permeability, while the core (second component) has higher melting point properties optimized for maintaining structural strength at elevated temperatures. This local quality assignment allows each region of the thread to perform its specific function without compromising the other, resolving the contradiction between permeability and high-temperature strength.
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
The substrate achieves high dimensional stability, good drapeability, and high mechanical strength, enabling the production of fiber preforms with complex geometries and improved impact resistance, while maintaining stability during matrix resin infiltration and curing.
Implementation Method 1
the first component is a fusible thermoplastic polymer material, and the multifilament reinforcing yarns arranged alongside one another are joined together via the first component of the transverse threads by meltbonding
Implementation Method 2
a nonwoven of thermoplastic polymer material is arranged on the at least one flat layer of multifilament reinforcing yarns and is adhesively bonded to the flat layer of the multifilament reinforcing yarns
Data Source
AI summary
A textile substrate made from reinforcing fibers for the production of composite-material preforms, Including an unidirectional composite consisting of at least one flat layer of multifilament reinforcing yarns arranged alongside and parallel to one another and joined by transverse threads, whereby a nonwoven of thermoplastic polymer material is arranged on the at least one flat layer of multifilament reinforcing yarns and is adhesively bonded to the flat layer of multifilament reinforcing yarns. The textile substrate wherein the transverse threads have a core/sheath structure with a first component forming the sheath and a second component forming the core, wherein the first component has a lower melting point than the second component, the first component is a fusible thermoplastic polymer material and the multifilament reinforcing yarns arranged alongside one another are joined together via the first component of the transverse threads by meltbonding.