Partially Cross-Linked Thermoplastic Porous Layer for Composite Impact Resistance
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Solution Overview
Problem
Existing reinforcement materials for composite parts, particularly in the aerospace industry, face challenges such as high manufacturing costs due to high melting point thermoplastic polymer porous layers, interaction with thermoset resins leading to microcracks, and poor impact resistance, which affects the durability of composite structures under hygrothermal cycles.
Innovation Solution
The use of a reinforcement material comprising a fiber reinforcement associated with a partially cross-linked thermoplastic polymer porous layer, where the polymer layer represents no more than 10% of the total weight, allowing for lower temperature manufacturing and preventing complete dissolution in thermoset resins, thus maintaining mechanical performance and reducing microcrack formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a thermoplastic polymer porous layer is added to improve impact resistance, then mechanical properties are improved, but manufacturing cost increases due to high melting point
Solution Approach 1:
The patent changes the key parameter of the thermoplastic polymer from high melting point to low melting point (below 150°C), which reduces manufacturing cost while maintaining the impact resistance improvement. This parameter change allows processing at lower temperatures, reducing energy consumption and manufacturing complexity.
Solution Approach 2:
The patent creates a composite reinforcement material combining fiber reinforcement (carbon, glass, or aramid fibers) with a thermoplastic polymer porous layer. This composite structure provides both the impact resistance enhancement from the thermoplastic layer and the structural strength from the fibers, while the low melting point of the thermoplastic component reduces overall manufacturing cost.
2Strength
If a thermoplastic polymer porous layer is added to improve impact resistance, then mechanical properties are improved, but manufacturing complexity increases
Solution Approach 1:
By changing the melting point parameter of the thermoplastic polymer to below 150°C, the patent simplifies the manufacturing process. The lower temperature requirement reduces the complexity of heating equipment, process control, and energy management, making the multi-layer composite manufacturing more feasible.
3Strength
If a thermoplastic polymer porous layer is used, then impact resistance is improved, but microcracks form due to interaction with thermoset resin
Solution Approach 1:
The patent changes the melting point parameter of the thermoplastic polymer to below 150°C, which prevents complete dissolution in the thermoset resin during processing. This parameter change maintains the structural integrity of the thermoplastic layer, preventing microcrack formation while preserving the impact resistance benefits.
Solution Approach 2:
The patent uses a partial cross-linked thermoplastic polymer that is partially soluble in the thermoset resin. This partial solubility allows sufficient interaction for bonding while preventing complete dissolution that would cause microcracks. The balance of solubility provides both adhesion and structural stability.
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 enables cost-effective and efficient production of composite parts with improved impact resistance and reduced microcrack formation, suitable for aerospace applications by allowing manufacturing at lower temperatures and maintaining mechanical integrity under hygrothermal stress.
Implementation Method 1
a porous layer made of a partially cross-linked thermoplastic polymer
Implementation Method 2
allowing for lower temperature manufacturing
Data Source
AI summary
The present invention relates to a reinforcement material including at least one fiber reinforcement associated on at least one of its faces with a porous layer, the porous layer(s) representing no more than 10% of the total weight of the reinforcement material, preferably from 0.5 to 10% of the total weight of the reinforcement material, and most preferably from 2 to 6% of the total weight of the reinforcement material, characterized in that the porous layer contains a partially cross-linked thermoplastic polymer. Another object of the invention is a precursor material of such a reinforcement material, as well as their preparation method and the methods for manufacturing a preform or a composite part from such materials.