Curved Composite Laminate Layout Without Overlapping Sheet Ends
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Solution Overview
Problem
Existing methods for manufacturing composite sheets in curved shapes result in unnecessary material waste and potential manufacturing defects due to difficulty in expanding and contracting composite sheets, leading to increased costs and reduced quality.
Innovation Solution
A laminate structure is formed by laminating first and second composite sheets with non-overlapping end portions along a curved arrangement direction, where the end portions of each sheet intersect, ensuring contiguity without overlap, and using a lamination method that aligns fiber directions with predetermined angles to avoid in-plane deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If composite sheets are cut from a flat rectangular laminate to manufacture a curved component, then the curved shape is achieved, but unnecessary material portions are generated increasing manufacturing cost
Solution Approach 1:
The laminate is divided into multiple composite sheets (first composite sheets and second composite sheets) with different fiber orientations. Each sheet is disposed along the curved arrangement direction with non-overlapping end portions, allowing the curved shape to be formed by assembling segmented sections rather than cutting a single large sheet, thereby eliminating material waste.
2Shape
If composite sheets are bent in a curved shape during lamination to manufacture a curved component, then the curved shape is achieved, but wrinkles are generated due to deformation increasing manufacturing defects
Solution Approach 1:
The laminate structure uses multiple composite sheets disposed along the curved arrangement direction with non-overlapping end portions. This segmentation allows each sheet to be laid out flat during manufacturing and then assembled into the curved configuration, eliminating the need to bend individual sheets and preventing wrinkle generation.
Solution Approach 2:
The laminate combines first composite sheets with first fiber base materials oriented in first fiber directions and second composite sheets with second fiber base materials oriented in second fiber directions. This composite structure allows the laminate to achieve curved shapes through the arrangement of multiple materials with different properties, preventing deformation and wrinkle generation in any single layer.
3Loss of substance
If composite sheets are disposed along a curved arrangement direction with non-overlapping end portions, then material waste is reduced, but the complexity of lamination process increases
Solution Approach 1:
The laminate is segmented into multiple composite sheets with non-overlapping end portions disposed along the curved arrangement direction. This segmentation enables efficient use of materials while the lamination process remains manageable through systematic layer-by-layer construction, where each sheet is positioned and laminated in sequence rather than requiring complex simultaneous operations.
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 allows for a laminate with a curved shape, reducing manufacturing costs and improving quality by minimizing material waste and preventing defects, while enhancing structural strength.
Implementation Method 1
a laminate in which composite sheets each including a fiber base material such as glass fiber or carbon fiber and a resin material are laminated
Data Source
AI summary
A layered body includes a first layer with a plurality of first composite sheets, and a second layer with a plurality of second composite sheets in a state of contacting the first layer. The first composite sheets are disposed along an arrangement direction shaped as a curved line so that an end in a first longitudinal direction of one first composite sheet and an end in the first longitudinal direction of an adjacent first composite sheet are close to each other without overlapping in the thickness direction, and so that the first longitudinal directions of the sheets intersect each other. The second composite sheets are disposed along the arrangement direction so that an end in a second longitudinal direction of one second composite sheet and an end in the second longitudinal direction of an adjacent second composite sheet are close to each other without overlapping in the thickness direction.