Textile Fiber-Composite Precursor for Complex Aircraft Shapes
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Solution Overview
Problem
Current methods for producing aircraft components with complex shapes, such as those with double curvature, are time-intensive and costly due to the need for extensive tape laying and the limited draping capability of thermoplastic fiber-composite materials, which restricts the production of components beyond single curvature radii.
Innovation Solution
A textile fiber-composite material precursor is developed, comprising multiple tiers of flexible textile planar structures with thermoplastic polymer matrix precursor tiers and reinforcement tiers, allowing for complete impregnation and production of components with multiple curvature radii, including spherical shapes, using a method that involves stacking and consolidating these tiers under pressure and heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the AFP method with narrow tapes is used to produce components with double curvature, then the component shape complexity is improved, but the production time and cost increase due to the large number of tapes required
Solution Approach 1:
The reinforcement material is divided into multiple tiers (first reinforcement tier, second reinforcement tier, third reinforcement tier) with different fiber orientations. Each tier is separately placed and then consolidated, allowing complex shapes to be achieved through the combination of simpler layered structures rather than requiring numerous narrow tapes
Solution Approach 2:
The invention transitions from using narrow tapes (one-dimensional linear arrangement) to using multi-tier fabric structures (two-dimensional planar arrangement). By stacking reinforcement tiers with different orientations and consolidating them together, the method achieves complex three-dimensional shapes more efficiently
2Ease of manufacture
If thermoplastic polymer films are used as matrix material, then the processing is simplified and material can be melted, but the draping capability is limited to single curvature radii
Solution Approach 1:
The invention creates a composite structure combining thermoplastic polymer matrix with multi-tier reinforcement materials having different fiber orientations. This composite approach allows the thermoplastic to maintain its processing advantages while the multi-tier reinforcement structure provides the flexibility needed for complex draping and shaping
3Manufacturing precision
If multiple reinforcement tiers with different orientations are used, then the fiber impregnation is improved, but the manufacturing complexity increases
Solution Approach 1:
The reinforcement tiers are prepared and positioned in the desired configuration before the thermoplastic matrix is applied and consolidated. By pre-arranging the reinforcement structure in the correct orientation and configuration, the method ensures complete fiber impregnation while avoiding complex in-process adjustments
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 the cost-effective production of complex-shaped aircraft components with complete impregnation of fibers, reducing production time and costs by allowing the creation of components with multiple curvature radii, including spherical shapes, while maintaining the benefits of thermoplastic materials like PEKK.
Implementation Method 1
The polymer softens or melts and under the prevailing pressure penetrates the non-crimp fabric so as to form the matrix
Implementation Method 2
The deposited prepreg is then consolidated under high pressure and at a high temperature so as to form a component precursor or a component
Data Source
AI summary
A textile fiber-composite material precursor and method for producing a component from fiber-composite material. Aircraft components can be produced from polymer fiber-composite materials, a matrix of which can be a high-performance plastics material such as polyether ketone ketone wherein a reinforcement of a non-crimp fabric of carbon fibers is embedded. Large-area non-crimp fabrics and large-area polymer films can be consolidated while being heated and pressed forming simple components. The flexible textile fiber-composite material precursor includes a stack of woven-fabric tiers from a polymer and of non-crimp fabric tiers from carbon fibers. Since both components are capable of draping, the fiber-composite material precursor can be deposited over a large area on curved shape-imparting surfaces and subsequently be consolidated under pressure and heated to form the fiber-composite material.