Fibre Composite Laminate Hybrid Impregnation

Solution Overview

Problem

There is a need for visible components with a homogeneous surface appearance that can have varying mechanical properties in different areas, which existing fiber composite laminates fail to achieve effectively.

Innovation Solution

A method for producing fiber composite laminates by varying the degree of impregnation of fiber layers with thermoplastic elastomer and duroplastic matrix, creating hybrid-impregnated areas with targeted flexural rigidity, while maintaining a uniform surface appearance and visible carbon look.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If fiber-reinforced composites are used as visible components with a top layer made opaque to create a carbon look, then the visual appearance is improved, but the surface homogeneity is worsened due to the outward-facing visual impression of individual fibers

Engineering Contradiction:

Improvevisual appearanceVSAvoidsurface homogeneity

Core Design Contradiction:

Illumination intensityVSManufacturing precision

Solution Approach 1:

The patent applies local quality by creating different impregnation degrees in different regions of the fiber preform. The thermoplastic elastomer completely impregnates the fiber layers in a first region while only partially impregnating them in a second region, allowing each region to have tailored mechanical properties while maintaining overall surface homogeneity

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent changes the impregnation parameter locally by varying the degree of thermoplastic elastomer penetration into the fiber layers. This is achieved through localized pressure and/or heat application during the impregnation process, transforming the uniform fiber structure into a differentiated structure with regions of complete and partial impregnation

Inventive Principle:

Principle #35Parameter changes

2Strength

If pressure and heat are applied to impregnate thermoplastic elastomer into fiber layers, then the mechanical properties are improved, but the energy consumption increases

Engineering Contradiction:

Improvemechanical propertiesVSAvoidenergy consumption

Core Design Contradiction:

StrengthVSUse of energy by moving object

Solution Approach 1:

The patent applies local quality by creating different impregnation degrees in different regions of the fiber preform. The thermoplastic elastomer completely impregnates the fiber layers in a first region while only partially impregnating them in a second region, allowing each region to have tailored mechanical properties while maintaining overall surface homogeneity

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent changes the impregnation parameter locally by varying the degree of thermoplastic elastomer penetration into the fiber layers. This is achieved through localized pressure and/or heat application during the impregnation process, transforming the uniform fiber structure into a differentiated structure with regions of complete and partial impregnation

Inventive Principle:

Principle #35Parameter changes

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 method allows for the creation of components with locally varying mechanical flexibility and a homogeneous surface structure, ensuring high mechanical properties and aesthetic appeal, with improved watertightness and cost-effective production.

Implementation Method 1

subjecting a first preform, which has one or more dry fiber layers and a thermoplastic elastomer, to pressure and/or heat

Methodology Applied

Scientific EffectPressure: Pressure Increase

Implementation Method 2

subjecting a first preform, which has one or more dry fiber layers and a thermoplastic elastomer, to pressure and/or heat

Methodology Applied

Scientific EffectHeat: Heating

Implementation Method 3

the thermoplastic component of the thermoplastic elastomer completely impregnates the dry fiber layers of the first preform in at least a first region and only partially impregnates them in at least a second region

Methodology Applied

Scientific EffectImpregnation: Absorption (physical)

Implementation Method 4

the dry fiber layers of the second region of the first preform, which are not yet impregnated by the thermoplastic component of the thermoplastic elastomer, are impregnated and cured in a thermoset polymer matrix

Methodology Applied

Scientific EffectCuring: Chemical Bonding

Implementation Method 5

The dry fiber layers are then embedded in a thermoplastic elastomer matrix to produce the first preform

Methodology Applied

Scientific EffectLamination: Lamination

Data Source

PatentEP3231591B1Fibre compound laminate and method for preparing a fibre compound laminate

Publication Date: 2023.04.19 AIRBUS DEFENCE & SPACE GMBH

Figure 1~4

AI summary

A method for producing a fiber composite laminate (5) includes the steps of applying pressure and/or heat to a first preform (3A), which has one or more dry fiber layers (1A) and a thermoplastic elastomer (2A,2), such that the thermoplastic portion of the thermoplastic elastomer (2) completely impregnates the dry fiber layers (1A) of the first preform (3A) in at least a first region (R1) and only partially impregnates them in at least a second region (R2), and of impregnating and curing the dry fiber layers (1A) of the second region (R2) of the first preform (3A) that are not impregnated by the thermoplastic portion of the thermoplastic elastomer (2) in a thermosetting polymer matrix.