Gapped UD Reinforcement Tape for Composite Impregnation
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Solution Overview
Problem
Existing fibrous reinforcements, such as multiaxial non-crimp fabrics, face challenges in maintaining layer integrity during production, especially in zero-degree or parallel orientations, and suffer from inadequate impregnation due to dense fiber stabilization hindering matrix flow, making composite material formation difficult.
Innovation Solution
A tape-like dry fibrous reinforcement with unidirectional fiber tows separated by porous adhesive layers and channels, allowing for efficient resin infiltration and improved handling, stability, and mechanical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If multiaxial reinforcements are densely packed and stabilized, then layer integrity is maintained, but matrix flow is hindered causing inadequate impregnation
Solution Approach 1:
The reinforcement is divided into discrete unidirectional tows separated by spacing elements, creating gaps between fiber bundles. This segmentation prevents dense packing while maintaining layer integrity, allowing matrix resin to flow through and impregnate fibers effectively.
Solution Approach 2:
Spacing elements create a porous structure with controlled voids between tows. This porous architecture maintains structural stability while providing channels for matrix flow, resolving the contradiction between layer integrity and impregnation quality.
2Ease of manufacture
If multiaxial reinforcements are not stabilized, then matrix flow is improved, but handling becomes difficult
Solution Approach 1:
The reinforcement consists of separate unidirectional tows rather than densely packed stabilized layers. This segmented structure improves matrix access while the tows remain aligned and manageable through the spacing element architecture.
Solution Approach 2:
Spacing elements act as intermediaries that maintain tow separation and alignment without requiring traditional stabilization methods. These elements facilitate both handling during manufacturing and matrix flow during impregnation.
3Ease of operation
If traditional woven fabrics are used, then handling is improved, but impregnation remains problematic due to permeability difficulties
Solution Approach 1:
Instead of continuous woven structures, the invention uses discrete unidirectional tows with intentional spacing. This segmentation creates inherent permeability pathways that improve impregnation while maintaining handling characteristics through tow alignment.
Solution Approach 2:
The spacing elements create a controlled porous structure that traditional woven fabrics lack. This porous architecture provides dedicated flow channels for matrix resin, improving impregnation quality while the tow structure maintains handling ease.
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 gapped UD reinforcement enables efficient resin infiltration, quickens wetting of fibers, and enhances the mechanical performance and quality of composite materials by maintaining structural integrity and allowing controlled matrix flow.
Implementation Method 1
at least one porous adhesive layer attached to the tows of the at least one fiber/filament layer by surface connection
Implementation Method 2
the tows of the at least one fiber/filament layer are separated from each other by separation channels
Implementation Method 3
enables efficient resin infiltration, quickens wetting of fibers
Data Source
AI summary
A tape-like dry fibrous reinforcement, the ‘Gapped UD reinforcement tape’, providing channels or flow-paths created by inclusion of a layer of separated fiber tows held by at least one adhesive layer. Hereby, quicker wetting of fibers with matrix is obtained, whereby improved composite materials can be economically produced. A method and apparatus for producing the Gapped UD tapes are also disclosed.