Hybrid Composite Laminates for Wrinkle-Free Curved Structures
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Solution Overview
Problem
Conventional methods for forming composite structures, such as aircraft parts, often result in wrinkled and heavier components due to the limitations of woven fiber fabrics and braided composites in achieving complex shapes.
Innovation Solution
The formation of hybrid composite laminates by stacking braided composite layers and steered unidirectional slit tapes, where each slit tape is aligned non-overlappingly to form a second ply, allowing for the creation of curved and complex structures with optimized reinforcement and reduced thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional braided composites are used to form curved structures, then the structure can be formed, but the resulting parts become wrinkled and heavier
Solution Approach 1:
The patent segments the braid into multiple discrete plies that can be independently positioned and oriented. This segmentation allows each ply to be precisely controlled during draping, preventing the interlacing fibers from creating wrinkles while maintaining the ability to form complex curved shapes.
Solution Approach 2:
The patent performs preliminary positioning and orientation of each braid ply before consolidation. By pre-aligning the discrete plies along desired paths and securing them in place before final forming, the method prevents wrinkles from developing during the draping process while enabling complex curved geometry.
2Area of stationary object
If conventional braided composites are used, then coverage is achieved, but the parts become heavier than desired
Solution Approach 1:
The patent applies different fiber orientations and ply configurations in different local regions of the composite part. By optimizing the fiber layout and ply stacking sequence for each specific area, the design achieves maximum structural efficiency and minimum weight while maintaining full coverage of the required geometry.
Solution Approach 2:
The patent combines discrete braid plies with unidirectional fiber tapes to create a hybrid composite structure. This composite approach allows optimization of each material type for its specific function, reducing overall weight while maintaining coverage and structural performance.
3Weight of stationary object
If multiple braided plies are layered to reduce weight, then thickness is reduced, but wrinkles increase
Solution Approach 1:
The patent performs preliminary positioning, alignment, and securing of each discrete brawd ply before consolidation. This pre-positioning ensures that multiple thin plies remain wrinkle-free during draping and forming operations, enabling weight reduction through reduced thickness without sacrificing surface quality.
4Ease of manufacture
If woven fiber fabrics are used, then manufacturing is simple, but complex curved shapes are difficult to achieve
Solution Approach 1:
The patent segments the traditional woven fabric into discrete braid plies that can be independently manipulated. This segmentation maintains manufacturing simplicity through automated placement while enabling each ply to be oriented and positioned to accommodate complex curved geometries that rigid woven fabrics cannot achieve.
Data Source
AI summary
At least one braided composite layer configured to form a first ply may be provided. A plurality of slit tapes may be arranged and aligned such that each slit tape is adjacent to one another and non-overlapping, to form a second ply. A hybrid composite laminate may be formed by stacking a plurality of plies that includes at least one first ply and at least one second ply. Each slit tape may be a steered unidirectional composite slit tape that is aligned along an axis, contour line, or curve of the hybrid composite laminate, a mold/tooling used to shape the laminate, or the resulting composite part. Hybrid composite laminates may be formed by stacking at least one first ply formed of a braided composite layer and at least one second ply formed from a plurality of slit tapes. Composite parts may be formed by consolidating such hybrid composite laminates.