Intermediate Material Cohesion via Punctual Heating Bridges
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Solution Overview
Problem
Composite materials used in industries like aerospace and automotive face issues with delamination during the removal process, particularly due to shear stresses, which can lead to mechanical instability and impact resistance problems.
Innovation Solution
A continuous deposition process is implemented for intermediate materials consisting of unidirectional reinforcing fibers associated with thermoplastic and/or thermosetting layers, where punctual application of forces through heating creates connecting bridges within the fibers, enhancing cohesion and resistance to delamination. This process involves applying tension and pressure during deposition and includes a step of partial melting or polymerization to improve bonding between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If intermediate materials are used to improve impact resistance and delamination resistance, then mechanical properties are improved, but the materials are susceptible to delamination during removal due to shear stresses
Solution Approach 1:
The patent applies punctual forces through heating before the removal process to create connecting bridges within the fiber layer. This preliminary action strengthens the internal cohesion of the intermediate material, enabling it to withstand shear stresses during subsequent removal operations while maintaining improved impact resistance
Solution Approach 2:
The patent changes the physical state of the thermoplastic material by applying heat, transforming it from a solid state to a melted state that can then solidify and form connecting bridges. This parameter change (temperature) enables the creation of internal bonds within the fiber layer that improve cohesion without compromising the impact resistance properties
2Stability of the object's composition
If punctual application of through forces with heating is applied to create connecting bridges, then cohesion is improved, but additional process steps and energy consumption are required
Solution Approach 1:
The patent applies heating locally at punctual points rather than uniformly across the entire intermediate material. This localized application of thermal energy creates connecting bridges only where needed within the fiber layer, improving cohesion while minimizing overall energy consumption compared to full-surface heating
3Ease of operation
If thermosetting resin is used for proper flow through preform, then resin flow is improved, but brittleness after polymerization results in low impact resistance
Solution Approach 1:
The patent creates a composite structure within the intermediate material by forming connecting bridges between thermoplastic material and reinforcing fibers. This internal composite structure combines the flow properties of thermosetting resin with the toughness of thermoplastic material, enabling both proper resin flow through the preform and improved impact resistance after polymerization
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 process effectively preserves the integrity of intermediate materials during removal, reducing delamination risks and enhancing the mechanical properties of composite parts by improving the bonding between layers, thus addressing the delamination issues and increasing the impact resistance of composite materials.
Implementation Method 1
heating resulting in at least partial melting of the thermoplastic material or partial or complete polymerization of the thermosetting material
Implementation Method 2
heating resulting in at least partial melting of the thermoplastic material or partial or complete polymerization of the thermosetting material
Implementation Method 3
with simultaneous application of tension and pressure to the intermediate material so as to apply it to the deposition surface
Data Source
Figure 1A~2
Figure 3~4A
Figure 4B~4C
AI summary
The present invention relates to a method for continuously applying to an application surface an intermediate material consisting of a unidirectional layer of reinforcing fibres which is associated on at least one of its sides with a layer of thermoplastic and/or thermosetting material which represents no more than 10% of the total weight of the intermediate material, in which method: the intermediate material has, prior to being applied, undergone an operation involving the point-wise application of through-loads accompanied by heating causing a penetration of the thermoplastic and/or thermosetting material and creating connecting bridges within the thickness of the unidirectional layer of reinforcing fibres, the intermediate material is applied continuously with the simultaneous application of tension and pressure so as to apply to the application surface a side of the intermediate material that is in the process of being applied that corresponds to a layer of thermoplastic and/or thermosetting material and activating said layer of thermoplastic and/or thermosetting material during the application thereof so as to create a bond between the applied intermediate material and the application surface; to a method of forming a stack for creating composite components that implement said method and to various uses thereof.