Laminate Composite Structures With Ultrasonic Interface Toughening

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Solution Overview

Problem

Current laminate composite fabrication methods are prone to variations that lead to mixed mode failures, reducing structural reliability and necessitating over-engineering to compensate for variability, thereby increasing weight and costs.

Innovation Solution

The use of Z-aligned discontinuous fiber materials excited by ultrasonic vibrations to enhance interstitial interaction and strength between laminate composite layers, creating toughened interfaces and improving load sharing capacity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional adhesives and static resin matrices are used to adhere laminate composite layers, then the fabrication process is simple, but the structural strength and reliability are reduced due to process variations and mixed mode failures

Engineering Contradiction:

Improvestructural reliabilityVSAvoidfabrication process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies ultrasonic vibration to the fabric layers during the resin infusion process. This mechanical vibration enhances the interaction between the fabric and resin, improves wetting and impregnation, and reduces void formation. The vibration is applied through a table or mold surface that transmits ultrasonic frequencies to the laminate stack, thereby improving structural reliability without significantly complicating the fabrication process

Inventive Principle:

Principle #18Mechanical vibration

Solution Approach 2:

The patent changes the physical state and behavior of the fabric layers by applying ultrasonic vibration during resin infusion. This parameter change affects the fabric's ability to interact with the resin, improving penetration and bonding. The vibration parameter (frequency, amplitude, duration) is controlled to optimize the impregnation process and reduce process variations that lead to failures

Inventive Principle:

Principle #35Parameter changes

2Strength

If process variations are accepted in conventional fabrication, then the fabrication process is easier to implement, but the structural strength and design allowables are reduced leading to over-engineering

Engineering Contradiction:

Improvestructural strengthVSAvoidfabrication ease

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Ultrasonic vibration is applied during resin infusion to consistently improve resin penetration and fabric impregnation. This reduces process variations in void content, resin distribution, and bonding quality, thereby increasing structural strength and design allowables without requiring over-engineering

Inventive Principle:

Principle #18Mechanical vibration

Solution Approach 2:

The patent replaces reliance on passive mechanical compression and gravity-driven resin flow with ultrasonic vibration-assisted resin infusion. This substitution actively controls the resin-fabric interaction, reducing variability in impregnation quality and improving structural strength while maintaining fabrication simplicity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If conventional resin infusion without vibration is used, then the fabrication process is simpler, but interstitial interaction and strength between layers are reduced

Engineering Contradiction:

Improveinterstitial strengthVSAvoidfabrication equipment complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

Ultrasonic vibration is applied to the laminate stack during resin infusion to enhance interstitial interaction between layers. The vibration promotes better resin penetration into the fabric thickness direction, improves fiber-matrix bonding, and reduces void formation, thereby increasing interstitial strength

Inventive Principle:

Principle #18Mechanical vibration

Solution Approach 2:

The ultrasonic vibration acts as an intermediary that facilitates the interaction between resin and fabric during infusion. It mediates the resin flow and penetration process, enhancing wetting and impregnation without requiring complex additional equipment or process steps

Inventive Principle:

Principle #24Intermediary (Mediator)

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 enhances the structural strength and durability of laminate composite structures, reducing variability in failure modes and enabling lighter, more reliable designs without sacrificing weight savings.

Implementation Method 1

The use of Z-aligned discontinuous fiber materials excited by ultrasonic vibrations to enhance interstitial interaction and strength between laminate composite layers

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Data Source

PatentUS20250289213A1Systems and methods for forming laminate composite structures

Publication Date: 2025.09.18 MAHER III MICHAEL CHRISTOPHER

AI summary

Systems, methods, schemes, techniques and processes are provided for forming laminate composite structures, including by implementing a unique ultrasonic fabrication support process to enhance interstitial interaction and strength between adjacent laminate composite layers and structures, realizing resultant improvements in structural strength and reliability against mixed mode failures in the fabricated laminate composite structures by exciting Z-aligned fibers in composite materials to be energized in an manner that facilitates at least contact or partial penetration of adjoining layers and structures with the energized Z-aligned fibers to create stronger and more reliable mechanical and structural bonds therebetween.