Multi-axial Fabric Laminates for Multi-directional Force Management
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Solution Overview
Problem
Existing fabric-based polymer-fiber laminates struggle to effectively handle forces of different magnitudes and directions in bolt-connected applications, such as wind turbine blades, due to limitations in their structural integrity and efficiency.
Innovation Solution
The development of multi-axial fabrics and laminates with reinforcing fibers oriented at different angles, including hybrid and triaxial configurations, where fibers are strategically aligned to enhance strength and durability, and the use of various types of fibers with distinct elastic moduli and tensile strengths to optimize performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional fabric-based polymer-fiber laminates are used, then manufacturing is simpler, but structural performance under multi-directional forces is insufficient
Solution Approach 1:
The patent applies composite materials by combining multiple fabric types (e.g., woven, knitted, non-woven) with different fiber orientations and material properties into a single laminate structure. This allows the laminate to handle multi-directional forces more effectively while maintaining manufacturing feasibility through standardized composite material processes.
Solution Approach 2:
The patent introduces multi-axial fiber orientations (0°, 45°, 90°, etc.) to transform the traditional unidirectional or bidirectional fabric structure into a multi-dimensional reinforcement system. This dimensional expansion of fiber arrangement enables the laminate to resist forces from multiple directions simultaneously.
2Adaptability or versatility
If multi-axial fabrics with multiple fiber orientations are used, then ability to handle forces in different directions is improved, but manufacturing complexity increases
Solution Approach 1:
The patent segments the laminate into multiple layers, each containing fabrics with specific fiber orientations (e.g., one layer with 0° fibers, another with 90° fibers). This segmentation allows each layer to be optimized for specific force directions while simplifying the overall manufacturing process by treating each layer as a separate, manageable unit.
Solution Approach 2:
The patent applies local quality by assigning different fabric types and fiber orientations to specific regions or layers of the laminate based on the expected stress distribution. High-stress areas receive multi-axial reinforcement, while lower-stress areas use simpler fabric configurations, optimizing both performance and manufacturability.
3Strength
If thicker laminates are used, then structural strength is improved, but weight increases
Solution Approach 1:
The patent uses composite materials with high strength-to-weight ratio fibers (such as carbon fiber, aramid fiber, or high-performance glass fiber) to achieve the required structural strength with reduced thickness. This allows the laminate to maintain strength while minimizing weight by using fewer layers or thinner individual layers.
Solution Approach 2:
The patent changes the material parameters by selecting fibers with superior mechanical properties (higher tensile strength, modulus of elasticity) to reduce the required laminate thickness. This parameter optimization allows achieving the same strength with less material, thereby reducing weight.
Data Source
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AI summary
Multi-axial fabrics (including hybrid, multi-axial fabrics) and polymer-fiber laminates are disclosed. Bodies (e.g., cylindrical and/or flanged bodies) incorporating the fabrics and/or laminates are also disclosed. The bodies exhibit improved performance and/or reduced costs for connecting applications.