Multi-layer Composite Ply with Nested Toughener
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Solution Overview
Problem
The existing methods for fabricating composite materials face challenges in achieving z-direction and in-plane performance while maintaining cost-effectiveness, as thinner plies provide better micro-crack resistance and mechanical performance but require increased manufacturing time and cost, and current methods struggle to stabilize fibers efficiently.
Innovation Solution
The proposed solution involves a multi-layered ply construction with sub-layers of fibers and enhanced performance materials positioned between them, allowing for improved micro-crack resistance and mechanical performance without the need for additional laydown procedures, and using enhanced performance materials to stabilize fibers and enhance z-direction and in-plane performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thinner plies are used to improve micro-crack resistance and mechanical performance, then the mechanical performance is improved, but the manufacturing time and cost increase significantly
Solution Approach 1:
The patent divides a single thick ply into multiple thinner sub-layers (e.g., three sub-layers of 0.0025 inches each to achieve a total thickness of 0.0075 inches). This segmentation provides the micro-crack resistance benefits of thinner plies while maintaining the same overall thickness, avoiding the need to produce twice as many plies and thereby reducing manufacturing time and cost.
Solution Approach 2:
The patent nests enhanced performance materials (such as toughener materials, veils, or films) within the ply structure by positioning them between the fiber sub-layers. This allows the thinner sub-layers to provide micro-crack resistance while the nested materials provide additional functional benefits, all within a single ply construction that avoids increased manufacturing complexity.
2Reliability
If through thickness stitching, z-pins, or toughener materials are added to enhance z-direction performance, then z-direction performance is improved, but manufacturing cost and material complexity increase
Solution Approach 1:
The patent merges the functions of fiber reinforcement and z-direction enhancement by integrating enhanced performance materials directly within the ply structure between sub-layers. This combination provides both in-plane strength from the fibers and z-direction performance from the nested materials, eliminating the need for separate stitching or z-pin processes and reducing overall material and process complexity.
Solution Approach 2:
The patent nests enhanced performance materials (toughener materials, veils, films) within the ply construction between fiber sub-layers. This nested configuration provides z-direction performance enhancement without requiring additional external components or complex assembly processes, thereby reducing material complexity while maintaining reliability.
3Strength
If fibers are spread to create a uniform fiber bed, then in-plane performance is improved, but z-direction performance deteriorates
Solution Approach 1:
The patent segments the fiber bed into multiple sub-layers with spread fibers for in-plane performance, then reintroduces z-direction performance by nesting enhanced performance materials between these sub-layers. This segmentation allows each sub-layer to provide in-plane strength while the nested materials restore z-direction performance that was lost during the spreading process.
Solution Approach 2:
The patent applies different structural qualities to different regions of the ply: the fiber sub-layers provide in-plane performance through spreading, while the nested enhanced performance materials localized between sub-layers provide z-direction performance. This local differentiation allows each region to optimize for its specific functional requirement without compromising the other.
Data Source
AI summary
A ply for fabricating composite material includes a first tow of a plurality of fibers, which are spread in a direction along a width of a cross section of the ply, wherein a first sheet of enhanced performance material overlies the first tow. A second tow of a plurality of fibers, which are spread in the direction along the width of the cross section of the ply, overlies the first sheet of the enhanced performance material. Another tow of a plurality of fibers, which are spread in the direction along the width of the cross section of the ply, are positioned against and laterally extend from the first tow, the second tow and the first sheet of enhanced performance material.