Offset Composite Laminate for Impact Resistance
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Solution Overview
Problem
Conventional composite materials, such as carbon fibre, lack the necessary impact resistance for aerospace applications, particularly in components like fan containment cases, where they fail to effectively absorb and distribute impact forces without causing catastrophic damage.
Innovation Solution
A method of forming composite components by displacing sub-layers of plies relative to each other, preventing alignment of ply boundaries, which enhances surface finish and structural strength by preventing crack propagation and improving impact performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional composite materials are used for fan containment cases, then weight reduction is achieved, but impact resistance is insufficient
Solution Approach 1:
The patent employs a composite structure combining carbon fibre plies with a specific architectural configuration (cross-ply laminates with alternating fiber orientations) to achieve both weight reduction and improved impact resistance. The composite material system maintains the lightweight advantage while the structured arrangement of plies provides enhanced damage tolerance and impact absorption capabilities
2Ease of manufacture
If plies are aligned in the same direction through the stack, then manufacturing is simplified, but surface finish deteriorates due to cumulative protrusion
Solution Approach 1:
The patent introduces asymmetry in the ply stacking sequence by alternating fiber orientations (e.g., 0°/90°/0°/90° pattern) and displacing plies relative to each other. This asymmetric arrangement prevents the cumulative protrusion effect that occurs with aligned plies, thereby achieving smooth surface finish while maintaining manufacturing feasibility through systematic patterning
3Ease of manufacture
If plies are aligned in the same direction through the stack, then structural assembly is simplified, but strength deteriorates due to crack propagation along boundaries
Solution Approach 1:
The patent utilizes a composite laminate structure with alternating ply orientations (cross-ply configuration) where adjacent plies have perpendicular fiber directions. This composite architectural design disrupts crack propagation paths by forcing cracks to change direction at each ply interface, thereby enhancing structural strength and damage tolerance while maintaining assembly simplicity through regular patterning
4Use of energy by moving object
If conventional composite structures are used, then fuel savings are achieved through weight reduction, but impact damage resistance is insufficient
Solution Approach 1:
The patent employs a specialized composite laminate structure with alternating fiber orientations and displaced ply arrangements that provide enhanced impact damage resistance. This composite architectural design allows the structure to absorb and distribute impact energy more effectively, preventing catastrophic failure while maintaining the weight advantages necessary for fuel savings in aerospace applications
Data Source
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AI summary
A method of forming a composite component in which the component comprises a series of sub -layers and in which the sub -layers are offset with respect to one or all of the other sub -layers forming the composite component.