Veil-Coated Ultrahigh-Temperature Particle Prepregs for Resin Infusion

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Solution Overview

Problem

Incorporation of ultrahigh-temperature materials into prepregs and preforms is difficult due to filtration during resin infusion and viscosity issues, compromising structural properties under high temperatures.

Innovation Solution

A method involving a modified veil layer coated with ultrahigh-temperature particles, layered with a fabric layer, and heat-treated to embed the particles within the fabric, forming a reinforced prepreg with controlled deposition of ultrahigh-temperature materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If ultrahigh-temperature particles are incorporated into prepregs using conventional techniques, then thermal stability is improved, but particles are completely filtered out during infusion with precursor matrix resin

Engineering Contradiction:

Improvethermal stabilityVSAvoidparticle incorporation

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

A veil layer is introduced as an intermediary carrier between the ultrahigh-temperature particles and the resin infusion process. The veil layer absorbs and holds the particles, preventing them from being filtered out during resin infusion while still allowing the resin to penetrate through the veil layer to impregnate the fabric. This mediator enables particle incorporation without compromising the infusion process.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The veil layer is positioned specifically at the interface between the particles and the resin, creating a localized zone with different properties. This local modification allows particles to be retained in the veil layer while the rest of the prepreg structure maintains its standard infusion characteristics, enabling selective particle incorporation without affecting overall manufacturing.

Inventive Principle:

Principle #3Local quality

2Quantity of substance

If ultrahigh-temperature particles are mixed with initial matrix resin in prepregs, then particle distribution is improved, but viscosity and tack problems occur in the fabric

Engineering Contradiction:

Improveparticle distributionVSAvoidviscosity and tack

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

The particle incorporation process is segmented into separate stages: first, particles are incorporated into the veil layer; second, the veil layer is integrated with the fabric and resin. This segmentation prevents particles from being directly mixed with the resin, avoiding viscosity and tack problems, while still achieving uniform particle distribution through the veil layer's integration into the composite structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The veil layer serves as an intermediary that separates the particles from the resin mixture. Instead of directly mixing particles with resin (which causes viscosity issues), the veil layer carries the particles and allows resin to flow through it, effectively distributing particles without creating problematic resin-particle mixtures.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If conventional techniques are used to incorporate ultrahigh-temperature materials, then manufacturing simplicity is maintained, but structural properties are compromised under high temperature

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidstructural properties

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The manufacturing process parameters are modified by introducing the veil layer with specific particle loading and composition. This parameter change enables the incorporation of ultrahigh-temperature particles while maintaining conventional prepreg manufacturing simplicity. The veil layer is processed using standard techniques, and the particles are retained through their absorption onto the veil layer structure, achieving both simplicity and enhanced structural properties under high temperature.

Inventive Principle:

Principle #35Parameter changes

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 prepreg maintains structural integrity and thermal stability across surfaces, providing improved thermal capabilities and barrier properties under ultrahigh temperatures, suitable for high-temperature environments.

Implementation Method 1

coating a nonwoven veil carrier with ultrahigh-temperature particles

Methodology Applied

Scientific EffectDeposition: Deposition (physical)

Implementation Method 2

heat-treating the reinforced fabric; decompose the nonwoven veil carrier

Methodology Applied

Scientific EffectDecomposition: Decomposition (biological)

Data Source

PatentUS20250249656A1Ultrahigh-temperature particle-incorporated composite and methods of manufacturing thereof

Publication Date: 2025.08.07 THE BOEING CO

AI summary

A prepreg that is embedded with ultrahigh-temperature particles by coating one or more veil carrier with ultrahigh-temperature particles, and then incorporating the one or more of the modified veil layer with one or more fabric layer to form a reinforced fabric for a prepreg to enable the formation of layups with tailored amounts of the ultrahigh-temperature particles that vary through the thickness of the reinforced fabric to enable a functionally graded composite that can withstand ultrahigh temperatures.