Polymer matrix composites, and methods of making the same
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Solution Overview
Problem
Carbon fibers suffer from poor compression strength and interlaminar shear strength, and tend to fail under angled tensile forces, limiting their application due to high manufacturing costs and inadequate mechanical properties from low-cost precursors.
Innovation Solution
Incorporating carbon fiber filaments with 3D graphene, either within the bulk, on the surface, or structurally coupled to the carbon fibers, along with a polymer matrix, to enhance mechanical strength, including compressive and interlaminar shear strength, and reduce manufacturing costs by using lower-cost precursors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional carbon fibers are used, then manufacturing cost is reduced, but mechanical strength (compression and interlaminar shear) is insufficient
Solution Approach 1:
The patent creates a composite carbon fiber structure by integrating 3D graphene networks within the carbon fiber matrix. This composite approach combines the high strength properties of carbon fibers with the exceptional mechanical reinforcement provided by 3D graphene, achieving improved compression and interlaminar shear strength while maintaining cost-effectiveness through the use of lower-cost precursor materials.
Solution Approach 2:
The patent modifies the structural parameters of carbon fibers by incorporating 3D graphene at various levels (bulk, surface, or structural coupling). This parameter change in the fiber architecture fundamentally enhances the mechanical properties, particularly compression and interlaminar shear strength, allowing the material to overcome the limitations of conventional carbon fibers.
2Strength
If carbon fibers are used, then tensile strength is improved, but resistance to angled forces is poor
Solution Approach 1:
The patent applies 3D graphene reinforcement at specific locations and orientations within the carbon fiber structure. By strategically placing 3D graphene networks at the bulk, surface, or structural interfaces, the material gains enhanced resistance to angled forces and delamination while preserving the high tensile strength properties of the carbon fiber backbone.
Solution Approach 2:
The composite structure of carbon fibers reinforced with 3D graphene creates a multi-scale hierarchical material that combines the directional strength of aligned carbon fibers with the isotropic reinforcement of 3D graphene networks. This composite architecture provides both high tensile strength and improved resistance to angled loading and delamination forces.
Data Source
AI summary
Carbon composites, including carbon fibers, are disclosed and exhibit unique, advantageous mechanical properties, including inter laminar shear strength, compression strength, and resistance to forces applied at angles deviating from parallel to the longitudinal axis of the overall fiber. These improvements allow use of less material while conveying improved strength in myriad practical applications, reducing overall financial cost of fabrication, distribution, and practical utilization of resulting products. These advantages are optimized via utilizing inventive fabrication techniques that incorporate carbon filaments into carbon fibers, preferably incorporating carbon filaments including three-dimensional (3D) graphene platelets into said fibers. The filaments mechanically reinforce both individual fibers, as well as compositions including multiple fibers strung together in a single cord, by “crosslinking” the individual fibers with 3D graphene ligands. The combined result of these inventive efforts includes materials exhibiting superior mechanical strength and reduced mass relative to conventional carbon fibers.