Printed Pattern Composite Fibers for Interlaminar Strength and Tack
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Solution Overview
Problem
Conventional composite laminates face issues such as separation at the resin-fiber interface, low interlaminar shear strength, low electrical conductivity, and susceptibility to corrosion, which affect their performance and manufacturing complexity.
Innovation Solution
A composite structure where a second material is systematically deposited onto reinforcing filaments in a printed pattern, altering properties like crack resistance, interlaminar shear strength, electrical conductivity, and tack, using techniques like inkjet printing or extrusion to control the length, width, and thickness of the deposited material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermoplastic material is randomly distributed in bulk throughout a composite layup, then mode II interlaminar strength is improved, but mode I interlaminar strength remains low and crack propagation is not prevented
Solution Approach 1:
The patent applies local quality by transitioning from random bulk distribution to targeted placement of thermoplastic material. The printed circuit board incorporates thermoplastic material at specific locations where crack-arresting features are needed, such as at the resin-fiber interface and within fiber tows. This localized approach improves mode I interlaminar strength and prevents crack propagation while maintaining mode II interlaminar strength enhancements.
2Reliability
If metallic meshes or foils are added across the surface of composite plies to improve electrical conductivity, then electrical conductivity is enhanced, but cost, complexity, and production time increase
Solution Approach 1:
The patent merges the electrical conductivity function with the existing printed circuit board traces. Instead of adding separate metallic meshes or foils, the thermoplastic material is integrated into the same printing process that creates the circuit traces. This combination achieves enhanced electrical conductivity while eliminating the need for additional metallic layers, thereby reducing manufacturing complexity and production time.
3Reliability
If fiberglass layer is added at the interface between composite laminate and metallic part to prevent corrosion, then corrosion resistance is improved, but cost and manufacturing complexity increase
Solution Approach 1:
The patent applies universality by making the thermoplastic material perform multiple functions simultaneously. At the interface between composite laminate and metallic parts, the thermoplastic material provides both crack-arresting features and corrosion protection. This multi-functional approach eliminates the need for separate fiberglass barrier plies, thereby reducing manufacturing complexity while maintaining enhanced corrosion resistance.
4Strength
If epoxy binders or nylons are added to dry fiber composite plies to improve tack, then tack is enhanced, but the range of temperatures and pressures required for ply stacking is limited
Solution Approach 1:
The patent applies parameter changes by utilizing the inherent temperature-dependent properties of thermoplastic material. The thermoplastic material is applied in a solid state at room temperature to provide immediate tack for ply stacking. During subsequent curing at elevated temperatures, the thermoplastic material transitions to a molten state, maintaining tack and enabling ply consolidation across a broad range of temperatures and pressures, thus overcoming the limitations of epoxy binders or nylons.
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 method enhances crack resistance, interlaminar shear strength, electrical conductivity, and corrosion resistance while improving tack, thereby stabilizing the composite structure and reducing manufacturing complexity.
Implementation Method 1
using techniques like inkjet printing or extrusion to control the length, width, and thickness of the deposited material
Implementation Method 2
using techniques like inkjet printing or extrusion to control the length, width, and thickness of the deposited material
Data Source
Figure 1
AI summary
A composite fiber may include at least one reinforcing filament formed of a first material. A second material maybe systematically deposited in a printed onto the at least one reinforcing filament such that at least one of a length, a width, and a thickness of the second material varies across a surface of the at least one reinforcing filament. The printed pattern may alter one or more properties of a composite structure containing the composite fiber.