Printing patterns onto composite laminates
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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 is developed 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 corrosion resistance, using techniques like inkjet printing or robotic deposition 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 bulk random distribution of thermoplastic material to localized deposition at specific positions within the composite layup. The printing device deposits modifier material precisely at targeted locations, providing local enhancement of interlaminar strength while maintaining control over the resin-fiber interface. This resolves the contradiction by achieving both improved mode II strength and precise interface control through spatially selective material placement.
2Strength
If tougheners are added to the resin to address low mode II interlaminar shear strength, then interlaminar strength is improved, but resin viscosity increases which inhibits resin flow during infusion
Solution Approach 1:
The patent applies segmentation by dividing the toughening function from the resin matrix itself. Instead of adding tougheners throughout the entire resin volume, the modifier material is deposited as discrete localized regions within the composite layup. This segmentation allows interlaminar strength enhancement without increasing the overall resin viscosity, as the toughening function is provided by distributed discrete particles rather than bulk resin modification.
3Reliability
If metallic meshes or foils are added across the surface of composite plies to address low electrical conductivity, then electrical conductivity is improved, but cost, complexity, and production time increase
Solution Approach 1:
The patent applies merging by combining the electrical conductivity function with the existing composite laminate structure. The modifier material deposited within the layup serves dual purposes: enhancing interlaminar strength and providing electrical conductivity pathways. This eliminates the need for separate metallic meshes or foils, reducing manufacturing complexity while achieving both mechanical and electrical performance goals through a single integrated approach.
4Reliability
If a separate layer of fiberglass 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 designing the modifier material to perform multiple functions simultaneously. The same material deposited within the composite layup provides both mechanical reinforcement (improving interlaminar strength) and corrosion protection at metal-composite interfaces. This multi-functional approach eliminates the need for separate barrier ply layers, reducing manufacturing complexity while achieving both structural and protective functions through a single material system.
Data Source
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.