Removable Support Tape Structure for Thin-Ply CFRP Placement
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Solution Overview
Problem
Automated fiber placement methods face challenges in processing thin-ply carbon fiber reinforced plastics (CFRP) tapes, particularly in cryogenic environments, due to issues such as curling, flipping, and edge quality impairment, which lead to microcracking and reduced laminate homogeneity.
Innovation Solution
A tape structure with a removable support layer, typically a polymer-based liner, is used to stabilize the second layer comprising thin-ply CFRP, preventing curling and edge impairment during processing, and a fiber placement device with integrated peeling and winding mechanisms to ensure precise placement and separation of layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If thin-ply CFRP tapes with thickness less than 100 μm are used to manufacture lightweight structures, then weight reduction and enhanced performance in cryogenic environments are achieved, but the tapes become sensitive to contact at edges, causing curling, flipping, and edge quality impairment during processing
Solution Approach 1:
A support layer is introduced as an intermediary element between the thin-ply CFRP tape and the processing environment. This support layer prevents direct contact between the fragile thin tape edges and processing surfaces, thereby eliminating edge quality impairment, curling, and flipping while allowing the thin tape to be processed successfully
Solution Approach 2:
The tape structure is segmented into multiple functional layers: the thin-ply CFRP functional layer and the support layer. This segmentation allows each layer to perform its specific function - the CFRP layer provides the lightweight structural performance while the support layer handles the mechanical protection during processing
2Device complexity
If thin-ply CFRP tapes are processed without a support layer, then the manufacturing process is simpler, but the tapes curl, flip, and warp during handling over spools in the automated fiber placement device
Solution Approach 1:
The support layer acts as a mediator that provides mechanical stability to the thin-ply CFRP tape during handling and processing. It prevents curling, flipping, and warping by providing a rigid backbone while being removable after placement, thus maintaining tape stability without permanently complicating the final structure
3Ease of operation
If standard thickness prepreg materials (125 to 250 μm) are used, then processing is easier and edge quality is maintained, but the laminate structure becomes thicker and less suitable for cryogenic applications requiring thinner layers to prevent microcracking
Solution Approach 1:
The laminate structure is segmented into multiple thin-ply layers rather than using a single thick layer. Each layer has thickness less than 100 μm, which prevents microcracking in cryogenic environments while the cumulative effect provides the required structural performance
Solution Approach 2:
The support layer serves as a temporary intermediary that enables processing of these ultra-thin layers (less than 100 μm) that would otherwise be too fragile to handle, allowing the manufacturing process to accommodate the thickness requirements for cryogenic application reliability
4Manufacturing precision
If tapes with sticky or tacky resins are used to ensure proper bonding, then laminate homogeneity is improved, but the tapes stick to processing surfaces and rollers, causing processing difficulties
Solution Approach 1:
The support layer functions as a protective intermediary barrier between the sticky/tacky resin in the thin-ply CFRP tape and the processing surfaces. It prevents adhesion to rollers and processing equipment while allowing the resin to maintain its bonding function, thus enabling processing of tapes with sticky resins
Data Source
AI summary
A tape structure for use in automated fiber placement method to manufacture a composite structure includes a first layer and a second layer connected to the first layer with the first layer being configured as a support layer and the second layer being configured as a pre-impregnated layer, wherein the first layer is removable from the second layer during or after placement of the second layer on the composite structure to be manufactured, an automated fiber placement device an automated fiber placement method and a composite structure manufactured in the method.