Segmented Prepreg Plies for Complex Composite Geometry Manufacturing
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Solution Overview
Problem
Current composite materials face challenges in optimizing costs and producing parts with complex geometries while maintaining high mechanical properties, as traditional methods require significant implementation times and result in scraps that are difficult to reuse, especially in the aeronautics sector.
Innovation Solution
The development of discrete segmented multilayer mattresses composed of staggered unidirectional fibers embedded in a resin matrix, allowing for the direct use of scraps and enabling the production of high-performance composite parts with complex geometries through innovative cutting techniques that preserve the integrity of the fibers and resin interface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If long fibers are used to maintain high mechanical properties, then strength and stiffness are improved, but the ability to manufacture parts with complex geometries deteriorates
Solution Approach 1:
The continuous fiber reinforcement is divided into segments of controlled length (at least 10 mm, preferably at least 50 mm or even at least 100 mm) while maintaining continuity within each segment. This segmentation allows the fibers to be processed and molded into complex geometries while preserving sufficient fiber length to maintain high mechanical properties through effective stress transfer from the matrix to the fibers.
2Strength
If standard composite materials with carbon fabrics or sheets are used, then mechanical performance is improved, but production time and cost increase
Solution Approach 1:
The reinforcement is pre-impregnated with resin in a controlled manner to form a paste-like composition with specific viscosity characteristics. This preliminary impregnation allows the material to be directly molded into complex parts without requiring additional processing steps such as separate resin application, thereby reducing production time while maintaining mechanical performance.
Solution Approach 2:
The resin viscosity is specifically controlled to be within the range of 10 to 1000 Pa.s at processing temperature. This parameter optimization enables the impregnated fibers to flow and conform to complex mold geometries during injection molding while maintaining sufficient resin content to ensure proper fiber bonding and mechanical properties.
3Ease of manufacture
If fibers are cut to enable complex geometry production, then ease of manufacture is improved, but fiber length and mechanical properties deteriorate
Solution Approach 1:
The reinforcement is divided into segments of controlled length (at least 10 mm, preferably at least 50 mm or even at least 100 mm) while maintaining continuity within each segment. This segmentation allows the fibers to be processed and molded into complex geometries while preserving sufficient fiber length to maintain high mechanical properties through effective stress transfer from the matrix to the fibers.
Data Source
Figure 1~2a
Figure 3~5
Figure 6~8a
AI summary
The invention relates to a discrete segmented pre-preg ply 8, a method for manufacturing same, a discrete segmented multilayer pad 80 manufactured by stacking discrete segmented pre-preg plies 8 and a method for manufacturing composite parts 90 from discrete segmented multilayer pads. The discrete segmented pre-preg ply 8 comprises: • a discrete segmented pre-preg layer 3ds having a thickness and consisting of unidirectional fibres arranged parallel to the longitudinal direction (D), the fibres being embedded in a resin matrix, and • a discrete anti-adhesive liner 2d applied to one face of the discrete segmented pre-preg layer 3ds, wherein only the discrete segmented layer 3ds comprises segments 4 which are cut along its entire thickness and arranged in staggered rows.