Thin-Ply AFP Tape Matrix Composition for Edge Stability
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Solution Overview
Problem
Existing automated fiber placement (AFP) methods face challenges in processing thin-ply carbon fiber reinforced plastics (CFRP) tapes, which are prone to edge quality issues, curling, and microcracking due to handling and tension, especially in cryogenic environments like liquid hydrogen storage tanks.
Innovation Solution
A tape structure with a thermosetting polymer matrix composition that includes specific monomers, oligomers, and additives, allowing the matrix to be solid at room temperature and softenable at higher temperatures, ensuring dimensional stability and tackiness during placement, along with a fiber placement device for precise handling and compaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the layer thickness of CFRP tapes is reduced to enhance performance in cryogenic environments, then the weight and performance of liquid hydrogen storage tanks are improved, but the tapes become more sensitive to processing damage such as edge quality deterioration and microcracking
Solution Approach 1:
The patent modifies the polymer matrix composition by incorporating specific plasticizers and adjusting the resin system to reduce the glass transition temperature and increase flexibility. This allows thin-ply tapes to maintain adequate toughness and resistance to processing damage while achieving the required weight reduction for cryogenic tank applications
Solution Approach 2:
The patent uses composite material strategies by combining multiple resin systems with plasticizers and toughening agents to create a polymer matrix that provides both the flexibility needed for thin-ply handling and the structural integrity required for cryogenic performance
2Reliability
If the number of tape layers is increased to prevent microcracking in cryogenic environments, then the structural integrity of the tank is improved, but the processing complexity and handling difficulty increase
Solution Approach 1:
By modifying the polymer matrix properties through plasticizer addition and resin system adjustment, the patent enables thin-ply tapes to be handled more easily during processing, reducing the operational complexity despite increasing the number of layers required for microcrack prevention in cryogenic service
3Manufacturing precision
If the polymer matrix is made softer to improve tape flexibility during handling, then the edge quality and laminate homogeneity are improved, but the tape becomes more prone to curling and deformation during processing
Solution Approach 1:
The patent carefully balances the polymer matrix properties by selecting plasticizers and resin combinations that provide sufficient softness for good edge quality and laminate homogeneity, while maintaining adequate dimensional stability to prevent excessive curling and deformation during automated fiber placement processing
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
Enables high-quality laminate manufacturing with reduced layer thickness and enhanced edge quality, preventing microcracking and undulations, facilitating automated processing of thin-ply tapes for cryogenic applications.
Implementation Method 1
The polymer matrix is configured to be solid or semi-solid in a first temperature range and configured to soften in a second temperature range different from the first temperature range
Implementation Method 2
The at least one reactive chain extender comprised in the composition catalyses the reaction between the matrix resin and the curing agent in terms of time and curing temperature
Data Source
AI summary
A tape structure of a tape for manufacturing a composite structure includes a layer of unidirectional pre-impregnated dry fibers embedded in a polymer matrix having a composition of 20% and 50%, or between 25% and 40% by weight of the polymer matrix of a first monomer or oligomer, between 30% and 60%, or between 35% and 40% by weight of the polymer matrix of a second monomer or oligomer, between 4% and 25%, or between 4% and 7% by weight of the polymer matrix of a curing agent, between 0.5% and 5%, or 0.8% and 1.5% by weight of the polymer matrix of at least one reactive chain extender, and an additive. The polymer matrix can be solid or semi-solid in a first temperature range and softened in a second temperature range different from the first temperature range. An automated fiber placement device, method and composite structure are disclosed.