Twisted Carbon Reinforcement Web for Resin Flow and Conductivity

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Solution Overview

Problem

Existing composite materials used in aerospace and other industries face challenges with low impact resistance due to brittle thermosetting resins, complex application processes for micro-perforated materials, and insufficient transverse permeability and electrical conductivity, which are not suitable for high production rates and stringent mechanical requirements.

Innovation Solution

A unidirectional reinforcing web made of individually twisted carbon yarns, associated with thermoplastic nonwoven fiber layers, provides improved transverse permeability and electrical conductivity without micro-perforations, using a twist of 3 to 15 turns/m, and a grammage of 126 to 280 g/m2, ensuring efficient resin diffusion and cohesion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If micro-perforated materials are used to improve transverse permeability and electrical conductivity, then these properties are enhanced, but the application process becomes more complex

Engineering Contradiction:

Improvetransverse electrical conductivityVSAvoidapplication process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent changes the structural parameters of the reinforcing yarns by applying twists with specific rates (3 to 15 turns per meter) and directions (S-twist and Z-twist). This structural modification naturally creates transverse channels for resin diffusion and electrical conductivity pathways without requiring micro-perforations, thereby maintaining reliability while reducing application complexity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite structure by combining carbon yarns with thermoplastic nonwoven fiber layers. This composite approach provides both the electrical conductivity needed for lightning strike protection and the permeability for resin infusion, eliminating the need for separate micro-perforated materials and simplifying the overall application process

Inventive Principle:

Principle #40Composite materials

2Reliability

If twisted carbon yarns are used to improve resin diffusion, then transverse permeability is enhanced, but yarn stability during application may be reduced

Engineering Contradiction:

Improvetransverse permeabilityVSAvoidyarn stability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent optimizes the twist rate parameter within a specific range (3 to 15 turns per meter) and uses alternating S-twist and Z-twist directions. This controlled parameter change creates sufficient transverse channels for resin diffusion while maintaining yarn stability during handling and application, resolving the contradiction between permeability and stability

Inventive Principle:

Principle #35Parameter changes

3Strength

If thermosetting resins are used to achieve high strength, then mechanical properties are improved, but impact resistance decreases due to brittleness

Engineering Contradiction:

Improvemechanical strengthVSAvoidimpact resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent employs a composite material system combining carbon fiber reinforcements with thermoplastic matrix resin. The thermoplastic matrix provides ductility and impact resistance, while the carbon fiber reinforcement maintains high mechanical strength. This composite approach resolves the contradiction between strength and impact resistance by leveraging the complementary properties of different materials

Inventive Principle:

Principle #40Composite materials

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 solution enhances impact resistance, reduces application complexity, and maintains high production rates while meeting aerospace industry standards for mechanical properties and electrical conductivity.

Implementation Method 1

having a twist suitable for ensuring the diffusion of the injected or infused resin during production of the composite part

Methodology Applied

Scientific EffectDiffusion: Diffusion

Implementation Method 2

The resin is injected or infused by means of a temperature pressure differential

Methodology Applied

Scientific EffectPressure differential flow: Pressure Gradient

Implementation Method 3

after all the required amount of resin is contained in the preform, the assembly is brought to a higher temperature to perform the polymerization/cross-linking cycle and thus cause it to harden

Methodology Applied

Scientific EffectPolymerization: Photopolymerisation

Data Source

PatentUS12606941B2Reinforcing material comprising twisted carbon threads for the manufacture of composite parts, and corresponding methods and use

Publication Date: 2026.04.21 HEXCEL REINFORCEMENTS SAS

AI summary

The invention relates to a reinforcing material (1) consisting of a unidirectional reinforcing web (2) formed of one or more carbon reinforcing yarns (3), associated on each of its faces with a veil of polymeric fibers (4, 5) chosen from among nonwoven materials, the polymeric portion of the reinforcing material representing from 0.5% to 10% of the total weight of the reinforcing material (1), and preferably from 2% to 6% of its total weight, said unidirectional reinforcing web (2) comprising one or a series of reinforcing yarns (3) individually twisted having a twist of 3 turns/m to 15 turns/m, preferably from 6 turns/m to 12 turns/m.