Twisted Carbon Yarn Composite Resin Flow
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Solution Overview
Problem
Current reinforcing materials for composite parts, particularly in the aeronautical industry, face challenges with high fragility after polymerization, low impact resistance, and difficulties in achieving high transverse permeability and electrical conductivity, especially when using unidirectional carbon wire layers, which are also cumbersome to produce and handle.
Innovation Solution
A unidirectional reinforcing sheet made from twisted carbon wires with a specific twist pattern, combined with a porous polymer layer, enhancing transverse cohesion and permeability while maintaining handling ease, and featuring a balanced mix of S and Z twist wires to improve electrical conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If unidirectional carbon wire layers are used to reduce weight, then weight is reduced, but transverse permeability and electrical conductivity deteriorate
Solution Approach 1:
The patent combines unidirectional carbon wire layers with woven carbon fabric layers to create a hybrid composite structure. The unidirectional layers provide weight reduction and longitudinal strength, while the woven layers provide transverse permeability and electrical conductivity, resolving the contradiction between weight reduction and maintaining transverse properties.
Solution Approach 2:
The patent applies different material configurations to different regions of the composite structure. Unidirectional carbon wire layers are used where weight reduction is critical, while woven carbon fabric layers are used where transverse permeability and electrical conductivity are needed, allowing local optimization of properties.
2Weight of moving object
If unidirectional carbon wire layers are used to reduce weight, then weight is reduced, but electrical conductivity deteriorates
Solution Approach 1:
The patent creates a composite structure combining unidirectional carbon wire layers with woven carbon fabric layers. The woven layers provide continuous conductive pathways in transverse directions while the unidirectional layers maintain weight reduction, thus improving overall electrical conductivity without sacrificing weight benefits.
3Productivity
If thermosetting resin with low viscosity is used for injection, then resin flow is improved, but impact resistance deteriorates
Solution Approach 1:
The patent incorporates a thermoplastic porous layer within the composite structure. This layer acts as an energy-absorbing zone that improves impact resistance by preventing crack propagation through the thermosetting matrix, while the low-viscosity thermosetting resin continues to flow effectively during injection.
Solution Approach 2:
The thermoplastic porous layer provides a controlled porous structure that absorbs impact energy through deformation and fracture of the porous framework. This porous zone interrupts crack propagation paths in the thermosetting resin, thereby improving impact resistance while maintaining resin flow characteristics.
4Strength
If thermoplastic porous layer is added to improve impact resistance, then impact resistance is improved, but handling ease deteriorates
Solution Approach 1:
The patent integrates the thermoplastic porous layer with the unidirectional carbon wire layers in a combined composite structure. This merging allows the thermoplastic layer to provide impact resistance while the carbon wire layers provide structural integrity and handling ease, as the carbon wires act as a rigid framework that maintains dimensional stability during handling.
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 provides reinforcing materials with improved mechanical properties, enhanced resin flow, and increased electrical conductivity, facilitating high-speed production of composite parts with reduced expansion and improved deposition resistance.
Implementation Method 1
a series of individually twisted carbon threads, according to a twist adapted to ensure the diffusion of the injected or infused resin
Implementation Method 2
associated on one of its faces or on each of its faces with a porous polymeric layer
Data Source
Figure 1A~1B
Figure 1C~2
Figure 3~4
AI summary
The reinforcing material comprises a unidirectional reinforcing ply (2) formed of one or more carbon yarns (3) and associated on one at least of its faces, preferably on each of its faces, with a porous polymeric layer (4, 5), where the polymeric part of the reinforcing material represents from 0.5% to 10% of its total mass and preferably from 2% to 6% of its total mass, characterized in that said carbon yarns (3) are individually twisted with a twist of 3 to 15 turns/m, preferably from 6 to 12 turns/m, and comprise at least one S-twist yarn and at least one Z-twist yarn, according to a selection in accordance with claim 1.