VACNT Interleave Lamination for Easier Composite Handling
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Solution Overview
Problem
The existing methods for integrating vertically aligned carbon nanotubes (VACNT) into laminated composite materials face challenges related to transportation and handling costs, safety precautions, and equipment requirements, which limits the widespread use and acceptance of VACNT in the manufacturing process of these materials.
Innovation Solution
The method involves depositing VACNT arrays onto a thin polymer film, preferably thermoplastic, which serves as a support for handling and lamination onto the preimpregnated fiber plies, ensuring compatibility and effective integration of the polymer film support for handling and lamination onto the fiber plies, allowing for safe transportation and handling without specialized equipment or safety precautions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If VACNT arrays are integrated directly into laminated composite materials using existing methods, then the mechanical properties are enhanced, but the transportation and handling costs increase, and specialized equipment and safety precautions are required
Solution Approach 1:
The patent introduces a polymer film as an intermediary carrier that holds the VACNT arrays during transportation and handling. This mediator allows the VACNT arrays to be safely transported and handled without requiring specialized equipment or safety precautions, while still enabling their integration into the composite material structure to enhance mechanical properties
Solution Approach 2:
The invention segments the VACNT arrays from the composite manufacturing process by providing them on a separate polymer film substrate. This segmentation allows the VACNT arrays to be independently manufactured, transported, and stored on the film, then integrated into the composite structure only when needed, reducing handling complexity and costs
2Ease of operation
If VACNT arrays are provided on a polymer film for easier handling, then the transportation and handling become safer and more efficient, but additional materials and processing steps are introduced
Solution Approach 1:
The patent merges the VACNT arrays with the polymer film into a single integrated unit that is laminated onto the composite structure in one step. This combining eliminates the need for separate handling and integration steps, as the VACNT arrays on the film are applied together with the film itself during the lamination process, maintaining ease of operation without adding processing complexity
3Stability of the object's composition
If the polymer film support is used for VACNT arrays, then the compatibility with thermosetting matrices is improved, but the film must be removed or dissolved without leaving detrimental interfaces
Solution Approach 1:
The patent utilizes parameter changes in the polymer film's physical state during processing. The film is provided in a solid, stable form for handling and lamination, then transformed during curing - either being removed entirely or dissolving into the thermosetting matrix - to ensure compatibility without leaving detrimental interfaces in the final composite structure
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
This approach ensures safe and efficient integration of VACNT into laminated composites, enhancing mechanical properties by bridging fibers without increasing interply thickness or introducing detrimental interfaces, thus improving the composite material's performance.
Implementation Method 1
said polymer film being melted at an elevated temperature during said consolidation step and dissolving in said thermosetting polymer
Implementation Method 2
comprising an array of vertically aligned carbon nanotubes, abridged VACNT, deposited onto a polymer film
Data Source
Figure 1-1a~1-2
Figure 1-3~1-4
Figure 1-5~1-6
AI summary
Method for manufacturing a composite article comprising a plurality of plies, wherein a ply comprising an array of vertically aligned carbon nanotubes, abridged VACNT, deposited onto a polymer film is deposited onto a ply of fibers which are possibly preimpregnated with a thermosetting resin.