Three-dimensional filament network for a composite laminate

Patent metadata

Field	Value
Publication number	US-10081722-B2
Application number	US-201414224278-A
Country	US
Kind code	B2
Filing date	Mar 25, 2014
Priority date	Mar 25, 2014
Publication date	Sep 25, 2018
Grant date	Sep 25, 2018

Abstract

A method and apparatus for forming a composite structure. The apparatus comprises a fiber layer. The fiber layer comprises a plurality of fiber bundles and a number of filler portions. The plurality of fiber bundles has a number of spaces between the plurality of fiber bundles. A number of filler is comprised of discontinuous filaments that substantially fill the number of spaces between the plurality of fiber bundles.

First claim

What is claimed is:

1. A composite structure comprising:
a number of fiber layers, a filament network associated with the number of fiber layers, and a resin;
a number of interlayer filler portions comprised of discontinuous filaments and located between the number of fiber layers;
wherein each fiber layer in the number of fiber layers includes a plurality of fiber bundles having a number of spaces between the plurality of fiber bundles;
wherein the filament network comprises a number of filler portions comprised of discontinuous filaments that substantially fill the number of spaces between the plurality of fiber bundles;
wherein the discontinuous filaments do not extend an entire length or width of the composite structure; and
wherein the number of fiber layers comprise at least two fiber layers;
wherein the number of fiber layers are laid up to form a reinforcement layup;
wherein the resin is infused within the number of fiber layers;
wherein the resin binds the number of fiber layers and the filament network associated with the number of fiber layers together; and
wherein the discontinuous filaments are selected from a group consisting of silica fibers, polyamide fibers, polyether ketone fibers, polyester fibers, polyether sulfone fibers, polyimide fibers, and polyurethane fibers.

2. The composite structure of claim 1 further comprising:
a number of outer filler portions comprised of the discontinuous filaments and located around the number of fiber layers.

3. The composite structure of claim 1 , wherein the number of filler portions form a portion of the filament network in the reinforcement layup.

4. The composite structure of claim 3 , wherein the filament network provides open spaces through which at least one of the resin or air are allowed to flow.

5. The composite structure of claim 3 , wherein the filament network provides open spaces through which at least one of air, undesired gases, or excess moisture are allowed to be removed.

6. The composite structure of claim 1 further comprising:
a number of filament layers positioned relative to the plurality of fiber bundles to form the number of filler portions, wherein a filament layer in the number of filament layers is selected from one of a nonwoven mat, a veil, a web, a sheet, and a tape.

7. The composite structure of claim 1 , wherein the number of filler portions further comprises:
a binding material configured to hold the discontinuous filaments together, the number of filler portions to the plurality of fiber bundles, and the plurality of fiber bundles together in response to at least one of heat, pressure, or a chemical reaction being applied to the binding material.

8. The composite structure of claim 1 , wherein the discontinuous filaments include filaments of at least one of different sizes, different diameters, different cross-sectional shapes, or different types.

9. The composite structure of claim 1 , wherein the discontinuous filaments are configured to improve a notch toughness of the composite structure and a resistance of the composite structure to a number of inconsistencies.

10. A composite structure comprising:
a number of fiber layers, wherein each fiber layer in the number of fiber layers includes a plurality of fiber bundles having a number of spaces between the plurality of fiber bundles;
a number of interlayer filler portions comprised of discontinuous filaments and located between the number of fiber layers;
a filament network comprising discontinuous filaments that substantially fill the number of spaces between the plurality of fiber bundles associated with the number of fiber layers and that are configured to improve a notch toughness of the composite structure and a resistance of the composite structure to a number of undesired inconsistencies; and
a resin that binds the number of fiber layers and the filament network associated with the number of fiber layers together;
wherein the discontinuous filaments do not extend an entire length or width of the composite structure; and
wherein the number of fiber layers comprise at least two fiber layers; wherein the number of fiber layers are laid up to form a reinforcement layup;
wherein the resin is infused within the number of fiber layers;
wherein the resin binds the number of fiber layers and the filament network associated with the number of fiber layers together; and
wherein the discontinuous filaments are selected from a group consisting of silica fibers, polyamide fibers, polyether ketone fibers, polyester fibers, polyether sulfone fibers, polyimide fibers, and polyurethane fibers.

11. The composite structure of claim 10 , wherein the filament network comprises:
a number of filler portions that fill the number of spaces between the plurality of fiber bundles in each of the number of fiber layers, wherein a filler portion in the number of filler portions comprises:
a binding material configured to hold the discontinuous filaments together and bind the discontinuous filaments to at least one of the plurality of fiber bundles.

12. The composite structure of claim 11 , wherein the composite structure is one of a fully cured composite structure, a partially cured composite structure, and an uncured composite structure.

13. The composite structure of claim 10 , wherein the discontinuous filaments are configured to improve a notch toughness of the composite structure and a resistance of the composite structure to a number of inconsistencies.

14. A method for forming a composite structure, the method comprising:
positioning a number of filament layers comprised of discontinuous filaments relative to a plurality of fiber bundles to form a fiber layer having a number of filler portions that substantially fill a number of spaces between the plurality of fiber bundles;
positioning a number of interlayer filler portions comprised of the discontinuous filaments and located between a number of fiber layers; and
forming a reinforcement layup for the composite structure using the fiber layer;
wherein the discontinuous filaments do not extend an entire length or width of the composite structure;
wherein the number of fiber layers are laid up to form a reinforcement layup;
wherein a resin is infused within the number of fiber layers;
wherein the resin binds the number of fiber layers and a filament network associated with the number of fiber layers together; and
wherein the discontinuous filaments are selected from a group consisting of silica fibers, polyamide fibers, polyether ketone fibers, polyester fibers, polyether sulfone fibers, polyimide fibers, and polyurethane fibers.

15. The method of claim 14 further comprising:
integrating a resin with the reinforcement layup to form the composite structures.

16. The method of claim 14 , wherein forming the fiber layer using the plurality of fiber bundles and the number of filament layers comprises:
positioning a filament layer relative to a fiber bundle such that the filament layer forms an S-shape.

17. The method of claim 14 , wherein forming the fiber layer using the plurality of fiber bundles and the number of filament layers comprises:
wrapping a filament layer in the number of filament layers around an outer surface of a fiber bundle in the plurality of fiber bundles such that at least one of the number of filament layers covers an entirety of the outer surface of the fiber bundle or leaves an exposed portion of the outer surface of the fiber bundle.

18. The method of claim 14 , wherein forming the fiber layer using the plurality o

Assignees

• Boeing Co

Inventors

• Meure Samuel James
• Howe Christopher Alan
• Wilson Thomas

Classifications

• B29C70/021

  Combinations of fibrous reinforcement and non-fibrous material · CPC title

• B29C70/22 Primary

  oriented in at least two directions forming a two-dimensional [2D] structure · CPC title

• B29L2009/00

  Layered products · CPC title

• B29C70/081

  Combinations of fibres of continuous or substantial length and short fibres · CPC title

• B29C70/30 Primary

  Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core · CPC title