Methods for manufacturing sublaminate modules and forming composite laminated structures from the same

Patent metadata

Field	Value
Publication number	US-10589474-B2
Application number	US-201615044573-A
Country	US
Kind code	B2
Filing date	Feb 16, 2016
Priority date	Jan 12, 2011
Publication date	Mar 17, 2020
Grant date	Mar 17, 2020

Abstract

Variously configured sub-laminate modules are provided, which comprise at least a first ply and a second ply, the first ply comprising fibers extending in a first orientation, the second ply comprising fibers extending in a second orientation. The second orientation is offset relative to the first orientation, which offset defines an acute angle between the two orientations. The acute angle is less than 90 degrees and in at least one embodiment, the acute angle is approximately 25°. In certain embodiments, the acute angle further defines an unbalanced structure of the sub-laminate module. In certain embodiments, the first and second plies may be further secured relative to one another in a non-crimped configuration. Composite laminated structures formed from various embodiments of the sub-laminate modules are also provided, at least some of which may be homogenized. Various methods of manufacturing the sub-laminate modules and the composite laminated structures are also provided.

First claim

That which is claimed:

1. A method of manufacturing a sub-laminate module for use in forming a composite laminate, the method consisting of the steps of:
positioning a first ply in a first orientation such that the first ply is aligned with a primary longitudinal axis that corresponds to a primary load-bearing axis of the sub-laminate module;
positioning a second ply in a second orientation, the second orientation being offset relative to the first orientation and the primary longitudinal axis such that the relative offset corresponds to an acute angle less than 90°;
stacking the second ply adjacent the first ply, the stacking of only the first and second plies forming an unbalanced structure due to the relative offset of the second ply; and
stitching the first ply and the second ply relative to one another in a substantially non-crimped configuration,
wherein the first ply and the second ply are opposing outer ply layers of the sub-laminate module.

2. The method of claim 1 , wherein during the positioning steps:
the first orientation is also a machine direction of the sub-laminate module; and
the acute angle is within a range of from about 10° to about 40° from the machine direction.

3. The method of claim 2 , wherein the acute angle is about 25°.

4. A method of manufacturing a sub-laminate module for use in forming a composite laminate, said method consisting of the steps of:
spreading a first tow comprising a plurality of fibers to form a first ply layer;
spreading a second tow comprising a plurality of fibers to form a second ply layer;
positioning the plurality of fibers of the first tow in a first orientation, such that the first ply layer is aligned with a primary longitudinal axis that corresponds to a primary load-bearing axis of the sub-laminate module;
positioning the plurality of fibers of the second tow in a second orientation, the second orientation being offset relative to the first orientation and the primary longitudinal axis such that the relative offset corresponds to and defines an acute angle there between, the acute angle being less than 90°;
stacking the second ply layer and the first ply layer adjacent one another, the stacking forming an unbalanced structure of the sub-laminate module due to the relative offset of the second ply layer; and
stitching the first ply layer and the second ply layer relative to one another in a non-crimped configuration,
wherein the first ply and the second ply are opposing outer ply layers of the sub-laminate module.

5. The method of claim 4 , wherein during the positioning steps:
the first orientation is also a machine direction of the sub-laminate module; and
the acute angle is within a range of from about 10° to about 40°.

6. The method of claim 5 , wherein the acute angle is about 25°.

7. A method of manufacturing a composite laminated structure, said method comprising the steps of:
forming a plurality of sub-laminate modules, each module consisting of:
a first ply comprising fibers extending in a first orientation such that the first ply is aligned with a primary longitudinal axis that corresponds to a primary load-bearing axis of each of the plurality of sub-laminate module;
a second ply comprising fibers extending in a second orientation, the second orientation being offset relative to the first orientation and the primary longitudinal axis; and
an acute angle defined by the relative offset between the first orientation and the second orientation, the acute angle being less than 90° and defining an unbalanced structure of the sub-laminate module;

stacking the plurality of sub-laminate modules adjacent one another;
securing respective ones of the plurality of sub-laminate layers relative to one another in a substantially non-crimped configuration; and
sequentially laying up each of the respectively secured plurality of sub-laminate layers so as to form the composite laminated structure,
wherein the first ply and the second ply of each of the plurality of sub-laminate modules are opposing outer ply layers of their respective sub-laminate module.

8. The method of claim 7 , wherein each of the plurality of sub-laminate modules has a thickness within a range of from about 0.040 millimeters to about 0.080 millimeters.

9. The method of claim 7 , wherein each of the fibers contained within each of the plurality of sub-laminate modules are oriented in one or the other of only the first orientation or the second orientation.

10. The method of claim 7 , further comprising, subsequent to the step of sequentially laying up the respectively secured plurality of sub-laminate layers so as to form the composite laminated structure, the step of:
sequentially dropping one or more of the respectively laid up plurality of sub-laminate modules so as to form a tapered surface on the composite laminated structure,
wherein the sequential dropping of the one or more sub-laminate modules does not alter the material composition of the composite laminated structure.

11. The method of claim 7 , wherein during the forming step:
the first orientation is also a machine direction of the sub-laminate module; and
the acute angle is within a range of from about 10° to about 40°.

12. The method of claim 11 , wherein the acute angle is about 25°.

13. The method of claim 7 , where each of the plurality of sub-laminate modules, during stacking, is oriented, as a whole, in the first orientation.

14. The method of claim 13 , wherein the orientation of each of the plurality of sub-laminate modules facilitates a one-axis layup process.

15. The method of claim 7 , wherein the plurality of sub-laminate modules comprise sixteen sub-laminate modules, each stacked and substantially secured relative to one another so as to form a homogenous composite material.

16. The method of claim 15 , wherein the substantially homogenous composite material has a thickness of about 2.0 millimeters.

17. The method of claim 7 , further comprising, prior to the step of stacking each of the plurality of sub-laminate modules adjacent one another, the step of:
folding each of the plurality of sub-laminate modules in half on itself, relative to an axis extending in the second orientation, such that:
the first ply forms two first ply layers; and
the second ply forms two second ply layers,
wherein both of the two second ply layers comprise fibers extending in the second orientation, one of the two first ply layers comprises fibers extending in a third orientation, the third orientation being opposite that of the first orientation relative to the second orientation.

18. The method of claim 17 , wherein the plurality of sub-laminate modules comprise eight sub-laminate modules, each stacked and substantially secured relative to one another so as to form a homogenous composite material.

19. The method of claim 18 , wherein the substantially homogenous composite material has a thickness of about 2.0 millimeters.

20. The method of claim 7 , further comprising, prior to the step of stacking each of the plurality of sub-laminate modules adjacent one another, the step of rotating at least a first subset of the plurality of sub-laminate modules 90 degrees relative to the first orientation.

21. The method of claim 20 , wherein the orientation of each of the plurality of sub-laminate modules within the first subset facilitates a two-axis layup process.

Assignees

• Cie Chomarat
• Univ Leland Stanford Junior

Inventors

• Tsai Stephen W
• Cognet Michel
• Sanial Philippe

Classifications

• B29C70/202 Primary

  arranged in parallel planes or structures of fibres crossing at substantial angles, e.g. cross-moulding compound [XMC] (B29C70/207 takes precedence) · CPC title

• B32B5/06

  characterised by a fibrous {or filamentary} layer {mechanically connected, e.g. by needling} to another layer, e.g. of fibres, of paper · CPC title

• B29K2307/04

  Carbon · CPC title

• B32B5/28

  impregnated with or embedded in a plastic substance {(not used)} · CPC title

• B32B5/12

  characterised by the relative arrangement of fibres or filaments of {different layers, e.g. the fibres or filaments being parallel or perpendicular to each other} · CPC title