Method for limiting interlaminar fatigue in composite laminate and a component incorporating the same

Patent metadata

Field	Value
Publication number	US-10870265-B2
Application number	US-202016781355-A
Country	US
Kind code	B2
Filing date	Feb 4, 2020
Priority date	Jul 14, 2014
Publication date	Dec 22, 2020
Grant date	Dec 22, 2020

Abstract

In some embodiments, a method of manufacturing composite laminate, including providing a first fibrous material having a plurality of fibers, providing a second fibrous material having a plurality of fibers, disposing the fibers of the first fibrous material in a first polymeric matrix, disposing the fibers of the second fibrous material in a second polymeric matrix, laying up a plurality of the first fibrous material on a rigid structure, laying up the second fibrous material on the rigid structure, wherein the first fibrous material is in contact with the second fibrous material, curing the first polymeric matrix, creating a plurality of baseline layers from the plurality of first fibrous material and the first polymeric matrix, and curing the second polymeric matrix, creating a compliant layer from the second fibrous material and the second polymeric matrix. The compliant layer is stronger than each individual baseline layers.

First claim

The invention claimed is:

1. A method of manufacturing composite laminate, comprising:
providing a first fibrous material having a plurality of fibers;
providing a second fibrous material having a plurality of fibers;
disposing the fibers of the first fibrous material in a first polymeric matrix that is an amine cured, toughened epoxy resin system;
disposing the fibers of the second fibrous material in a second polymeric matrix;
laying up a plurality of the first fibrous material on a rigid structure;
laying up the second fibrous material on the rigid structure, wherein the first fibrous material is in contact with the second fibrous material;
curing the first polymeric matrix, creating a plurality of baseline layers from the plurality of first fibrous material and the first polymeric matrix; and
curing the second polymeric matrix, creating a compliant layer from the second fibrous material and the second polymeric matrix;
wherein the compliant layer is stronger than each individual baseline layer;
wherein the second polymeric matrix is stronger than the first polymeric matrix.

2. The method of claim 1 , wherein the plurality of fibers of the first fibrous material are carbon fiber.

3. The method of claim 2 , wherein the first fibrous material is disposed within the first polymeric matrix prior to being laid up on the rigid structure.

4. The method of claim 1 , wherein the second fibrous material is laid up at a location that will experience peak interlaminar stresses.

5. The method of claim 1 , wherein laying up the second fibrous material on the rigid structure comprises laying up the second fibrous material such that the second fibrous material overlaps at least one of the plurality of first fibrous material.

6. The method of claim 1 , wherein laying up the second fibrous material on the rigid structure comprises laying up the second fibrous material such that a planar dimension of the second fibrous material is substantially the same as a planar dimension of a composite component that comprises the composite laminate.

7. The method of claim 1 , wherein the first fibrous material and the second fibrous material have the same type of fiber, and the type of fiber is selected from the group consisting of glass, carbon, basalt, and aramid.

8. The method of claim 1 , wherein the first fibrous material and the second fibrous material are unidirectional fabric layers.

Assignees

• Bell Textron Inc

Inventors

• Krasnowski Bogdan Roman
• Brack Robert Arnold
• Li Xiaoming
• Wardlaw Robert

Classifications

• B32B37/144 Primary

  using layers with different mechanical or chemical conditions or properties, e.g. layers with different thermal shrinkage, layers under tension during bonding (constructional features for tensioning B32B38/1825) · CPC title

• B29C70/30

  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

• B32B27/08 Primary

  of synthetic resin · CPC title

• B32B2305/72

  Cured, e.g. vulcanised, cross-linked · CPC title

• B29C70/06

  Fibrous reinforcements only · CPC title