Method of designing composite material, method of evaluating composite material, and composite material

Patent metadata

Field	Value
Publication number	US-11292576-B2
Application number	US-201816059207-A
Country	US
Kind code	B2
Filing date	Aug 9, 2018
Priority date	Aug 17, 2017
Publication date	Apr 5, 2022
Grant date	Apr 5, 2022

Abstract

A composite material includes stacked reinforced fiber substrates and has a thickness-varying part whose thickness in a stacking direction changes from a large thickness to a small thickness. The reinforced fiber substrate that has the drop-off portion and is positioned between a base substrate and a cover substrate in the stacking direction is set as a cut substrate. Stress analysis is performed on the base substrate, the cut substrate, and the cover substrate to calculate an evaluation value concerning stress on the cut substrate. A reinforced fiber substrate in the thickness-varying part is set at the cut substrate, based on the calculated evaluation value.

First claim

The invention claimed is:

1. A composite material comprising:
a thick part including a first quantity of stacked reinforced fiber layers, the thick part having a first thickness;
a thin part including a second quantity of stacked reinforced fiber layers, the first quantity being greater than the second quantity, the thin part having a second thickness less than the first thickness; and
a thickness-varying part between the thick part and the thin part and having a thickness decreasing from the first thickness to the second thickness,
wherein the thickness-varying part includes:
a plurality of connection layers forming some of the stacked reinforced fiber layers of the thick part and forming all of the stacked reinforced fiber layers of the thin part; and
a plurality of drop-off layers forming some of the reinforced fiber layers of the thick part, each of the plurality of drop-off layers extending from the thick part and having a cut end within the thickness-varying part,

wherein the cut ends of the plurality of drop-off layers are displaced from each other along a direction from the thick part to the thin part,
wherein each of the stacked reinforced fiber layers of the thick part, each of the stacked reinforced fiber layers of the thin part, and each of the stacked reinforced fiber layers of the thickness-varying part is a ply substrate having a fiber direction aligned in one direction,
wherein, in a plane orthogonal to a stacking direction in which the reinforced fiber layers of each of the thick part, the thin part, and the thickness-varying part are stacked, an angle formed between a reference direction and the fiber direction of each ply substrate is an orientation angle, and
wherein the plurality of drop-off layers comprises a pair of adjacent drop-off layers including a first ply substrate and a second ply substrate contacting each other, and the orientation angle of the first ply substrate of the pair of adjacent drop-off layers is different than the orientation angle of the ply substrate of the pair of adjacent drop-off layers.

2. The composite material according to claim 1 , wherein the composite material comprises:
a first-side stacked structure including the reinforced fiber layers stacked on a first side of a center line connecting centers of the thick part, the thin part, and the thickness-varying part in the stacking direction; and
a second-side stacked structure including the remaining reinforced fiber layers stacked on a second side with respect to the center line,
wherein the first-side stacked structure and the second-side stacked structure are a symmetric stack in which an orientation angle of the reinforced fiber layers is symmetric about the center line, and
wherein the plurality of drop-off layers are disposed in at least one of the first-side stacked structure and the second-side stacked structure in a direction from a thick part side to a thin part side of the thickness-varying part.

3. The composite material according to claim 2 , wherein the plurality of drop-off layers are alternately disposed in the first-side stacked structure and the second-side stacked structure in a direction from the thick part side to the thin part side of the thickness-varying part.

4. The composite material according to claim 1 , wherein a plane in which a thickness of the thin part extends to the thick part is defined as a baseline, and at least one of the plurality of drop-off layers is on the baseline.

5. The composite material according to claim 1 , wherein the cut ends of at least two of the drop-off layers are located on a line parallel to a direction in which at least one of the reinforced fiber layers of the thick part extends.

6. The composite material according to claim 1 , wherein the plurality of drop-off layers comprises at least four drop-off layers.

7. The composite material according to claim 1 , wherein at least one of the connection layers forming some of the stacked reinforced fiber layers is interposed between the plurality of drop-off layers with respect to a stacking direction in which the reinforced fiber layers of each of the thick part, the thin part, and the thickness-varying part are stacked.

8. The composite material according to claim 1 , wherein the ply substrate of the first one of the adjacent pair is directly above the ply substrate of the second one of the adjacent pair, and
wherein the ply substrate of the first one of the adjacent pair and the ply substrate that is directly below the ply substrate of the second one of the adjacent pair extend in contact with each other on a thin part side of the thickness-varying part with respect to the cut end of the ply substrate of the second one of the adjacent pair.

9. A composite material comprising:
a thick part including a first quantity of stacked reinforced fiber layers, the thick part having a first thickness;
a thin part including a second quantity of stacked reinforced fiber layers, the first quantity being greater than the second quantity, the thin part having a second thickness less than the first thickness; and
a thickness-varying part between the thick part and the thin part and having a thickness decreasing from the first thickness to the second thickness,
wherein the thickness-varying part includes:
a plurality of connection layers forming some of the stacked reinforced fiber layers of the thick part and forming all of the stacked reinforced fiber layers of the thin part; and
a plurality of drop-off layers forming some of the reinforced fiber layers of the thick part, each of the plurality of drop-off layers extending from the thick part and having a cut end within the thickness-varying part,

wherein the cut ends of the plurality of drop-off layers are displaced from each other along a direction from the thick part to the thin part,
wherein each of the stacked reinforced fiber layers of the thick part, each of the stacked reinforced fiber layers of the thin part, and each of the stacked reinforced fiber layers of the thickness-varying part is a ply substrate having a fiber direction aligned in one direction,
wherein, in a plane orthogonal to a stacking direction in which the reinforced fiber layers of each of the thick part, the thin part, and the thickness-varying part are stacked, an angle formed between a reference direction and the fiber direction of each ply substrate is an orientation angle, and
wherein the orientation angle of the ply substrate of a first drop-off layer of an adjacent pair of the drop-off layers is different than the orientation angle of the ply substrate of a second drop-off layer of the adjacent pair of the drop-off layers,
wherein the ply substrate of the first drop-off layer of the adjacent pair of the drop-off layers is directly above the ply substrate of the second drop-off layer of the adjacent pair of the drop-off layers, and
wherein the ply substrate of the first drop-off layer of the adjacent pair of the drop-off layers and the ply substrate of a reinforced fiber layer directly below the ply substrate of the second drop-off layer of the adjacent pair of the drop-off layers extend in contact with each other on a side of the thickness-varying part closer to the thin part relative to a cut end of the ply substrate of the second drop-off layer of the adjacent pair of the drop-off layers.

10. The composite material according to claim 9 , wherein the composite material comprises:
a first-side stacked structure including the reinforced fiber layers stacked on a first side of a center line connecting centers of the thick part, the thin part, and the thickness-varying part in the stacking direction; and
a second-side stacked structure including the remaining reinforced fiber

Assignees

• Mitsubishi Heavy Ind Ltd

Inventors

• Kamo Sota
• Takagi Kiyoka
• Shitani Tooru
• Abe Toshio
• Obata Sae
• Takahashi Kosuke

Classifications

• B64C3/20 Primary

  Integral or sandwich constructions · CPC title

• B29C70/207 Primary

  arranged in parallel planes of fibres crossing at substantial angles · 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

• B64C1/00

  Fuselages; Constructional features common to fuselages, wings, stabilising surfaces or the like · CPC title

• B64C1/26

  Attaching the wing or tail units or stabilising surfaces · CPC title