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

Patent metadata

Field	Value
Publication number	US-2016159013-A1
Application number	US-201615044573-A
Country	US
Kind code	A1
Filing date	Feb 16, 2016
Priority date	Jan 12, 2011
Publication date	Jun 9, 2016
Grant date	—

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 comprising the steps of:
positioning a first ply in a first orientation; positioning a second ply in a second orientation, the second orientation being offset relative to the first orientation such that an acute angle less than 90° is defined; stacking the second ply adjacent the first ply such that an unbalanced structure is formed; and stitching the first ply and the second ply relative to one another in a substantially non-crimped configuration.

2 . The method of claim 1 , wherein during the positioning steps:
the first orientation is at least one of a machine direction or a primary load-bearing axis 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 approximately 25°.

4 . The method of claim 1 , wherein during the positioning steps:
the first orientation is approximately 60° offset relative to at least one of a machine direction or a primary load-bearing axis of the sub-laminate module; and the second orientation is approximately 85° offset relative to at least one of the machine direction or the primary load-bearing axis of the sub-laminate module.

5 . The method of claim 1 , further comprising the steps of:
positioning a third ply in the first orientation; positioning a fourth ply in the second orientation; stacking the third ply adjacent the fourth ply such that an unbalanced structure is formed; and stitching the third ply relative to both the second ply and the fourth ply in a substantially non-crimped configuration.

6 . A method of manufacturing a sub-laminate module for use in forming a composite laminate, said method comprising 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; positioning the plurality of fibers of the second tow in a second orientation, the first and the second orientations defining an acute angle there between, the acute angle being less than 90° and defining an unbalanced structure of the sub-laminate layer; stacking the second ply layer and the first ply layer adjacent one another; and stitching the first ply layer and the second ply layer relative to one another in a non-crimped configuration.

7 . The method of claim 6 , wherein during the positioning steps:
the first orientation is at least one of a machine direction or a primary load-bearing axis of the sub-laminate module; and the acute angle is within a range of from about 10° to about 40°.

8 . The method of claim 7 , wherein the acute angle is approximately 25°.

9 . The method of claim 6 , wherein during the positioning steps:
the first orientation is approximately 60° offset relative to at least one of a machine direction or a primary load-bearing axis of the sub-laminate module; and the second orientation is approximately 85° offset relative to at least one of the machine direction or the primary load-bearing axis of the sub-laminate module.

10 . The method of claim 6 , further comprising the steps of:
spreading a third tow comprising a plurality of fibers to form a third ply layer; spreading a fourth tow comprising a plurality of fibers to form a fourth ply layer; positioning the plurality of fibers of the third tow in the first orientation; positioning the plurality of fibers of the fourth tow in the second orientation; stacking the third ply layer and the fourth ply layer adjacent one another; and stitching the plurality of fibers of the third ply layer relative to both the second ply layer and the fourth ply layer in a substantially non-crimped configuration.

11 . A method of manufacturing a composite laminated structure, said method comprising the steps of:
forming a plurality of sub-laminate modules, each module comprising:
a first ply comprising fibers extending in a first orientation;
a second ply comprising fibers extending in a second orientation; 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 the respectively secured plurality of sub-laminate layers so as to form the composite laminated structure.

12 . The method of claim 11 , wherein during the forming step:
the first orientation is at least one of a machine direction or a primary load-bearing axis of the sub-laminate module; and the acute angle is within a range of from about 10° to about 40°.

13 . The method of claim 12 , wherein the acute angle is approximately 25°.

14 . The method of claim 11 , wherein during the forming step:
the first orientation is approximately 60° offset relative to at least one of a machine direction or a primary load-bearing axis of the sub-laminate module; and the second orientation is approximately 85° offset relative to at least one of the machine direction or the primary load-bearing axis of the sub-laminate module.

15 . The method of claim 11 , where each of the plurality of sub-laminate modules, during stacking, is oriented, as a whole, in the first orientation.

16 . The method of claim 15 , wherein the orientation of each of the plurality of sub-laminate modules facilitates a one-axis layup process.

17 . The method of claim 11 , 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.

18 . The method of claim 11 , 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.

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

20 . The method of claim 11 , 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.

21 . The method of claim 11 , 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 a first and a fourth ply layer; and
the second ply forms a second and a third ply layer,
wherein the third ply layer comprises fibers extending in the second orientation, the fourth ply layer comprises fibers extending in a third orientation, the third orientation being opposite that of the first orientation relative to the second orientation.

22 . The method of claim 21 , 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.

23 . The me

Assignees

• Cie Chomarat
• Univ Leland Stanford Junior

Inventors

• Tsai Stephen W
• Cognet Michel
• Sanial Philippe

Classifications

• B32B5/28

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

• Y10T156/10

  Methods of surface bonding and/or assembly therefor · CPC title

• Y10T156/1051

  by folding · CPC title

• 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

• B32B5/12

  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