Methods and preforms for forming composite members with interlayers formed of nonwoven, continuous materials
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B32B-005/26
B32B-005/06
B32B-003/06
B32B-005/28
B32B-007/08
D04H-013/00
B29B-011/16
C08J-005/04
B29C-070/08
B29C-070/44
B29C-067/20
출원번호
US-0561566
(2012-07-30)
등록번호
US-8852713
(2014-10-07)
발명자
/ 주소
Tsotsis, Thomas Karl
출원인 / 주소
The Boeing Company
대리인 / 주소
Alston & Bird LLP
인용정보
피인용 횟수 :
0인용 특허 :
30
초록▼
Materials and methods are provided for producing preform materials for impact-resistant composite materials suitable for liquid molding. Interlayers formed of nonwoven, continuous fibers, such as spunbonded, spunlaced, or mesh fabric, are introduced between non-crimped layers of unidirectional reinf
Materials and methods are provided for producing preform materials for impact-resistant composite materials suitable for liquid molding. Interlayers formed of nonwoven, continuous fibers, such as spunbonded, spunlaced, or mesh fabric, are introduced between non-crimped layers of unidirectional reinforcing fibers to produce a preform for use in liquid-molding processes to produce a composite member. Curing of the preform provides increased impact resistance by increasing the amount of energy required to propagate localized fractures due to impact.
대표청구항▼
1. A preform for forming a composite member, the preform comprising: a plurality of reinforcing layers formed of fibers of a reinforcing material;a plurality of interlayers, the interlayers being disposed alternately between the reinforcing layers, each interlayer being formed of a nonwoven fabric o
1. A preform for forming a composite member, the preform comprising: a plurality of reinforcing layers formed of fibers of a reinforcing material;a plurality of interlayers, the interlayers being disposed alternately between the reinforcing layers, each interlayer being formed of a nonwoven fabric of continuous thermoplastic fibers, different than the fibers of the reinforcing layers, such that the layers and interlayers are configured to be infused with a matrix material, wherein the plurality of interlayers have different respective thicknesses; andstitching extending through the reinforcing layers and the interlayers and configured to engage the reinforcing layers and the interlayers,wherein a material of the interlayers is adapted to increase the impact resistance of the composite member. 2. A preform according to claim 1 wherein each interlayer comprises a nonwoven fabric formed by at least one of the group consisting of spunbonding, spunlacing, and fabric meshing. 3. A preform according to claim 1 wherein the material of the interlayers comprises at least one of the group consisting of polyamide, polyimide, polyamide-imide, polyester, polybutadiene, polyurethane, polypropylene, polyetherimide, polysulfone, polyethersulfone, polyphenylsulfone, polyphenylene sulfide, polyetherketone, polyethertherketone, polyarylamide, polyketone, polyphthalamide, polyphenylenether, polybutylene terephthalate, polyethylene terephthalate, polyester-polyarylate, polyaramid, polybenzoxazole, viscose, carbon-fiber, and glass-fiber. 4. A preform according to claim 1 wherein the material of the interlayers is substantially tackless. 5. A preform according to claim 1 wherein the material of the interlayers is adapted to remain intact while the matrix material is infused therethrough and cured. 6. A preform according to claim 1 wherein a width of the preform is at least about 50 inches. 7. A preform according to claim 1 wherein the fabric of each interlayer comprises a mechanical mix of dissimilar fibers. 8. A preform according to claim 1 wherein the fabric of each interlayer comprises multi-component fibers. 9. A preform according to claim 1 wherein the respective thicknesses of the interlayers are dependent upon a relative position of the interlayers with respect to the plurality of reinforcing layers. 10. A preform according to claim 1 wherein a first interlayer is positioned between a pair of reinforcing layers and a second interlayer is positioned proximate an outer face of an outermost reinforcing layer, wherein the second interlayer is thinner than the first inter layer. 11. A composite member defining a predetermined configuration, the composite member comprising: a plurality of reinforcing layers formed of fibers of a reinforcing material;a plurality of interlayers, the interlayers being disposed alternately between the reinforcing layers, each interlayer being formed of a nonwoven fabric of continuous thermoplastic fibers, different than the fibers of the reinforcing material, wherein the plurality of interlayers have different respective thicknesses;stitching extending through the reinforcing layers and the interlayers and configured to engage the reinforcing layers and the interlayers; anda matrix material infused in the reinforcing material, the matrix material being cured with the reinforcing layers and interlayers defining the predetermined configuration,wherein a material of the interlayers is adapted to increase the impact resistance of the composite member. 12. A composite member according to claim 11 wherein each interlayer comprises a nonwoven fabric formed by at least one of the group consisting of spunbonding, spunlacing, and fabric meshing. 13. A composite member according to claim 11 wherein the material of the interlayers comprises at least one of the group consisting of polyamide, polyimide, polyamide-imide, polyester, polybutadiene, polyurethane, polypropylene, polyetherimide, polysulfone, polyethersulfone, polyphenylsulfone, polyphenylene sulfide, polyetherketone, polyethertherketone, polyarylamide, polyketone, polyphthalamide, polyphenylenether, polybutylene terephthalate, polyethylene terephthalate, polyester-polyarylate, polyaramid, polybenzoxazole, viscose, carbon-fiber, and glass-fiber. 14. A composite member according to claim 11 wherein the material of the interlayers is substantially tackless. 15. A composite member according to claim 11 wherein a width of the composite member is at least about 50 inches. 16. A composite member according to claim 11 wherein the fabric of each interlayer comprises a mechanical mix of dissimilar fibers. 17. A composite member according to claim 11 wherein the fabric of each interlayer comprises multi-component fibers. 18. A composite member according to claim 11 wherein the respective thicknesses of the interlayers are dependent upon a relative position of the interlayers with respect to the plurality of reinforcing layers.
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