Resin impregnated multi orientation composite material

• US 20040074592A1
• Filed: 10/14/2003
• Published: 04/22/2004
• Est. Priority Date: 11/18/1999
• Status: Abandoned Application

• Current Assignee: Craig B. Simpson, Larry J. Ashton, Mike Glen Allman, Rex W. Kay, Troy L. White
• Original Assignee: Craig B. Simpson, Larry J. Ashton, Mike Glen Allman, Rex W. Kay, Troy L. White
• Inventors: Kay, Rex W., Ashton, Larry J., White, Troy L., Simpson, Craig B., Allman, Mike Glen
• Application Number:
  US10/684,762
• Publication Number:
  US 20040074592A1
• Time in Patent Office: Days
• US Class Current: 156/175
• CPC Class Codes: B29C 37/0064 of reinforced material
• CPC Class Codes: B29C 53/582 comprising reinforcements, e.g. wires, threads
• CPC Class Codes: B29C 53/66 with axially movable winding feed member , e.g. lathe type winding
• CPC Class Codes: B29C 53/8016 Storing, feeding or applying winding materials, e.g. reels, thread guides, tensioners
• CPC Class Codes: B29C 53/8066 Impregnating impregnating as pretreatment B29B15/10
• CPC Class Codes: B29C 70/202 arranged in parallel planes or structures of fibres crossing at substantial angles, e.g. cross-moulding compound [XMC] B29C70/207 takes precedence
• CPC Class Codes: B29C 70/32 on a rotating mould, former or core
• CPC Class Codes: B29C 70/44 using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
• CPC Class Codes: B29C 70/443 and impregnating by vacuum or injection
• CPC Class Codes: B29C 70/543 Fixing the position or configuration of fibrous reinforcements before or during moulding for non-woven fabrics D04H3/08
• CPC Class Codes: B29C 70/546 Measures for feeding or distributing the matrix material in the reinforcing structure
• CPC Class Codes: B29L 2031/3085 Wings
• CPC Class Codes: B32B 37/0038 involving application of liquid to the layers prior to lamination, e.g. wet laminating B32B37/12 takes precedence
• CPC Class Codes: B64C 3/20 Integral or sandwich constructions
• CPC Class Codes: D04H 3/04 in rectilinear paths, e.g. crossing at right angles
• CPC Class Codes: D04H 3/07 otherwise than in a plane, e.g. in a tubular way
• CPC Class Codes: D04H 3/12 with filaments or yarns secured together by chemical or thermo-activatable bonding agents, e.g. adhesives, applied or incorporated in liquid or solid form
• CPC Class Codes: Y02T 50/40 Weight reduction
• CPC Class Codes: Y10T 428/24116 Oblique to direction of web
• CPC Class Codes: Y10T 428/24994 Fiber embedded in or on the surface of a polymeric matrix

Abstract

A composite material made of multiple filament bands is disclosed. The filament bands are wound to create a composite material. The filament bands may be impregnated with a solid or semi-solid resin. The filament bands are wound in multiple orientations to form a sheet of composite material. Additionally, the composite material may be made to have a varying number of layer and fiber orientations throughout the sheet of composite material. In another embodiment, a composite component requiring multiple layers and fiber orientations may be substantially manufactured during a filament winding process.

Claims

1. A process for manufacturing a composite material comprising:

pre-impregnating a first filament band with a resin that is solid or semi-solid at ambient temperatures;

winding the first filament band at a first angle;

pre-impregnating a second filament band with a resin that is solid or semi-solid at ambient temperatures;

winding the second filament band in a second direction, wherein the second angle has an intersecting orientation with the first angle, such that the first filament band and the second filament band form a composite material.

2. The process, as recited in claim 1, wherein the intersecting orientation of the first angle and the second angle is substantially perpendicular.

3. The process, as recited in claim 1, wherein the composite material is wound on a rotating mandrel.

4. The process, as recited in claim 1, wherein the orientation of the filament bands is controlled by a filament application section of a filament winding machine.

5. The process, as recited in claim 4, wherein the application section impregnates the filament bands with the resin.

6. The process, as recited in claim 1, wherein the first filament band and the second filament band have a plurality of overlapping locations.

7. The process, as recited in claim 6, wherein an effective amount of resin is present in the overlapping locations.

8. The process, as recited in claim 1, wherein the first filament band and the second filament band are impregnated with a substantially similar quantity of resin.

9. A process for manufacturing a composite component comprising:

determining load requirement for the component;

identifying the number of layers and orientation of filament bands to meet load requirements for the component;

creating a manufacturing control plan; and

winding a plurality of filament bands on a mandrel, wherein the plurality of filament bands are pre-impregnated with a resin that is solid or semi-solid at ambient temperatures, the plurality of filament bands being wound according to the manufacturing control plan, such that the number of layers and orientations of filament bands create a pre-form for the component.

10. The process, as recited in claim 9, wherein the filament bands are wound into a plurality of layers having at least three different filament band orientations.

11. The process, as recited in claim 9, further comprising cutting the pre-form from the composite material.

12. The process, as recited in claim 11, further comprising curing the pre-form on a shape defining form.

13. The process, as recited in claim 9, wherein a plurality of performs are simultaneously wound.

14. The process, as recited in claim 9, wherein the pre-form is wound in a sheet of composite material.