Multi-axial laminate composite structures and methods of forming the same

• US 20060222837A1
• Filed: 03/31/2005
• Published: 10/05/2006
• Est. Priority Date: 03/31/2005
• Status: Abandoned Application

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Kismarton, Max U.
• Application Number:
  US11/096,727
• Publication Number:
  US 20060222837A1
• Time in Patent Office: Days
• US Class Current: 428/297.400
• CPC Class Codes: B29C 70/083 Combinations of continuous fibres or fibrous profiled structures oriented in one direction and reinforcements forming a two dimensional structure, e.g. mats B29D24/00, B29D99/001 take precedence
• 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 70/207 arranged in parallel planes of fibres crossing at substantial angles
• CPC Class Codes: B29C 70/226 the structure comprising mainly parallel filaments interconnected by a small number of cross threads
• CPC Class Codes: B29C 70/228 the structure being stacked in parallel layers with fibres of adjacent layers crossing at substantial angles
• CPC Class Codes: B29C 70/24 oriented in at least three directions forming a three dimensional structure
• CPC Class Codes: B29L 2031/3076 Aircrafts blades, propellers B29L2031/08
• CPC Class Codes: B29L 2031/3082 Fuselages
• CPC Class Codes: B29L 2031/3085 Wings
• CPC Class Codes: Y02T 50/40 Weight reduction
• CPC Class Codes: Y10T 428/24994 Fiber embedded in or on the surface of a polymeric matrix

Abstract

Composite laminate structures and methods of forming the same are disclosed. In one embodiment, the structure includes a first bidirectional layer having a first portion that includes parallel reinforcement fibers oriented at a first angle relative to a first direction and a second portion that includes parallel reinforcement fibers oriented at a second angle relative to the first direction. The structure further includes a second bidirectional layer having a first portion that includes parallel reinforcement fibers oriented at a third angle relative to the first direction and a second portion that includes parallel reinforcement fibers oriented at a fourth angle relative to the first direction. At least one unidirectional layer having a plurality of parallel reinforcement fibers is coupled to at least one of the first bidirectional layer and the second bidirectional layer.

Claims

1. A composite laminate structure, comprising:

a first bidirectional layer having a first portion that includes a plurality of parallel reinforcement fibers oriented at a first selected shallow angle relative to a first selected direction and a second adjacent portion that includes approximately parallel reinforcement fibers oriented at a second selected shallow angle relative to the first direction; and

a second bidirectional layer having a first portion that includes a plurality of parallel reinforcement fibers oriented at a third selected broad angle relative to the first selected direction and a second adjacent portion that includes approximately parallel reinforcement fibers oriented at a fourth selected broad angle relative to the first direction.

2. The composite laminate structure of claim 1, further comprising at least one unidirectional layer having a plurality of parallel reinforcement fibers and coupled to at least one of the first bidirectional layer and the second bidirectional layer.

3. The composite laminate structure of claim 2, wherein the plurality of reinforcement fibers of the at least one unidirectional layer are approximately aligned with the first selected direction.

4. The composite laminate structure of claim 1, wherein the first selected angle is an angle α

and the second selected angle is an angle −

α

.

5. The composite laminate structure of claim 4, wherein the angle α

ranges between one of approximately about one degree and approximately about three degrees, approximately about three degrees and approximately about seven degrees, approximately about seven degrees and approximately about 15 degrees, and approximately about 45 degrees and approximately about 90 degrees.

6. The composite laminate structure of claim 1, wherein the third selected angle is an angle β

and the fourth selected angle is an angle −

β

.

7. The composite laminate structure of claim 6, wherein the angle β

ranges between one of approximately about one degree and approximately about three degrees, approximately about three degrees and approximately about seven degrees, approximately about seven degrees and approximately about 15 degrees, and approximately about 45 degrees and approximately about 90 degrees.

8. The composite laminate structure of claim 1, wherein the first selected angle is an angle α

and the second selected angle is an angle β

, further wherein the third selected angle is an angle −

α and

the fourth selected angle is an angle −

β

.

9. The composite laminate structure of claim 1, wherein the first selected angle is an angle α

and the fourth selected angle is an angle β

, further wherein the third selected angle is an angle −

α and

the second selected angle is an angle −

β

.

10. The composite laminate structure of claim 2, wherein the at least one unidirectional layer is interposed between the first bidirectional layer and the second bidirectional layer.

11. The composite laminate structure of claim 1, wherein at least one of the respective first and second portions of the first bidirectional layer, and the respective first and second portions of the second bidirectional layer comprises a woven bidirectional layer.

12. The composite laminate structure of claim 2, wherein the at least one unidirectional layer further comprises a first unidirectional layer having a plurality of reinforcement fibers oriented in the first selected direction and a second unidirectional layer having a plurality of parallel reinforcement fibers oriented in a second selected direction, the first selected direction being approximately perpendicular to the first selected direction.

13. The composite laminate structure of claim 12, wherein the first unidirectional layer and the second unidirectional layer further comprise a woven reinforcement layer.

14. The composite laminate structure of claim 1, wherein the first bidirectional layer comprises at least about 60 percent of a volume of the structure.

15. The composite laminate structure of claim 1, wherein the first bidirectional layer comprises approximately about 80 percent of a volume of the structure.

16. A method of forming a composite laminate structure, comprising:

forming a first bidirectional layer by positioning a first reinforcement layer adjacent to a second reinforcement layer, the first layer including a plurality of parallel reinforcement fibers oriented at a first selected shallow angle relative to a first selected direction and the second layer including a plurality of approximately parallel reinforcement fibers oriented at a second selected shallow angle relative to the first direction;

forming a second bidirectional layer by positioning a third reinforcement layer adjacent to a fourth reinforcement layer, the third layer including a plurality of parallel reinforcement fibers oriented at a third selected broad angle relative to the first selected direction and the fourth layer including a plurality of approximately parallel reinforcement fibers oriented at a fourth selected broad angle relative to the first direction; and

coupling the first bidirectional layer to the second bidirectional layer.

17. The method of claim 16, further comprising providing at least one unidirectional layer having a plurality of parallel reinforcement fibers;

and

coupling the at least one unidirectional layer to at least one of the first bidirectional layer and the second bidirectional layer.

18. The method of claim 17, wherein coupling the at least one unidirectional layer to at least one of the first bidirectional layer and the second bidirectional layer further comprises coupling the unidirectional layer to at least one of the first bidirectional layer and the second bidirectional layer with a resin-based adhesive.

19. The method of claim 17, wherein providing at least one unidirectional layer further comprises aligning the plurality of reinforcement fibers of the at least one unidirectional layer with the first selected direction.

20. The method of claim 16, wherein forming a first bidirectional layer further comprises orienting the reinforcement fibers in the first reinforcement layer at an angle α

with the first selected direction, and orienting the reinforcement fibers in the second reinforcement layer at an angle −

α

with the first selected direction, further wherein forming a second bidirectional layer further comprises orienting the reinforcement fibers in the third reinforcement layer at an angle β

with the first selected direction, and orienting the reinforcement fibers in the fourth reinforcement layer at an angle −

β

with the first selected direction.

21. The method of claim 16, wherein forming a first bidirectional layer further comprises orienting the reinforcement fibers in the first reinforcement layer at an angle α

with the first selected direction, and orienting the reinforcement fibers in the third reinforcement layer at an angle β

with the first selected direction, further wherein forming a second bidirectional layer further comprises orienting the reinforcement fibers in the third reinforcement layer at an angle −

α

with the first selected direction, and orienting the reinforcement fibers in the fourth reinforcement layer at an angle −

β

with the first selected direction.

22. The method of claim 17, further comprising disposing at least one of the first bidirectional layer, the second bidirectional layer and the at least one unidirectional layer using a tape material that includes a plurality of reinforcement fibers.

23. The method of claim 17, wherein providing at least one unidirectional layer having a plurality of parallel reinforcement fibers further comprises interposing a first unidirectional layer between the first bidirectional layer and the second bidirectional layer, and further comprising positioning a second unidirectional layer adjacent to one of the first bidirectional layer and the second bidirectional layer.

24. The method of claim 16, wherein forming the first bidirectional layer further comprises forming the first layer to include at least about 60 percent of a volume of the structure.

25. An aerospace vehicle, comprising:

a fuselage;

wing assemblies and an empennage operatively coupled to the fuselage; and

a composite laminate structure incorporated into a selected portion of at least one of the fuselage, the wing assemblies and the empennage, further comprising;

a first bidirectional layer having a first portion that includes a plurality of parallel reinforcement fibers oriented at a first selected shallow angle relative to a first selected direction and a second adjacent portion that includes approximately parallel reinforcement fibers oriented at a second selected shallow angle relative to the first direction;

a second bidirectional layer having a first portion that includes a plurality of parallel reinforcement fibers oriented at a third selected broad angle relative to the first selected direction and a second adjacent portion that includes approximately parallel reinforcement fibers oriented at a fourth selected broad angle relative to the first direction; and

at least one unidirectional layer having a plurality of parallel reinforcement fibers and coupled to at least one of the first bidirectional layer and the second bidirectional layer.