Composite laminate manufacture with multiaxial fabrics

• US 6,372,072 B1
• Filed: 11/26/1999
• Issued: 04/16/2002
• Est. Priority Date: 12/04/1998
• Status: Expired due to Term

• Current Assignee: Airbus Operations Limited (Airbus SE)
• Original Assignee: BAE Systems Plc
• Inventors: Healey, Michael J
• Primary Examiner(s): AFTERGUT, JEFFRY H
• Application Number:
  US09/449,997
• Time in Patent Office: 872 Days
• Field of Search: 156/60, 156/166, 156/180, 156/175, 156/299, 156/148, 442/204
• US Class Current: 156/148
• CPC Class Codes: B32B 2305/07 Parts immersed or impregnated in a matrix
• CPC Class Codes: B32B 2305/08 Reinforcements
• CPC Class Codes: B32B 2605/18 Aircraft blades, propellers B32B2603/00
• CPC Class Codes: B32B 5/16 characterised by features of a layer formed of particles, e.g. chips, powder or granules layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02
• CPC Class Codes: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: Y10T 156/1092 All laminae planar and face to face
• CPC Class Codes: Y10T 442/3187 Triaxially woven fabric

Abstract

A method of manufacturing a composite laminate and a composite laminate manufactured according to the method are provided. The laminate comprises a series of fabric plies (1 to 15) of fibrous reinforcing material set in plastics matrix material. The method includes the steps of providing a relatively small number of fabric styles from which to choose; selecting at least one of those fabric styles according to design requirements for a particular portion of the laminate; laying up that portion with the said selection, and repeating the selection and layup steps as required to complete the layup of the laminate.

Claims

1. A method of manufacturing a composite laminate, the laminate comprising a series of fabric plies of fibrous reinforcing material set in plastics matrix material, the method including the steps of:

providing at least one multiaxial fabric style comprising 90 deg and obliquely angled fibres and at least one unidirectional 0 deg fabric style,

selecting at least one of said fabric styles according to design requirements for a particular portion of the laminate,

laying up said portion with the said selection, and

repeating the said selection and laying up steps as required to complete layup of the laminate, further including the steps of;

determining the ratio of required fibre content of obliquely angled and 90 deg orientated fibre in differing portions of the laminate for optimum stiffness thereof,

determining an intermediate value of said ratio, and

selecting at least a multiaxial fabric style having fibre orientations in said intermediate value of said ratio.

2. A method as in claim 1 in which at least one said multiaxial fabric style comprises a triaxial fabric style.

3. A method as in claim 1 in which the at least one multiaxial fabric style comprises two oppositely handed versions of a single triaxial fabric style.

4. A method as in claim 1 in which the at least one unidirectional 0 deg fabric style comprises at least two unidirectional 0 deg fabric styles.

5. A method as in claim 1 in which the said intermediate ratio is substantially within the range 4.5 to 5.5:

1.

6. A method as in claim 1 in which the said intermediate ratio is substantially 5:

1.

7. A method as in claim 1 in which the said intermediate ratio is substantially within the range 2.0 to 3.0:

1.

8. A method as in claim 1 in which the said intermediate ratio is substantially 2.5:

1.

9. A method as in claim 5 including the step of providing two 0 deg unidirectional fabric styles from which to choose.