Methods for improving conformability of non-crimp fabric and contoured composite components made using such methods
First Claim
Patent Images
1. A method comprising:
- forming a self-conforming non-crimp fabric comprising layers of unidirectional fibers and stitching by tailoring at least a first parameter of the stitching to anchor the fabric and at least a second parameter of the stitching to provide conformability of the fabric, the first and second parameters selected from the group consisting of stitch type, stitch spacing, stitch density, stitch material, stitch weight, stitch tension, and combinations thereof;
infusing the fabric with a resin; and
thencuring the resin to form a component containing the layers and the stitching, the component comprising an anchoring region including the stitching tailored by the first parameter and a conforming region including the stitching tailored by the second parameter.
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Abstract
Methods for making a self-conforming non-crimp fabric involving tailoring at least a first parameter to anchor the fabric and at least a second parameter to provide conformability of the fabric, the first and second parameters selected from stitch type, stitch spacing, stitch density, stitch material, stitch weight, stitch tension, and combinations of the same.
18 Citations
24 Claims
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1. A method comprising:
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forming a self-conforming non-crimp fabric comprising layers of unidirectional fibers and stitching by tailoring at least a first parameter of the stitching to anchor the fabric and at least a second parameter of the stitching to provide conformability of the fabric, the first and second parameters selected from the group consisting of stitch type, stitch spacing, stitch density, stitch material, stitch weight, stitch tension, and combinations thereof; infusing the fabric with a resin; and
thencuring the resin to form a component containing the layers and the stitching, the component comprising an anchoring region including the stitching tailored by the first parameter and a conforming region including the stitching tailored by the second parameter. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 21, 22)
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15. A method comprising:
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forming a self-conforming non-crimp fabric comprising layers of unidirectional fibers and stitching by tailoring at least one of a first parameter of the stitching to anchor the fabric and at least one of a second parameter of the stitching to provide conformability of the fabric wherein the first parameter is at least one selected from the group consisting of a simple stitch type, smaller stitch spacing, high stitch density, rigid stitch material, heavy stitch weight, taut stitch tension, and combinations thereof, and the second parameter is at least one selected from the group consisting of a complex stitch type, larger stitch spacing, low stitch density, elastic stitch material, light stitch weight, slack stitch tension, and combinations thereof wherein the non-crimp fabric comprises fibers selected from the group consisting of carbon fibers, graphite fibers, glass fibers, ceramic fibers, aromatic polyamide fibers, and combinations thereof; infusing the fabric with a resin; and
thencuring the resin to form a component containing the layers and the stitching, the component comprising an anchoring region including the stitching tailored by the first parameter and a conforming region including the stitching tailored by the second parameter. - View Dependent Claims (16, 17, 18, 19, 20, 23, 24)
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Specification