Composite laminated structures and methods for manufacturing and using the same

• US 9,296,174 B2
• Filed: 10/12/2011
• Issued: 03/29/2016
• Est. Priority Date: 01/12/2011
• Status: Active Grant

• Current Assignee: Compagnie Chomarat, Board of Trustees of the Leland Stanford Junior University (Stanford Management Co.)
• Original Assignee: Compagnie Chomarat, Board of Trustees of the Leland Stanford Junior University (Stanford Management Co.)
• Inventors: Tsai, Steven W., Sanial, Philippe, Cognet, Michel
• Primary Examiner(s): Austin, Aaron
• Assistant Examiner(s): FIGG, LAURA B
• Application Number:
  US13/272,139
• Publication Number:
  US 20120177872A1
• Time in Patent Office: 1,630 Days
• Field of Search: 428105-113
• US Class Current: 1/1
• 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 70/30 Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
• CPC Class Codes: B29K 2105/0881 unidirectional
• CPC Class Codes: B29K 2307/04 Carbon
• CPC Class Codes: B32B 5/06 characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
• CPC Class Codes: B32B 5/12 characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
• 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: B32B 5/28 impregnated with or embedded in a plastic substance not used
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 156/1051 by folding
• CPC Class Codes: Y10T 428/24124 Fibers

Abstract

Variously configured sub-laminate modules are provided, which comprise at least a first ply and a second ply, the first ply comprising fibers extending in a first orientation, the second ply comprising fibers extending in a second orientation. The second orientation is offset relative to the first orientation, which offset defines an acute angle between the two orientations. The acute angle is less than 90 degrees and in at least one embodiment, the acute angle is approximately 25°. In certain embodiments, the acute angle further defines an unbalanced structure of the sub-laminate module. In certain embodiments, the first and second plies may be further secured relative to one another in a non-crimped configuration. Composite laminated structures formed from various embodiments of the sub-laminate modules are also provided, at least some of which may be homogenized. Various methods of manufacturing the sub-laminate modules and the composite laminated structures are also provided.

Claims

1. A sub-laminate module for use in forming a composite laminated structure, the sub-laminate module consisting of:

a primary longitudinal axis corresponding to a primary load-bearing axis of the sub-laminate module;

a first ply comprising fibers extending in a first orientation;

a second ply comprising fibers extending in a second orientation, the second orientation being offset relative to the first orientation; and

an acute angle defined by the relative offset between the first orientation and the second orientation, the acute angle being less than 90° and

defining an unbalanced structure of the sub-laminate module,

wherein;

the first orientation is aligned with the primary longitudinal axis of the sub-laminate module such that the first ply is aligned with the primary load-bearing axis of the sub-laminate module;

the second orientation is offset relative to the first orientation and the primary longitudinal axis such that the relative offset corresponds to the acute angle and defines the unbalanced structure of the sub-laminate module; and

the first ply and the second ply are secured relative to one another via a plurality of transversely oriented stitches, the plurality of transverse stitches being oriented substantially perpendicular relative to the primary longitudinal axis of the sub-laminate module so as to at least in part define a non-crimped configuration.

2. The sub-laminate module of claim 1, wherein the acute angle is less than 45°

.

3. The sub-laminate module of claim 1, wherein the acute angle is within a range from about 10°

to about 40°

.

4. The sub-laminate module of claim 3, wherein the acute angle is within a range of from about 15°

to about 30°

.

5. The sub-laminate module of claim 4, wherein the acute angle is approximately 25°

.

6. The sub-laminate module of claim 1, wherein the fibers of the first and second plies comprise carbon fibers.

7. The sub-laminate module of claim 1, wherein the fibers of the first ply comprise carbon fibers and the fibers of the second ply comprise glass fibers, so as to form a hybrid composition.

8. The sub-laminate module of claim 1, wherein the sub-laminate module is folded in half on itself, relative to an axis extending in the second orientation, such that:

the first ply forms a first and a fourth ply layer; and

the second ply forms a second and a third ply layer,

wherein the fourth ply layer comprises fibers extending in the first orientation and the third ply layer comprises fibers extending in a third orientation, the third orientation being opposite that of the second orientation relative to the primary load-bearing axis of the sub-laminate module.

9. The sub-laminate module of claim 1, wherein at least the first ply has a thickness within a range of from about 0.020 millimeters to about 0.080 millimeters.

10. The sub-laminate module of claim 1, wherein at least the first ply has a thickness of approximately 0.0625 millimeters and a weight of approximately 75 g/m².

11. A sub-laminate module for use in forming a composite laminate, the sub-laminate module consisting of:

a primary longitudinal axis corresponding to a primary load-bearing axis of the sub-laminate module;

a first ply comprising fibers extending in a first orientation, the fibers of the first ply comprising a plurality of spread tows lying adjacent to each other;

a second ply comprising fibers extending in a second orientation, the fibers of the second ply comprising a plurality of spread tows lying adjacent to each other, the second orientation being offset relative to the first orientation; and

an acute angle defined by the relative offset between the first and the second orientations, the acute angle being less than 90° and

defining an unbalanced structure of the sub-laminate layer,

wherein;

the first orientation is aligned with the primary longitudinal axis of the sub-laminate module such that the first ply is aligned with the primary load-bearing axis of the sub-laminate module;

the second orientation is offset relative to the first orientation and the primary longitudinal axis such that the relative offset corresponds to the acute angle and defines the unbalanced structure of the sub-laminate module; and

the fibers of the first and the second plies are secured relative to one another via a plurality of stitches.

12. The sub-laminate module of claim 11, wherein the acute angle is within a range of from about 10°

to about 40°

.

13. The sub-laminate module of claim 12, wherein the acute angle is approximately 25°

.

14. The sub-laminate module of claim 11, wherein the fibers of the first and second plies comprise carbon fibers.

15. The sub-laminate module of claim 14, wherein the fibers of the first ply comprise carbon fibers and the fibers of the second ply comprise glass fibers, so as to form a hybrid composition.

16. The sub-laminate module of claim 11, wherein the sub-laminate module is folded in half on itself, relative to an axis extending in the second orientation, such that:

the first ply forms a first and a fourth ply layer, the fourth ply layer comprising a plurality of spread tows lying adjacent to each other; and

the second ply forms a second and a third ply layer, the third ply layer comprising a plurality of spread tows lying adjacent to each other,

wherein the fourth ply layer comprises fibers extending in the first orientation and the third ply layer comprises fibers extending in a third orientation, the third orientation being opposite that of the second orientation relative to the primary load-bearing axis of the sub-laminate module.

17. The sub-laminate module of claim 11, wherein at least the first ply has a thickness of approximately 0.0625 millimeters and a weight of approximately 75 g/m².

18. A composite laminated structure, the composite laminated structure comprising:

a plurality of sub-laminate modules, each module consisting of;

a primary longitudinal axis corresponding to a primary load-bearing axis of the sub-laminate module;

a first ply comprising fibers extending in a first orientation;

a second ply comprising fibers extending in a second orientation, the second orientation being offset relative to the first orientation; and

an acute angle defined by the relative offset between the first orientation and the second orientation, the acute angle being less than 90° and

defining an unbalanced structure of the sub-laminate module,

wherein;

the first orientation is aligned with the primary longitudinal axis of the sub-laminate module such that the first ply is aligned with the primary load-bearing axis of the sub-laminate module;

the second orientation is offset relative to the first orientation and the primary longitudinal axis such that the relative offset corresponds to the acute angle and defines the unbalanced structure of the sub-laminate module; and

the first ply and the second ply are secured relative to one another via a plurality of transversely oriented stitches, the plurality of transverse stitches being oriented substantially perpendicular relative to the primary longitudinal axis of the sub-laminate module so as to at least in part define a non-crimped configuration.

19. The composite laminated structure of claim 18, wherein each of the plurality of sub-laminate modules has a thickness within a range of from about 0.040 millimeters to about 0.080 millimeters.

20. The composite laminated structure of claim 18, wherein the structure comprises at least sixteen sub-laminate modules so as to form a homogenous composite material.

21. The composite laminated structure of claim 20, wherein the structure has a thickness of approximately 2.0 millimeters.

22. The composite laminated structure of claim 18, wherein each of the fibers contained within the plurality of sub-laminate modules are oriented in one or the other of only the first orientation or the second orientation.

23. The composite laminated structure of claim 18, wherein:

the acute angle defined within at least a first subset of the plurality of the sub-laminate modules is positively oriented relative to the first orientation; and

the acute angle defined within at least a second subset of the plurality of the sub-laminate modules is negatively oriented relative to the first orientation.

24. The composite laminated structure of claim 23, wherein the first orientation for both the first and the second subsets of the plurality of sub-laminate modules is the same.

25. The composite laminated structure of claim 24, wherein the structure comprises at least eight sub-laminate modules so as to form a homogenous composite material.

26. The composite laminated structure of claim 24, wherein the structure has a thickness of approximately 2.0 millimeters.

27. The composite laminated structure of claim 23, wherein:

the first orientation for the second subset of the plurality of the sub-laminate modules is offset at an angle of approximately 90 degrees relative to the first orientation for the first subset of the plurality of the sub-laminate modules.

28. The composite laminated structure of claim 27, wherein the structure comprises at least eight sub-laminate modules so as to form a homogenous composite material.

29. The composite laminated structure of claim 27, wherein the structure has a thickness of approximately 2.0 millimeters.

30. A composite laminated structure, the composite laminated structure comprising:

a plurality of sub-laminate modules, each module consisting of;

a primary longitudinal axis corresponding to a primary load-bearing axis of the sub-laminate module;

a first ply comprising fibers extending in a first orientation, the fibers of the first ply comprising a plurality of spread tows lying adjacent to each other;

a second ply comprising fibers extending in a second orientation, the fibers of the second ply comprising a plurality of spread tows lying adjacent to each other, the second orientation being offset relative to the first orientation; and

an acute angle defined by the relative offset between the first and the second orientations, the acute angle being less than 90° and

defining an unbalanced structure of the sub-laminate layer,

wherein;

the first orientation is aligned with the primary longitudinal axis of the sub-laminate module such that the first ply is aligned with the primary load-bearing axis of the sub-laminate module;

the second orientation is offset relative to the first orientation and the primary longitudinal axis such that the relative offset corresponds to the acute angle and defines the unbalanced structure of the sub-laminate module; and

the fibers of the first and the second plies are secured relative to one another via a plurality of stitches.

31. The composite laminated structure of claim 30, wherein the acute angle is within a range from about 10°

to about 40°

.

32. The composite laminated structure of claim 30, wherein the acute angle is within a range of from about 15°

to about 30°

.

33. The composite laminated structure of claim 30, wherein the acute angle is approximately 25°

.

34. The composite laminated structure of claim 30, wherein at least the first ply has a thickness of approximately 0.0625 millimeters and a weight of approximately 75 g/m².

35. The composite laminated structure of claim 30, wherein the structure comprises at least sixteen sub-laminate modules.

36. The composite laminated structure of claim 30, wherein the structure has a thickness of approximately 2.0 millimeters.

37. A sub-laminate module for use in forming a composite laminated structure, the sub-laminate module consisting of:

a primary longitudinal axis corresponding to a primary load-bearing axis of the sub-laminate module;

a first ply comprising fibers extending in a first orientation aligned with the primary load-bearing axis of the sub-laminate module;

a second ply comprising fibers extending in a second orientation, the second orientation being offset relative to the first orientation; and

an acute angle defined by the relative offset between the first orientation and the second orientation, the acute angle being less than 30°

,

wherein the first ply and the second ply are secured relative to one another via a plurality of transversely oriented stitches, the plurality of transverse stitches being oriented substantially perpendicular relative to the primary longitudinal axis of the sub-laminate module so as to at least in part define a non-crimped configuration.

38. The sub-laminate module of claim 37, wherein the acute angle is approximately 25°

.