# US 10,870,265 B2 · Method for limiting interlaminar fatigue in composite laminate and a component incorporating the same

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- Number: US 10,870,265 B2
- Document ID: US10870265B2
- Status: Granted
- Kind: B2
- Application number: 16/781,355
- Filed: 2020-02-04
- Published: 2020-07-16
- Granted: 2020-12-22
- Earliest claimed: 2014-07-14
- Assignees: Bell Textron Inc.
- Applicants: Bell Textron Inc.
- Inventors: Bogdan Roman Krasnowski; Robert Arnold Brack; Xiaoming Li; Robert Wardlaw
- Web page: https://patentgrep.com/patent/US10870265B2

## CPC

- B32B 27/08: of synthetic resin
- B29C 70/06: Fibrous reinforcements only
- 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
- B32B 5/142: {Variation across the area of the layer}
- B32B 27/38: comprising epoxy resins
- B32B 37/144: {using layers with different mechanical or chemical conditions or properties, e.g. layers with different thermal shrinkage, layers under tension during bonding (constructional features for tensioning B32B38/1825)}
- B29L 2031/3088: {Helicopters}
- B32B 2262/0269: Aromatic polyamide fibres
- B32B 2262/101: Glass fibres
- B32B 2262/106: Carbon fibres, e.g. graphite fibres
- B32B 2305/72: Cured, e.g. vulcanised, cross-linked
- B32B 2307/552: Fatigue strength
- B32B 2605/18: Aircraft
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

In some embodiments, a method of manufacturing composite laminate, including providing a first fibrous material having a plurality of fibers, providing a second fibrous material having a plurality of fibers, disposing the fibers of the first fibrous material in a first polymeric matrix, disposing the fibers of the second fibrous material in a second polymeric matrix, laying up a plurality of the first fibrous material on a rigid structure, laying up the second fibrous material on the rigid structure, wherein the first fibrous material is in contact with the second fibrous material, curing the first polymeric matrix, creating a plurality of baseline layers from the plurality of first fibrous material and the first polymeric matrix, and curing the second polymeric matrix, creating a compliant layer from the second fibrous material and the second polymeric matrix. The compliant layer is stronger than each individual baseline layers.

## Claims

### Claim 1

A method of manufacturing composite laminate, comprising:
providing a first fibrous material having a plurality of fibers;
providing a second fibrous material having a plurality of fibers;
disposing the fibers of the first fibrous material in a first polymeric matrix that is an amine cured, toughened epoxy resin system;
disposing the fibers of the second fibrous material in a second polymeric matrix;
laying up a plurality of the first fibrous material on a rigid structure;
laying up the second fibrous material on the rigid structure, wherein the first fibrous material is in contact with the second fibrous material;
curing the first polymeric matrix, creating a plurality of baseline layers from the plurality of first fibrous material and the first polymeric matrix; and
curing the second polymeric matrix, creating a compliant layer from the second fibrous material and the second polymeric matrix;
wherein the compliant layer is stronger than each individual baseline layer;
wherein the second polymeric matrix is stronger than the first polymeric matrix.

### Claim 2 (depends on 1)

The method of claim 1, wherein the plurality of fibers of the first fibrous material are carbon fiber.

### Claim 3 (depends on 2)

The method of claim 2, wherein the first fibrous material is disposed within the first polymeric matrix prior to being laid up on the rigid structure.

### Claim 4 (depends on 1)

The method of claim 1, wherein the second fibrous material is laid up at a location that will experience peak interlaminar stresses.

### Claim 5 (depends on 1)

The method of claim 1, wherein laying up the second fibrous material on the rigid structure comprises laying up the second fibrous material such that the second fibrous material overlaps at least one of the plurality of first fibrous material.

### Claim 6 (depends on 1)

The method of claim 1, wherein laying up the second fibrous material on the rigid structure comprises laying up the second fibrous material such that a planar dimension of the second fibrous material is substantially the same as a planar dimension of a composite component that comprises the composite laminate.

### Claim 7 (depends on 1)

The method of claim 1, wherein the first fibrous material and the second fibrous material have the same type of fiber, and the type of fiber is selected from the group consisting of glass, carbon, basalt, and aramid.

### Claim 8 (depends on 1)

The method of claim 1, wherein the first fibrous material and the second fibrous material are unidirectional fabric layers.