Hybrid fiber multi-axial prepreg
AssigneeHoneywell International Inc.
InventorsGary Kratzer, David A. Hurst, Lori L. Wagner, Ashok Bhatnagar
Life of this patent
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Abstract
Multi-ply, hybrid composite materials useful in the formation of thin walled, hollow, tubular articles having improved resistance to hoop stress. Two different, single-ply pre-pregs are impregnated with binders and laminated together with the fibers of the layers oriented at a bias relative to each other. The hybrid composite is rolled into a tubular article having excellent strength uniformity along the full length of the tubular article.
Claims20
A multilayer, hollow, tubular article formed from a multi-ply, hybrid composite material, said hybrid composite material comprising:
- a first unidirectional fibrous ply bonded to a second unidirectional fibrous ply, said first unidirectional fibrous ply comprising first fibers and a first polymeric binder material, wherein the first fibers and the second fibers comprise different polymers, and said second unidirectional fibrous ply comprising second fibers and a second polymeric binder material,
- wherein the first polymeric binder material and the second polymeric binder material combined comprise at least 30% by weight of the composite material,
- wherein the composite material has a fiber areal density of at least 80 grams/m2,
- wherein the second fibrous ply has a fiber areal density of at least three times the fiber areal density of the first fibrous ply,
- wherein the first fibrous ply has a fiber areal density of 20 grams/m2 or less, and
- wherein the second fibrous ply has a fiber areal density of at least 60 grams/m2;
- wherein the hybrid composite material is overlapped onto and sealed to itself to form a multilayer, hollow, tubular article.
A process for forming a multilayer, hollow, tubular article comprising a multi-ply, hybrid composite material, the process comprising:
- a) forming a first unidirectional fibrous ply comprising first fibers and a first polymeric binder material on a release substrate, wherein the first fibrous ply has a fiber areal density of 20 grams/m2 or less;
- b) providing a second unidirectional fibrous ply comprising second fibers and a second polymeric binder material, wherein the second fibrous ply has a fiber areal density of at least 60 grams/m2 and wherein the first fibers and the second fibers comprise different polymers;
- c) laminating the first unidirectional fibrous ply onto the second unidirectional fibrous ply,
- d) removing the release substrate, whereby the first unidirectional fibrous ply remains on and is adhered to the second unidirectional fibrous ply, thereby forming a multi-ply, hybrid composite material wherein the first polymeric binder material and the second polymeric binder material combined comprise at least 30% by weight of the composite material, and wherein the composite material has a fiber areal density of at least 80 grams/m2;
- e) forming the composite material into a tubular structure by wrapping the composite material around itself, leaving a hollow central opening;
- and
- f) optionally subjecting the tubular structure to heat and/or pressure to consolidate the first and second unidirectional fiber plies together.
A multi-ply, hybrid composite material comprising:
- a first ply of unidirectionally oriented elongate bodies bonded to a second ply of unidirectionally oriented elongate bodies, said first ply comprising first elongate bodies and a first polymeric binder material and said second ply comprising second elongate bodies and a second polymeric binder material, wherein the first elongate bodies and the second elongate bodies comprise different polymers,
- wherein the first polymeric binder material and the second polymeric binder material combined comprise at least 30% by weight of the composite material,
- wherein the composite material has a fiber areal density of at least 80 grams/m2,
- wherein the first ply has a fiber areal density of 20 grams/m2 or less, and
- wherein the second ply has a fiber areal density of at least 60 grams/m2.
Dependencies are inferred from the claim text.