US 12,766,796 B2Granted

Methods for designing composite materials with improved toughness

AssigneeThe Board of Trustees of The University of Alabama

InventorSamit Roy

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Abstract

Disclosed herein are methods for designing composite materials with improved toughness.

Claims18

Dependent claims

A method for designing a proposed isotropic composite material with a particular fracture toughness or a proposed orthotropic composite material with a particular delamination toughness, the method comprising:

receiving, using a processing device, a measured fracture toughness value for a matrix material;
receiving, using the processing device, a plurality of measured fracture toughness values of a plurality of isotropic composite materials or a plurality of measured delamination toughness values of a plurality of orthotropic composite materials;
wherein the plurality of isotropic composite materials each comprise a first reinforcing material dispersed throughout the matrix material;
wherein the plurality of orthotropic materials each comprise the first reinforcing material and a second reinforcing material dispersed throughout the matrix material;
wherein the first reinforcing material comprises a plurality of particles;
wherein the second reinforcing material comprises a plurality of fibers;
wherein, for each of the plurality of isotropic composite materials, the first reinforcing material has a median particle size and a median particle thickness, and each of the isotropic composite materials includes the first reinforcing material at a volume fraction and a number density, and wherein the plurality of isotropic materials each has a different volume fraction, number density, median particle size, median particle thickness, or combination thereof;
wherein, for each of the plurality of orthotropic composite materials, the first reinforcing material has a median particle size and a median particle thickness, and each of the orthotropic composite materials includes the first reinforcing material at a volume fraction and a number density, and the plurality of orthotropic materials each has a different volume fraction, number density, median particle size, median particle thickness, or combination thereof;
optionally storing, using the processing device, the measured fracture toughness value for the matrix material, and the plurality of measured fracture toughness values of the plurality of isotropic composite materials or the plurality of measured delamination toughness values of the plurality of orthotropic composite materials;
and
determining, using the processing device, the median particle size and volume fraction that achieves the particular fracture toughness in the proposed isotropic composite material or the particular delamination toughness in the proposed orthotropic composite material using a fracture mechanics based model that incorporates the effects of crack-tip shielding due to microcracking induced by the first reinforcing material and local toughness degradation in a fracture process zone;
wherein the proposed isotropic composite material has a particular mode I fracture toughness or wherein the proposed orthotropic composite material has a particular mode I delamination toughness, the method comprising:
measuring the mode I fracture toughness of the matrix material, wherein the matrix material has an elastic modulus;
measuring the mode I facture toughness of at least nine different isotropic composite materials;
wherein each isotropic composite material comprises a first reinforcing material dispersed throughout the matrix material, wherein the first reinforcing material comprises a plurality of particles;
wherein, for each of the at least nine different isotropic materials, the first reinforcing material has a median particle size and a median particle thickness;
wherein each of the nine different isotropic materials includes the first reinforcing material at a volume fraction and a number density;
wherein the at least nine different isotropic composite materials includes at least three sets of isotropic composite materials;
wherein, for each set, the first reinforcing material has a particular median particle size, and each set includes at least three different isotropic composite materials, each having a particular volume fraction of the first reinforcing material having the particular median particle size, wherein the particular volume fraction is different for each of the at least three different isotropic composite materials in the set, such that each set of isotropic composite materials includes at least three different volume fractions of the first reinforcing material having the particular median particle size;
wherein the particular median particle size is different for each of the at least three sets of isotropic composite materials, such that the at least nine different isotropic composite materials includes at least three different median particle sizes;
using the measured mode I fracture toughness of the matrix material and the measured mode I facture toughness of at least nine isotropic composite material samples in Equation (A) below to determine power-law parameters β and q:
(
K
IC
⁢
brittle
2
/
K
IC
⁢
composite
2
)
=
(
1
-
β
⁢
n
q
)
(
A
)
wherein
KIC brittle is measured value of the mode I toughness for the matrix material;
KIC composite is the measured value of the mode I toughness for the isotropic composite materials;
and
n is the number density of the first reinforcing material in the isotropic composite materials;
and
for designing the proposed isotropic composite material, using the determined power-law parameters β and q and the measured value of the mode I toughness of the matrix material in equation (B) below to determine the volume fraction, the median particle size, and the median particle thickness of the first reinforcing material that achieves the particular mode I fracture toughness for the proposed isotropic composite material:
K
IC
⁢
composite
=
K
IC
⁢
brittle
(
1
-
V
f
⁢
reinforc
)
⁢
(
1
1
-
β
⁡
(
V
f
⁢
reinforc
l
2
⁢
t
)
q
)
(
B
)
wherein
KIC brittle is measured value of the mode I toughness for the matrix material;
Vfreinforc is the volume fraction of the first reinforcing material;
l is the median particle size of the first reinforcing material;
t is the median particle thickness of the first reinforcing material;
and
KIC composite is the particular mode I fracture toughness for the proposed isotropic composite material;
or
for designing the proposed orthotropic composite material:
the proposed orthotropic composite material comprising the first reinforcing material and a second reinforcing material dispersed throughout the matrix material;
the second reinforcing material comprising a plurality of fibers and having an elastic modulus, a shear modulus, and a Poisson's ratio;
the proposed orthotropic composite material comprising the second reinforcing material and the matrix material each at a particular volume fraction;
using the determined power-law parameters β and q and the measured value of the mode I toughness of the matrix material in the equations below to determine the particular volume fraction, the median particle size, and the median particle thickness of the first reinforcing material that achieves the particular mode I delamination toughness for the proposed orthotropic composite material:
G
IC
⁢
composite
=
K
IC
⁢
brittle
(
1
-
V
fiber
)
2
⁢
(
1
2
⁢
E
1
⁢
E
2
)
1
/
2
[
(
E
1
E
2
)
1
/
2
+
(
E
1
-
2
⁢
γ
12
⁢
G
12
2
⁢
G
12
)
]
1
/
2
E
1
=
E
f
⁢
V
f
+
E
m
⁢
V
m
E
2
=
E
f
⁢
E
m
E
f
⁢
V
m
+
E
m
⁢
V
fiber
γ
12
=
γ
f
⁢
V
fiber
+
γ
m
⁢
V
m
G
12
=
G
f
⁢
G
m
G
f
⁢
V
m
+
G
m
⁢
V
fiber
E
m
=
E
brittle
(
1
-
β
⁡
(
V
f
⁢
reinforc
l
2
⁢
t
)
q
)
wherein
GIC composite is the particular mode I delamination toughness for the proposed orthotropic composite material;
KIC brittle is measured value of the mode I toughness for the matrix material;
Vfiber is the particular volume fraction of the second reinforcing material in the proposed orthotropic composite material;
Ef is the elastic modulus of the second reinforcing material;
Vm is the particular volume fraction of the matrix material in the proposed orthotropic composite material;
γf is Poisson's ratio of the second reinforcing material;
γm is Poisson's ratio of the matrix material;
Gf is the shear modulus of the second reinforcing material;
Gm is the shear modulus of the matrix material;
Ebrittle is the elastic modulus of the matrix material;
Vf reinforc is the volume fraction of the first reinforcing material;
l is the median particle size of the first reinforcing material;
and
t is the median particle thickness of the first reinforcing material.

266 more elements

Dependencies are inferred from the claim text.

Facts

Application: 17/984,335Filed 10 Nov 2022 · us provisional application
Priority: 10 Jan 2022
Published: US 2023/0219304 A113 Jul 2023
Granted: 20 Oct 2026
Term ends: Not estimatedThe source records don’t support an estimate.

Classification15 codes

B29C 70/04
Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts: comprising reinforcements only,…
B82Y 30/00
Nanotechnology for materials or surface science
C08J 5/005
Manufacture of articles or shaped materials containing macromolecular substances: reinforced macromolecular compounds with nanosized materials,…
C08J 5/041
With inorganic fibres: with metal fibres

Family

Application63/297,900Us provisional application · filed 10 Jan 2022
US 2023/0219304 A1Pre-grant publication · published 13 Jul 2023
US 12,766,796 B2This patent

From the US filing history. Foreign family members aren’t listed.

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receiving, using a processing device, a measured fracture toughness value for a matrix material;
receiving, using the processing device, a plurality of measured fracture toughness values of a plurality of isotropic composite materials or a plurality of measured delamination toughness values of a plurality of orthotropic composite materials;
wherein the plurality of isotropic composite materials each comprise a first reinforcing material dispersed throughout the matrix material;
wherein the plurality of orthotropic materials each comprise the first reinforcing material and a second reinforcing material dispersed throughout the matrix material;
wherein the first reinforcing material comprises a plurality of particles;
wherein the second reinforcing material comprises a plurality of fibers;
wherein, for each of the plurality of isotropic composite materials, the first reinforcing material has a median particle size and a median particle thickness, and each of the isotropic composite materials includes the first reinforcing material at a volume fraction and a number density, and wherein the plurality of isotropic materials each has a different volume fraction, number density, median particle size, median particle thickness, or combination thereof;
wherein, for each of the plurality of orthotropic composite materials, the first reinforcing material has a median particle size and a median particle thickness, and each of the orthotropic composite materials includes the first reinforcing material at a volume fraction and a number density, and the plurality of orthotropic materials each has a different volume fraction, number density, median particle size, median particle thickness, or combination thereof;
optionally storing, using the processing device, the measured fracture toughness value for the matrix material, and the plurality of measured fracture toughness values of the plurality of isotropic composite materials or the plurality of measured delamination toughness values of the plurality of orthotropic composite materials;
and
determining, using the processing device, the median particle size and volume fraction that achieves the particular fracture toughness in the proposed isotropic composite material or the particular delamination toughness in the proposed orthotropic composite material using a fracture mechanics based model that incorporates the effects of crack-tip shielding due to microcracking induced by the first reinforcing material and local toughness degradation in a fracture process zone;
wherein the proposed isotropic composite material has a particular mode I fracture toughness or wherein the proposed orthotropic composite material has a particular mode I delamination toughness, the method comprising:
measuring the mode I fracture toughness of the matrix material, wherein the matrix material has an elastic modulus;
measuring the mode I facture toughness of at least nine different isotropic composite materials;
wherein each isotropic composite material comprises a first reinforcing material dispersed throughout the matrix material, wherein the first reinforcing material comprises a plurality of particles;
wherein, for each of the at least nine different isotropic materials, the first reinforcing material has a median particle size and a median particle thickness;
wherein each of the nine different isotropic materials includes the first reinforcing material at a volume fraction and a number density;
wherein the at least nine different isotropic composite materials includes at least three sets of isotropic composite materials;
wherein, for each set, the first reinforcing material has a particular median particle size, and each set includes at least three different isotropic composite materials, each having a particular volume fraction of the first reinforcing material having the particular median particle size, wherein the particular volume fraction is different for each of the at least three different isotropic composite materials in the set, such that each set of isotropic composite materials includes at least three different volume fractions of the first reinforcing material having the particular median particle size;
wherein the particular median particle size is different for each of the at least three sets of isotropic composite materials, such that the at least nine different isotropic composite materials includes at least three different median particle sizes;
using the measured mode I fracture toughness of the matrix material and the measured mode I facture toughness of at least nine isotropic composite material samples in Equation (A) below to determine power-law parameters β and q:
(
K
IC
⁢
brittle
2
/
K
IC
⁢
composite
2
)
=
(
1
-
β
⁢
n
q
)
(
A
)
wherein
KIC brittle is measured value of the mode I toughness for the matrix material;
KIC composite is the measured value of the mode I toughness for the isotropic composite materials;
and
n is the number density of the first reinforcing material in the isotropic composite materials;
and
for designing the proposed isotropic composite material, using the determined power-law parameters β and q and the measured value of the mode I toughness of the matrix material in equation (B) below to determine the volume fraction, the median particle size, and the median particle thickness of the first reinforcing material that achieves the particular mode I fracture toughness for the proposed isotropic composite material:
K
IC
⁢
composite
=
K
IC
⁢
brittle
(
1
-
V
f
⁢
reinforc
)
⁢
(
1
1
-
β
⁡
(
V
f
⁢
reinforc
l
2
⁢
t
)
q
)
(
B
)
wherein
KIC brittle is measured value of the mode I toughness for the matrix material;
Vfreinforc is the volume fraction of the first reinforcing material;
l is the median particle size of the first reinforcing material;
t is the median particle thickness of the first reinforcing material;
and
KIC composite is the particular mode I fracture toughness for the proposed isotropic composite material;
or
for designing the proposed orthotropic composite material:
the proposed orthotropic composite material comprising the first reinforcing material and a second reinforcing material dispersed throughout the matrix material;
the second reinforcing material comprising a plurality of fibers and having an elastic modulus, a shear modulus, and a Poisson's ratio;
the proposed orthotropic composite material comprising the second reinforcing material and the matrix material each at a particular volume fraction;
using the determined power-law parameters β and q and the measured value of the mode I toughness of the matrix material in the equations below to determine the particular volume fraction, the median particle size, and the median particle thickness of the first reinforcing material that achieves the particular mode I delamination toughness for the proposed orthotropic composite material:
G
IC
⁢
composite
=
K
IC
⁢
brittle
(
1
-
V
fiber
)
2
⁢
(
1
2
⁢
E
1
⁢
E
2
)
1
/
2
[
(
E
1
E
2
)
1
/
2
+
(
E
1
-
2
⁢
γ
12
⁢
G
12
2
⁢
G
12
)
]
1
/
2
E
1
=
E
f
⁢
V
f
+
E
m
⁢
V
m
E
2
=
E
f
⁢
E
m
E
f
⁢
V
m
+
E
m
⁢
V
fiber
γ
12
=
γ
f
⁢
V
fiber
+
γ
m
⁢
V
m
G
12
=
G
f
⁢
G
m
G
f
⁢
V
m
+
G
m
⁢
V
fiber
E
m
=
E
brittle
(
1
-
β
⁡
(
V
f
⁢
reinforc
l
2
⁢
t
)
q
)
wherein
GIC composite is the particular mode I delamination toughness for the proposed orthotropic composite material;
KIC brittle is measured value of the mode I toughness for the matrix material;
Vfiber is the particular volume fraction of the second reinforcing material in the proposed orthotropic composite material;
Ef is the elastic modulus of the second reinforcing material;
Vm is the particular volume fraction of the matrix material in the proposed orthotropic composite material;
γf is Poisson's ratio of the second reinforcing material;
γm is Poisson's ratio of the matrix material;
Gf is the shear modulus of the second reinforcing material;
Gm is the shear modulus of the matrix material;
Ebrittle is the elastic modulus of the matrix material;
Vf reinforc is the volume fraction of the first reinforcing material;
l is the median particle size of the first reinforcing material;
and
t is the median particle thickness of the first reinforcing material.

266 more elements

Facts

Application

17/984,335Filed 10 Nov 2022 · us provisional application

Priority

10 Jan 2022

Published

US 2023/0219304 A113 Jul 2023

Granted

20 Oct 2026

Term ends

Not estimatedThe source records don’t support an estimate.

Classification15 codes

B29C 70/04
Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts: comprising reinforcements only,…
B82Y 30/00
Nanotechnology for materials or surface science
C08J 5/005
Manufacture of articles or shaped materials containing macromolecular substances: reinforced macromolecular compounds with nanosized materials,…
C08J 5/041
With inorganic fibres: with metal fibres