# US 8,541,090 B2 · Method for making a composite material, composite material and end product

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- Number: US 8,541,090 B2
- Document ID: US8541090B2
- Status: Granted
- Kind: B2
- Application number: 13/522,976
- Filed: 2011-01-28
- Published: 2012-12-20
- Granted: 2013-09-24
- Earliest claimed: 2011-01-28
- Assignees: Stichting National Lucht-En Ruimtevaart Laboratorium
- Applicants: Martin Herman Nagelsmit; Christos Kassapoglou; Hubertus Gerardus Stephanus Jozef Thuis; Zafer Gürdal; Willem Antonius Roy Wildvank
- Inventors: Martin Herman Nagelsmit; Christos Kassapoglou; Hubertus Gerardus Stephanus Jozef Thuis; Zafer Gürdal; Willem Antonius Roy Wildvank
- Web page: https://patentgrep.com/patent/US8541090B2

## CPC

- B29C 70/386: {Automated tape laying [ATL]}
- 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)}
- B32B 3/14: characterised by a face layer formed of separate pieces of material {which are juxtaposed side-by-side (B32B5/02 takes precedence)}
- B32B 3/18: characterised by an internal layer formed of separate pieces of material {which are juxtaposed side-by-side (B32B5/02 takes precedence)}
- 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}
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 5/28: impregnated with or embedded in a plastic substance {(not used)}
- B32B 27/04: as impregnant, bonding, or embedding substance {(not used)}
- B32B 27/12: next to a fibrous or filamentary layer
- D04H 3/04: in rectilinear paths, e.g. crossing at right angles
- B32B 2250/20: All layers being fibrous or filamentary
- B32B 2307/50: having particular mechanical properties
- Y10T 428/1314: Contains fabric, fiber particle, or filament made of glass, ceramic, or sintered, fused, fired, or calcined metal oxide, or metal carbide or other inorganic compound [e.g., fiber glass, mineral fiber, sand, etc.]
- Y10T 428/1362: Textile, fabric, cloth, or pile containing [e.g., web, net, woven, knitted, mesh, nonwoven, matted, etc.]
- Y10T 428/1369: Fiber or fibers wound around each other or into a self-sustaining shape [e.g., yarn, braid, fibers shaped around a core, etc.]
- Y10T 428/24091: with additional layer[s]
- Y10T 428/24132: including grain, strips, or filamentary elements in different layers or components parallel
- Y10T 428/249922: Embodying intertwined or helical component[s]
- Y10T 428/2936: Wound or wrapped core or coating [i.e., spiral or helical]
- Y10T 428/2938: Coating on discrete and individual rods, strands or filaments
- 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)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- D04H: MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL (weaving D03; knitting D04B; braiding D04C; net-making D04G; sewing D05B; tufting D05C; finishing non-woven fabrics D06); FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING {; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION}(non-woven fabrics having an intermediate or external layer of a different kind, e.g. of woven fabric, B32B)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A method is presented for making a composite material from strips comprising longitudinal fibers and a binder or resin, which material comprises a number of layer assemblies one on top of the other. Each layer assembly comprises m sets (with m at least 2) of parallel strips each extending in a different direction, Each layer assembly is manufactured by successive steps of depositing groups of parallel strips according to a well defined pattern (without longitudinally interweaving strips with previously deposited strips). Before completing a layer assembly, with the exception of the last layer assembly, by depositing its last group of parallel strips, the first group of parallel strips of the following layer assembly is already deposited. A composite material manufactured with such a method is presented too.

## Claims

### Claim 1

Method for making a composite material from strips comprising longitudinal fibers and a binder or resin, which material comprises a number of layer assemblies one on top of the other, wherein each layer assembly comprises m sets, m being equal to or greater than 2, of parallel strips each extending in a different direction and wherein each layer assembly is manufactured by the successive steps of:
a. depositing, as part of a first set of strips, a first group of parallel strips side by side at a predetermined spacing;
b. depositing, as part of a second set of strips, on top of the first group of strips, a second group of parallel strips side by side at said predetermined spacing and each extending at an angle different from 180° with respect to the strips of the first group;
c. repeating step b. for all remaining sets of the m sets of strips, wherein the strips deposited as part of each next set of parallel strips are deposited at an angle different from 180° with respect to the strips of all the previous sets;
d. positioning, as a further part of the first set of strips, on top of the previously deposited groups of strips, a next group of parallel strips side by side at said predetermined spacing, in parallel to and immediately adjacent to the strips of the first group;
e. positioning, as a further part of the second set of strips, on top of the previously deposited groups of strips, a next group of parallel strips side by side at said predetermined spacing, in parallel to and immediately adjacent to the strips of the second group;
f. repeating step e. for all remaining sets of the m sets of strips;
g. repeating the steps d. to f. until a last group of parallel strips is deposited as part of the last set of strips such that all the predetermined spacings are completely occupied by adjacently positioned strips and a layer assembly is completed,
and wherein, before completing a layer assembly, with the exception of the last layer assembly, by depositing its last group of parallel strips during the respective step g, the first group of parallel strips of the following layer assembly is deposited in accordance with the respective step a.

### Claim 2 (depends on 1)

Method according to claim 1, wherein the strips of the first group of parallel strips of the following layer assembly are deposited at an angle with respect to the strips of the last group of parallel strips of the previous layer assembly.

### Claim 3 (depends on 1)

Method according to claim 1, wherein the strips of each group are deposited at a spacing substantially equal to an integer multiple n of the strip width and wherein step g. comprises repeating the steps d.to f. n−1 times.

### Claim 4 (depends on 3)

Method according to claim 3, wherein the strips of each group are deposited at a spacing substantially equal to the strip width and wherein step g is omitted.

### Claim 5 (depends on 1)

Method according to claim 1, wherein at least one layer assembly comprises only two sets (m=2) of parallel strips.

### Claim 6 (depends on 1)

Method according to claim 1, wherein at least one layer assembly comprises four sets (m=4) of parallel strips.

### Claim 7 (depends on 1)

Method according to claim 1, wherein all the layer assemblies basically comprise the same number and arrangement of sets of strips.

### Claim 8

Composite material made from strips comprising longitudinal fibers and a binder or resin, which material comprises a number of layer assemblies one on top of the other, wherein each layer assembly comprises m sets, m being equal to or greater than 2, of parallel strips each extending in a different direction, with
a. a first group of parallel strips deposited side by side at a predetermined spacing;
b. on top of the first group of strips, a second group of parallel strips deposited side by side at said predetermined spacing and each extending at an angle different from 180° with respect to the strips of the first group;
c. a repetition of groups according to b. for all remaining sets of the m sets of strips, wherein the strips deposited as part of each next set of parallel strips are deposited at an angle different from 180° with respect to the strips of all the previous sets;
d. on top of the previously deposited groups of strips, a next group of parallel strips deposited side by side at said predetermined spacing, in parallel to and immediately adjacent to the strips of the first group;
e. on top of the previously deposited groups of strips, a next group of parallel strips deposited side by side at said predetermined spacing, in parallel to and immediately adjacent to the strips of the second group;
f. a repetition of groups according to e. for all remaining sets of the m sets of strips;
g. a repetition of groups according to d. to f. until a last group of parallel strips is deposited such that all the predetermined spacings are completely occupied by adjacently positioned strips,
and wherein the first group of parallel strips according to a. of a following layer assembly is deposited below the last group of parallel strips according to g of a previous layer assembly.

### Claim 9 (depends on 8)

Composite material according to claim 8, wherein the strips of the first group of parallel strips of the following layer extend at an angle with respect to the strips of the last group of parallel strips of the previous layer assembly.

### Claim 10 (depends on 8)

Composite material according to claim 8, wherein the strips of each group are deposited at a spacing substantially equal to an integer multiple n of the strip width.

### Claim 11 (depends on 8)

Composite material according to claim 8, wherein the strips of each group are deposited at a spacing substantially equal to the strip width.

### Claim 12 (depends on 8)

Composite material according to claim 8, wherein at least one layer assembly comprises only two sets (m=2) of parallel strips.

### Claim 13 (depends on 8)

Composite material according to claim 8, wherein at least one layer assembly comprises four sets (m=4) of parallel strips.

### Claim 14 (depends on 8)

Composite material according to claim 8, wherein all the layer assemblies comprise the same number and arrangement of sets of strips.

### Claim 15

End product comprising composite material made from strips comprising longitudinal fibers and a binder or resin, which material comprises a number of layer assemblies one on top of the other,
wherein each layer assembly comprises m sets, m being equal to or greater than 2, of parallel strips each extending in a different direction, with
a. a first group of parallel strips deposited side by side at a predetermined spacing;
b. on top of the first group of strips, a second group of parallel strips deposited side by side at said predetermined spacing and each extending at an angle different from 180° with respect to the strips of the first group;
c. a repetition of groups according to b. for all remaining sets of the m sets of strips, wherein the strips deposited as part of each next set of parallel strips are deposited at an angle different from 180° with respect to the strips of all the previous sets;
d. on top of the previously deposited groups of strips, a next group of parallel strips deposited side by side at said predetermined spacing, in parallel to and immediately adjacent to the strips of the first group;
e. on top of the previously deposited groups of strips, a next group of parallel strips deposited side by side at said predetermined spacing, in parallel to and immediately adjacent to the strips of the second group;
f. a repetition of groups according to e. for all remaining sets of the m sets of strips;
g. a repetition of groups according to d. to f. until a last group of parallel strips is deposited such that all the predetermined spacings are completely occupied by adjacently positioned strips,
and wherein the first group of parallel strips according to a. of a following layer assembly is deposited below the last group of parallel strips according to g of a previous layer assembly.

### Claim 16 (depends on 5)

Method according to claim 5, wherein the only two sets of parallel strips extend orthogonally to each other.

### Claim 17 (depends on 6)

Method according to claim 6, wherein the four sets of parallel strips extend at 45°, 90°and −45° with respect to each other.

### Claim 18 (depends on 12)

Composite material according to claim 12, wherein the only two sets of parallel strips extend orthogonally to each other.

### Claim 19 (depends on 13)

Composite material according to claim 13, wherein the four sets of parallel strips extend at 45°, 90°and −45° with respect to each other.

### Claim 20 (depends on 15)

End product according to claim 15, wherein at least one layer assembly comprises only two sets (m=2) of parallel strips extending orthogonally to each other or four sets (m=4) of parallel strips extending at 45°, 90°and −45° with respect to each other.