Methods and preforms for forming composite members with interlayers formed of nonwoven, continuous materials
AssigneeThe Boeing Company
InventorThomas Karl Tsotsis
Life of this patent
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Abstract
Materials and methods are provided for producing preform materials for impact-resistant composite materials suitable for liquid molding. Interlayers formed of nonwoven, continuous fibers, such as spunbonded, spunlaced, or mesh fabric, are introduced between non-crimped layers of unidirectional reinforcing fibers to produce a preform for use in liquid-molding processes to produce a composite member. Curing of the preform provides increased impact resistance by increasing the amount of energy required to propagate localized fractures due to impact.
Claims18
A preform for forming a composite member, the preform comprising:
- a plurality of reinforcing layers formed of fibers of a reinforcing material;
- a plurality of interlayers, the interlayers being disposed alternately between the reinforcing layers, each interlayer being formed of a nonwoven fabric of continuous thermoplastic fibers, different than the fibers of the reinforcing layers, such that the layers and interlayers are configured to be infused with a matrix material, wherein the plurality of interlayers have different respective thicknesses;
- and
- stitching extending through the reinforcing layers and the interlayers and configured to engage the reinforcing layers and the interlayers,
- wherein a material of the interlayers is adapted to increase the impact resistance of the composite member.
A composite member defining a predetermined configuration, the composite member comprising:
- a plurality of reinforcing layers formed of fibers of a reinforcing material;
- a plurality of interlayers, the interlayers being disposed alternately between the reinforcing layers, each interlayer being formed of a nonwoven fabric of continuous thermoplastic fibers, different than the fibers of the reinforcing material, wherein the plurality of interlayers have different respective thicknesses;
- stitching extending through the reinforcing layers and the interlayers and configured to engage the reinforcing layers and the interlayers;
- and
- a matrix material infused in the reinforcing material, the matrix material being cured with the reinforcing layers and interlayers defining the predetermined configuration,
- wherein a material of the interlayers is adapted to increase the impact resistance of the composite member.
Dependencies are inferred from the claim text.