EP1613457A2 - Splinter resistant composite laminate - Google Patents

Splinter resistant composite laminate

Info

Publication number
EP1613457A2
EP1613457A2 EP04750208A EP04750208A EP1613457A2 EP 1613457 A2 EP1613457 A2 EP 1613457A2 EP 04750208 A EP04750208 A EP 04750208A EP 04750208 A EP04750208 A EP 04750208A EP 1613457 A2 EP1613457 A2 EP 1613457A2
Authority
EP
European Patent Office
Prior art keywords
splinter
arrestor
composite material
tows
recited
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP04750208A
Other languages
German (de)
French (fr)
Inventor
Bruce F. Kay
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sikorsky Aircraft Corp
Original Assignee
Sikorsky Aircraft Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sikorsky Aircraft Corp filed Critical Sikorsky Aircraft Corp
Publication of EP1613457A2 publication Critical patent/EP1613457A2/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
    • B29C70/202—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres arranged in parallel planes or structures of fibres crossing at substantial angles, e.g. cross-moulding compound [XMC]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0089—Impact strength or toughness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/07—Parts immersed or impregnated in a matrix
    • B32B2305/076—Prepregs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/558—Impact strength, toughness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2571/00—Protective equipment
    • B32B2571/02—Protective equipment defensive, e.g. armour plates or anti-ballistic clothing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24058—Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in respective layers or components in angular relation
    • Y10T428/24124—Fibers

Definitions

  • the present invention relates to fiber reinforced resin matrix composites and, more particularly, to a composite laminated structure which resists splintering typical from ballistic impacts.
  • Kevlar, graphite, and fiberglass are known and have found increasing use in load bearing structural applications due to their high strength, light weight, and ability to be fashioned into complex shapes. Such composite structural materials are particularly suitable for aircraft structures.
  • a composite component is typically formed through a lay-up of composite material layers.
  • the lay-up technique employs the use of a multiple of discrete plies of a substrate material having a plurality of parallel fibers that are impregnated with a resinous material.
  • the multiple of layered plies are laminated in a mold and then placed in an autoclave or oven for application of heat and pressure such that the lay-up cures into the finished composite component.
  • the fiber orientation be optimally tailored to meet the strength and stiffness requirements for a particular application.
  • the outermost layers or plies of the composite component include a single fiber orientation, which may be subject to splintering or peeling in response to impact hazards. Since composites have relatively low interlaminar peel strength, the splinters may become relatively long. These elongated splinters may compromise structural integrity. A relatively small puncture may thus damage a relatively larger area. Even if integrity is not an issue, the repair covers a large area through which the splinter extends.
  • the composite component according to the present invention includes splinter arrestors laminated transverse to the fiber orientation of an outermost composite material layer.
  • the splinter arrestors are tows located upon the outermost composite material layers at a predetermined distance from each other.
  • the predetermined distance is a distance which will constrain a splinter of fibers from the outermost composite material layers to an acceptable length.
  • tows may be eliminated in subsurface layers to avoid an increase in the overall weight of the composite component.
  • the present invention therefore provides a composite laminate which resists splintering when damaged, particularly from ballistic impact.
  • Figure 1 is a general exploded view of a composite component
  • Figure 2 is a general perspective view of a single tow of a plurality of fibers
  • Figure 3 is a general perspective view of a composite component illustrating splinter arrestors according to the present invention.
  • Figure 4. is a general exploded view of another composite component with subsurface tows which correspond to the splinter arrestors eliminated.
  • Figure 1 illustrates an exploded view of a composite component 10 manufactured from a plurality of prepreg composite material layers 12 which are selectively oriented and selectively chosen to achieve the desired strength.
  • the plurality of prepreg composite material layers 12 maybe laid up upon each other or may skin a core material 14 such as honecomb, foam, or the like.
  • the actual lay-up of one or more prepregs is well known and further description of the details thereof need not be provided herein.
  • Each material layer 12 is preferably manufactured of unidirectional fiber material which is laid down as a plurality of parallel tows. That is, each material layer 12 includes a plurality of tows 12t ( Figure 2) which are manufactured as a bundle of continuous monofiber strands. As will be apparent, each tow or tow strand is essentially a bundle of a plurality of fiber filaments. Suitable fibers include high strength fibers such as graphite fibers, fiberglass fibers, ceramic fibers, and aramid fibers, which are commercially available.
  • the outermost composite material layers 12' define a single fiber orientation which may be subject to splintering or peeling in response to damage. That is, one or more tows may be peeled away from a subsurface layer.
  • splinter arrestors 16 are located transverse to the single fiber orientation of the outermost composite material layers 12'.
  • the splinter arrestors 16 are preferably individual tows oriented perpendicular to the direction of the tows 12t within the outermost composite material layers 12' ( Figure 2).
  • Suitable splinter arrestors 16 include high strength fibers such as graphite fibers, fiberglass fibers, ceramic fibers, and aramid fibers, as well as lower strength fabric tape, woven cloth, and/or nonwoven fabric of interbonding fibers. Fiber placement machines are preferably utilized to locate single splinter arrestor tows 16t upon the outermost composite material layers 12'.
  • the outermost layer is formed as a checkerboard-like pattern. It should be understood that various automated and hand layup methods of layer and splinter placement will benefit from the present invention.
  • the splinter arrestors 16 are located upon the outermost composite material layers
  • the predetermined distance is preferably a distance, which will constrain a splinter of fibers from the outermost composite material, layers 12' to an acceptable length should a projectile p damage the component 10 ( Figure 3).
  • the acceptable length will typically depend at least upon the composite component 10 size and location within a composite structure.
  • tows 12t' in subsurface layers which correspond to the splinter arrestors 16 may be eliminated such that the overall weight of the composite component 10 is not increased.
  • the tows 12t' which are oriented in the same direction and are directly below the splinter arrestors 16 are eliminated.
  • the eliminated tows 12t' need not be immediately below the outermost composite material layers 12' but may be within a deeper subsurface layer within the composite component 10'.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
  • Aiming, Guidance, Guns With A Light Source, Armor, Camouflage, And Targets (AREA)

Abstract

A composite component includes splinter arrestors laminated transverse to the fiber orientation of an outermost composite material layer. The splinter arrestors are located upon the outermost composite material layers at a predetermined distance from each other to constrain a splinter of fibers from the outermost composite material layers to an acceptable length.

Description

SPLINTER RESISTANT COMPOSITE LAMINATE
BACKGROUND OF THE INVENTION
[1] This invention was made with government support under Contract No.:
DAAHlO-98-2-0001 awarded by the Department of the Army. The government therefore has certain rights in this invention.
[2] The present invention relates to fiber reinforced resin matrix composites and, more particularly, to a composite laminated structure which resists splintering typical from ballistic impacts.
[3] Articles fabricated from fiber reinforced resin matrix composite materials, e.g.,
Kevlar, graphite, and fiberglass, are known and have found increasing use in load bearing structural applications due to their high strength, light weight, and ability to be fashioned into complex shapes. Such composite structural materials are particularly suitable for aircraft structures.
[4] A composite component is typically formed through a lay-up of composite material layers. The lay-up technique employs the use of a multiple of discrete plies of a substrate material having a plurality of parallel fibers that are impregnated with a resinous material. The multiple of layered plies are laminated in a mold and then placed in an autoclave or oven for application of heat and pressure such that the lay-up cures into the finished composite component.
[5] To maximize the benefits of composites, it is essential that the fiber orientation be optimally tailored to meet the strength and stiffness requirements for a particular application. Disadvantageously, the outermost layers or plies of the composite component include a single fiber orientation, which may be subject to splintering or peeling in response to impact hazards. Since composites have relatively low interlaminar peel strength, the splinters may become relatively long. These elongated splinters may compromise structural integrity. A relatively small puncture may thus damage a relatively larger area. Even if integrity is not an issue, the repair covers a large area through which the splinter extends.
[6] Accordingly, it is desirable to provide a composite laminate which resists splintering when damaged particularly from ballistic impact. SUMMARY OF THE INVENTION
[7] The composite component according to the present invention includes splinter arrestors laminated transverse to the fiber orientation of an outermost composite material layer.
[8] The splinter arrestors are tows located upon the outermost composite material layers at a predetermined distance from each other. The predetermined distance is a distance which will constrain a splinter of fibers from the outermost composite material layers to an acceptable length. Alternatively or in addition, tows may be eliminated in subsurface layers to avoid an increase in the overall weight of the composite component.
[9] The present invention therefore provides a composite laminate which resists splintering when damaged, particularly from ballistic impact.
BRIEF DESCRIPTION OF THE DRAWINGS
[10] The various features and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the currently preferred embodiment. The drawings that accompany the detailed description can be briefly described as follows:
[11] Figure 1 is a general exploded view of a composite component;
Figure 2 is a general perspective view of a single tow of a plurality of fibers;
[12] Figure 3 is a general perspective view of a composite component illustrating splinter arrestors according to the present invention; and
[13] Figure 4. is a general exploded view of another composite component with subsurface tows which correspond to the splinter arrestors eliminated.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[14] Figure 1 illustrates an exploded view of a composite component 10 manufactured from a plurality of prepreg composite material layers 12 which are selectively oriented and selectively chosen to achieve the desired strength. The plurality of prepreg composite material layers 12 maybe laid up upon each other or may skin a core material 14 such as honecomb, foam, or the like. The actual lay-up of one or more prepregs is well known and further description of the details thereof need not be provided herein.
[15] Each material layer 12 is preferably manufactured of unidirectional fiber material which is laid down as a plurality of parallel tows. That is, each material layer 12 includes a plurality of tows 12t (Figure 2) which are manufactured as a bundle of continuous monofiber strands. As will be apparent, each tow or tow strand is essentially a bundle of a plurality of fiber filaments. Suitable fibers include high strength fibers such as graphite fibers, fiberglass fibers, ceramic fibers, and aramid fibers, which are commercially available. The outermost composite material layers 12' define a single fiber orientation which may be subject to splintering or peeling in response to damage. That is, one or more tows may be peeled away from a subsurface layer.
[16] To prevent peeling of the outermost composite material layers 12' splinter arrestors 16 are located transverse to the single fiber orientation of the outermost composite material layers 12'. The splinter arrestors 16 are preferably individual tows oriented perpendicular to the direction of the tows 12t within the outermost composite material layers 12' (Figure 2). Suitable splinter arrestors 16 include high strength fibers such as graphite fibers, fiberglass fibers, ceramic fibers, and aramid fibers, as well as lower strength fabric tape, woven cloth, and/or nonwoven fabric of interbonding fibers. Fiber placement machines are preferably utilized to locate single splinter arrestor tows 16t upon the outermost composite material layers 12'. Relatively wider tows, multiple tows, or tapes will also benefit from the present invention. The outermost layer is formed as a checkerboard-like pattern. It should be understood that various automated and hand layup methods of layer and splinter placement will benefit from the present invention.
[ 17] The splinter arrestors 16 are located upon the outermost composite material layers
12' at a predetermined distance from each other. The predetermined distance is preferably a distance, which will constrain a splinter of fibers from the outermost composite material, layers 12' to an acceptable length should a projectile p damage the component 10 (Figure 3). The acceptable length will typically depend at least upon the composite component 10 size and location within a composite structure.
[18] Referring to Figure 4, tows 12t' in subsurface layers which correspond to the splinter arrestors 16 may be eliminated such that the overall weight of the composite component 10 is not increased. Preferably, the tows 12t' which are oriented in the same direction and are directly below the splinter arrestors 16 are eliminated. The eliminated tows 12t' need not be immediately below the outermost composite material layers 12' but may be within a deeper subsurface layer within the composite component 10'.
[19] The foregoing description is exemplary rather than defined by the limitations within. Many modifications and variations of the present invention are possible in light of the above teachings. The preferred embodiments of this invention have been disclosed, however, one of ordinary skill in the art would recognize that certain modifications would come within the scope of this invention. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. For that reason the following claims should be studied to determine the true scope and content of this invention.

Claims

CLAIMSWhat is claimed is:
1. A composite component comprising: a plurality of composite material layers comprising a plurality of tows; and a splinter arrestor laminated to an outermost layer of said plurality of composite material layers, said splinter arrestor substantially transverse to a fiber direction of said outermost layer.
2. The composite component as recited in claim 1, wherein said splinter arrestor comprise material equivalent to the composite material layers.
3. The composite component as recited in claim 1, wherein said splinter arrestor comprises a tow.
4. The composite component as recited in claim 1, wherein said splinter arrestor comprises a monofilament.
5. The composite component as recited in claim 1, wherein said splinter arrestor comprises a plurality of tows spaced a predetermined distance form each other to form a checkerboard like pattern with said outermost layer of said plurality of composite material layers.
6. The composite component as recited in claim 1, wherein tows in a subsurface composite material layer which are directly below said splinter arrestor are eliminated.
7. A method of manufacturing a composite component comprising the steps of:
(1) laminating a splinter arrestor to an outermost layer of a plurality of composite material layers, the splinter arrestor substantially transverse to a fiber direction of the outermost layer.
8. A method as recited in claim 7, wherein said step (1) further comprises laminating a plurality of relatively parallel splinter arrestors spaced a predetermined distance form each other to the outermost layer.
9. A method as recited in claim 7, wherein said step (1) further comprises eliminating tows in a subsurface composite material layer which correspond to the splinter arrestor.
10. A method as recited in claim 7, wherein said step (1) further comprises eliminating tows in a subsurface composite material layer which are parallel to and directly below the splinter arrestor.
EP04750208A 2003-04-17 2004-04-16 Splinter resistant composite laminate Withdrawn EP1613457A2 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US10/418,262 US20040216594A1 (en) 2003-04-17 2003-04-17 Splinter resistant composite laminate
PCT/US2004/011753 WO2004094123A2 (en) 2003-04-17 2004-04-16 Splinter resistant composite laminate

Publications (1)

Publication Number Publication Date
EP1613457A2 true EP1613457A2 (en) 2006-01-11

Family

ID=33309526

Family Applications (1)

Application Number Title Priority Date Filing Date
EP04750208A Withdrawn EP1613457A2 (en) 2003-04-17 2004-04-16 Splinter resistant composite laminate

Country Status (4)

Country Link
US (1) US20040216594A1 (en)
EP (1) EP1613457A2 (en)
CA (1) CA2492106A1 (en)
WO (1) WO2004094123A2 (en)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2949239B1 (en) * 2009-08-21 2011-10-28 Gilbert Chomarat REINFORCEMENT HAVING GLASS THREAD PARRALLELES.

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US5343796A (en) * 1990-03-08 1994-09-06 Allied-Signal Inc. Armor systems
US5306557A (en) * 1992-02-27 1994-04-26 Madison Thomas J Composite tactical hard body armor
IL105788A (en) * 1992-06-01 1996-10-16 Allied Signal Inc Stitched composite constructions having improved penetration resistance
FR2697626B1 (en) * 1992-11-03 1994-12-02 Gallet Sa Ballistic protection shield, and its application.
US5776567A (en) * 1993-10-28 1998-07-07 Pactec, Inc. Multi-layer filter for separating solid and liquid waste
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Also Published As

Publication number Publication date
WO2004094123A3 (en) 2005-03-24
CA2492106A1 (en) 2004-11-04
WO2004094123A2 (en) 2004-11-04
US20040216594A1 (en) 2004-11-04

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