WO2003024705A1 - Three-dimensional knit spacer fabric sandwich composite - Google Patents
Three-dimensional knit spacer fabric sandwich composite Download PDFInfo
- Publication number
- WO2003024705A1 WO2003024705A1 PCT/US2002/029312 US0229312W WO03024705A1 WO 2003024705 A1 WO2003024705 A1 WO 2003024705A1 US 0229312 W US0229312 W US 0229312W WO 03024705 A1 WO03024705 A1 WO 03024705A1
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- WIPO (PCT)
- Prior art keywords
- woven
- fiber
- fabric
- resin
- spacer fabric
- Prior art date
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Classifications
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- 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
- B32B5/02—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 structural features of a fibrous or filamentary layer
- B32B5/08—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 structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
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- 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
- B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
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- 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
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
- B29C70/443—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding and impregnating by vacuum or injection
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- 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
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
- B29C70/48—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
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- 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
- B29C70/28—Shaping operations therefor
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
- B29C70/546—Measures for feeding or distributing the matrix material in the reinforcing structure
- B29C70/547—Measures for feeding or distributing the matrix material in the reinforcing structure using channels or porous distribution layers incorporated in or associated with the product
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- 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
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/04—Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
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- 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
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
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- 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
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
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- 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
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
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- 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
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/18—Handling of layers or the laminate
- B32B38/1866—Handling of layers or the laminate conforming the layers or laminate to a convex or concave profile
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- 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
- B32B5/02—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 structural features of a fibrous or filamentary layer
- B32B5/022—Non-woven fabric
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- 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
- B32B5/02—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 structural features of a fibrous or filamentary layer
- B32B5/024—Woven fabric
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- 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
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B21/00—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
- D04B21/20—Warp knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes specially adapted for knitting articles of particular configuration
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- 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
- B32B2250/00—Layers arrangement
- B32B2250/20—All layers being fibrous or filamentary
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- 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
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/02—Composition of the impregnated, bonded or embedded layer
- B32B2260/021—Fibrous or filamentary layer
- B32B2260/023—Two or more layers
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- 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
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/04—Impregnation, embedding, or binder material
- B32B2260/046—Synthetic resin
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- 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
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0261—Polyamide fibres
- B32B2262/0269—Aromatic polyamide fibres
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- 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
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0276—Polyester fibres
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- 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
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
- B32B2262/101—Glass fibres
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- 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
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
- B32B2262/106—Carbon fibres, e.g. graphite fibres
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- 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
- B32B2305/08—Reinforcements
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- 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
- B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
- B32B2309/60—In a particular environment
- B32B2309/68—Vacuum
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2403/00—Details of fabric structure established in the fabric forming process
- D10B2403/02—Cross-sectional features
- D10B2403/021—Lofty fabric with equidistantly spaced front and back plies, e.g. spacer fabrics
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2505/00—Industrial
- D10B2505/02—Reinforcing materials; Prepregs
Definitions
- the present invention relates generally to the novel use and application of a core material providing improved infusion of a resin and achieving increased stiffness and other properties of a sandwich composite. More specifically it relates to the use of three- dimensional knit spacer fabric as a laminate interface to enhance laminate bonding, and particularly to correct the interfacial planarity of monolithic grid core elements cut and placed to attempts to conform to curvature in the desired structure.
- Fiber reinforced plastic (FRP) composite structures are generally well known and take many shapes and forms in end applications ranging from marine craft to bathtubs to aircraft, etc., and ranging from simple to complex configurations.
- the construction of these forms includes providing a reinforcing fibrous structure, woven or non-woven, that is laid up into an open mold of the desired shape, generally referred to as a preform.
- a preform Commonly also a core structure is interposed between the internal and external laminae of the composite.
- This dry fiber reinforcement must then be thoroughly wet out with a curable, generally thermosetting, resin, and generally using manual application techniques. After wetting out, the preform, the resin is then allowed to cure to form the composite of the desired shape.
- the resulting composite structure is ultimately removed from the mold and after suitable after-treatments may then be used.
- FRP laminates are commonly inferior to alternative low-density materials such as wood when the ability of a panel of a given weight to resist bending moments is considered.
- the stiffness of a panel is dependent not only on the material's flexural modulus, the measure of the stiffness of the material, but is also generally a function of the cube of the thickness of the panel. Accordingly, while the thickness of such a panel could be increased by some relatively small amount to realize a substantial increase the stiffness of the composite, this also has penalties in weight and expense. That is, one approach for stiffening an FRP panel would obviously be to make it thicker, but this can result in the disadvantage that an unnecessarily very heavy laminate would result with perhaps unnecessary strength characteristics and also one that is unnecessarily expensive and that may present practical construction problems for the final desired structure.
- the problem of inadequate strength, modulus can also frequently arise from inadequate uniformity in the FRP composite fabrication.
- the resin component may be inadequately distributed throughout the fiber matrix, may have voids therein leading to strength-deteriorating surface discontinuities or may have irregularly cured (e.g., reached a premature gel point) before full distribution of the resin within the fiber matrix had been achieved.
- a preferred technique to increase the stiffness of an FRP panel is the use of a sandwich construction. Sandwich construction in a laminate offers the comparable advantages of an I-beam configuration, but instead of the web and flanges of a typical I- beam, a sandwich construction makes use of a light-weight core material faced on one or both sides by skins of FRP. The role of such skins in the composite structure is to withstand the bending moments on the panel or beam by resisting the compressive and tensile loading set up in the opposite skins when the panel is subjected to bending load forces.
- the skins For the skins to be able to resist the bending moments they must be rigidly held spaced from the neutral axis of the sandwich (the centerline) and prevented from moving relative to each other. It is the task of the selected core material, and of the bond line strength between the core and the skins, to provide and meet these requirements. For a given industrial application, irrespective of the selected skin and core materials, the integrity of a sandwich construction is especially dependent upon the interfacial bond strength between the skins and the core elements.
- the physical or mechanical utilization of the core in a laminate is also very much dependent upon the fabrication techniques employed for a given structure.
- a vacuum bag technique is usefully employed.
- vacuum bag techniques the skin is laid up and wet out, the core elements applied thereto, with or without a bonding adhesive, and a vacuum bag applied to the assembly. As air is removed, the external ambient air pressure tends to press the core elements uniformly onto the skin surface, however contact between the lamina and the core element is limited by dimensional shape of the core elements.
- the vacuum bag is commonly left in place until the outside skin (e.g.
- lateral dimensions of one or more of the scored, commonly rectilinear, core sections may be greater than the radius of the desired mold curvature for the intended structure. This can and does result in a void at the interface of the fiber lay-up and the core elements. In such cases, the ultimate desired intimate contact between the skin and the core can commonly only be achieved through the use of an excess of adhesive or other filler to occupy the resulting dimensional gap.
- the present invention provides a novel technique for skin to core bonding through the use of three- dimensional knit spacer fabrics as a bond interface in the lay up to achieve greatly enhanced bonding properties.
- the present invention 's novel use of a three-dimensional knit spacer fabric as a skin to core laminae interface, or as an intermediate lamina, enhances the interfacial planarity of monolithic core elements grid cut and departs from the conventional concepts and designs of the prior art. In so doing it provides a technique, material and product developed for the purpose of increasing the FRP skin to core bond line integrity.
- the present invention generally comprises of the use of a three-dimensional knit spacer fabric having resilient Z-direction fibers used as a lamina within the laminae between the skin and the core. This technique not only provides for an improved skin to core bonding but is also a constituent of the laminate.
- an object of the present invention is to provide a three-dimensional knit spacer fabric with as a bond media between the skin and core in a sandwich composite that will overcome the shortcomings of the prior art devices.
- a further object of the present invention is to provide a three-dimensional knit spacer fabric as a bond media between the skin and core in a sandwich composite for use in all processes for composite manufacturing.
- Figure 1 schematically illustrates in cross-section an FRP laminate construction according to the prior art.
- Figure 2 schematically illustrates in cross-section an FRP laminate construction according to this invention.
- Figure 3 schematically illustrates a three-dimensional spacer fabric used in this invention in its uncompressed state.
- Figure 4 schematically illustrates a three-dimensional spacer fabric used in this invention in its compressed state.
- Figure 5 is an enlarged schematic illustration of the three-dimensional spacer fabric used in this invention in its uncompressed state.
- Figure 6 is an enlarged schematic illustration of the three-dimensional spacer fabric used in this invention in its compressed state.
- Figure 7 is a schematic illustration in plan view of another embodiment of the invention.
- a woven or non-woven fiber reinforcement preform layer (12) (ultimately, here, the outer skin) is applied to a mold of the desired shape (10).
- elements of the core material (14) are placed between inner (12) and outer (16) layers of fiber reinforcement or lamina to make up the laminae structure.
- the curvature of the mold shape (10) is such that a void (18) is formed between the outer skin (12) and the core elements (14). It is then desired to fill the space (18) the resin of choice for bonding the several components of the composite.
- FIG. 3 is a further schematic illustration of the spacer fabric construction (30). It will be seen that it is composed of two spaced apart woven and/or stitched outer layers (32) and (34). Extending between and so made as to connect those two layers are transverse fibers (36). These transverse fibers are so made as to be relative resilient.
- FIG 4 is a schematic illustration of the spacer fabric of Figure 3 but now shown in a compressed state (40), by the application of external pressure.
- the external layers (42) and (44) retain fairly well their uncompressed orientation and configuration, but the transverse fibers (46) are now angularly displaced with a resultant decrease in thickness of the lamina.
- the application of pressure and displacement of the transverse fibers (46) nonetheless leaves the resilient fibers with a tendency to spring back and resist the deformation. Since the overall spacer fabric is of course flexible, it has the property of conforming to the irregularities of the shapes of the core elements and of the mold surface itself so that voids therebetween are diminished.
- this spacer fabric commonly referred to by applicants' by their trademark name "PolybeamTM"
- PolybeamTM has the great advantage during fabrication of composite structures of facilitating the flow and dispersion of the liquid resin throughout the fiber/fabric preforms, and thereby as well enabling a filling of voids even as between the core elements prior to a gel point for the resin.
- the three-dimensional knit spacer fabric (50) in Figure 5 is itself composed of a first woven fabric layer (52), a second fabric layer (54), and the intermediate resilient spacer yarns (56), which may be a monofilament polyester, fiberglass, etc., interconnecting the two layers (52) and (54).
- the fibers of the woven layers (52) and (54) generally extend in the X and Y directions, as the Figure indicates.
- the resilient yarns (56) extending generally in the Z direction (albeit angled) hold the two fabric layers apart with a free form, pressure-free thickness that may conveniently range from approximately .0625" to 1".
- a wide range of fabric and yarn fiber types may be used in the spacer yarn, such as polyester, fiberglass, Kevlar, carbon, and combinations.
- the three-dimensional knit spacer fabric (60) is resiliently compressed in the illustrated Z direction when a vacuum (i.e. under ambient pressure) is applied to press the core elements against the skin, as in Figure 2. While this spacer fabric is thereby somewhat planarized, it can nonetheless conform to the core-skin interface so that throughout the interface a more uniform reinforced structure is achieved.
- the planarized interface may then be infused with adhesive or resin, etc., dependent upon the fabrication technique used, but is preferably filled with resin during the ongoing procedure. Even though compressed as shown in this figure, there remains a significant free open space between the outer layers in that the fiber density continues to be significantly less than that of the outer surfaces. While difficult to measure, calculations presently indicate that while an uncompressed spacer fabric might have about 88-90% free volume, the compressed spacer fabric would still retain about 65 - 75% free volume or open space for resin infusion.
- Figure 7 illustrates in plan view an embodiment of the invention and it will be understood that the "Tool” as shown in plan view can signify a mold face having a complex arcuate form.
- the "Vacuum” legend signifies that a vacuum is pulled at the upper end of the figure and Resin Input is shown at the bottom.
- the precise point of resin input could be elsewhere but is generally most useful at a location relatively remote from the location of the lead to the vacuum pump.
- a portion of a spiral cut tube is shown which conveniently serves as a manifold resin entry device.
- Laminae A and Laminae B as shown in this figure, in each instance including the three-dimensional spacer fabric, are explained in greater detail hereinafter.
- balsa wood core elements within an FRP composite, arranged so that the end grain is normal to the planar surface of the resulting structure.
- four test panels were fabricated with end-grain balsa core elements, as indicated. The following description sets forth the laminate schedule for each panel. Each panel was fabricated with a Hetron 922 vinyl ester resin and infused and cured under a vacuum of 25 in of Hg.
- Panel 1 18 oz. 3Tex Glass
- Panel 2 18 oz. 3Tex Glass
- Panel 3 18 oz. 3Tex Glass Panel 4: 18 oz. Glass
- PolybeamTM is the trademark for the spacer fabric used in these panels.
- PolybeamTM 730 fabric is a three bar Raschel knitted spacer fabric from a double bed machine having the following characteristics: The wales/meter are 590, The courses/meter are 530
- the inner and outer “skins” are of an orthogonally woven fiberglass material, supplied from 3 Tex.
- Test #1 ASTM C-393 "Flexure Test" is an evaluation of the stiffness and strength of sandwich panel specimens subjected to bending loads.
- Test #2 ASTM C-297 "Flat-wise Tension Test" is an evaluation of the tensile strength and modulus of structural cores in a direction perpendicular to the sandwich facings.
- Edgewise loading of a sandwich panel can induce buckling on the faces of the sandwich panel. This outward buckling is representative of these flat-wise stresses.
- 2415 is 24 oz./yd 2 biaxial stitched roving with 1.5 oz./ft. 2 CSM stitch to one side.
- (-) refers to the mat up, with the roving against the PolybeamTM.
- Laminae A is designed to provide a laminate ⁇ .157" in thickness (4 mm) and Laminae B is designed to provide a laminate ⁇ .354" in thickness (9 mm) per the ASTM standard requirements.
- the reinforcing lamina are comprised of stitch bound fiberglass, supplied from Johnson Industries, and having the following characteristics:
- Fiber Type Fiberglass (E)
- Laminae A (Table 1) was accomplished but cutting the lamina to the 24" x 24" dimension and placing them in the specified sequence onto the tool surface.
- Laminae B (in Table 2) was accomplished by repeating the ply stacking sequence of Laminae A in a 6" x 24" lamina in the correct orientation on top of Group A in alignment with one edge.
- a single vacuum port was fitted adjacent to Laminae B and spiral cut tubing wrap for resin input was fitted on the opposite edge of Laminae A, again as shown in Figure 7.
- a flexible vacuum bag was then fitted and sealed about the laminate, the resin input tube sealed with a clamp, and vacuum drawn.
- Vacuum was read by a gauge affixed to a standard resin trap. When vacuum reached 26" Hg, the clamp was removed from the resin inlet tube, and the tube was subsequently placed in the vinylester resin (-230 cps.). A uniform flow front across the part was noted. The resin clamp was reaffixed to the inlet tube when the resin front reached the vacuum port. Full vacuum (26" Hg.) was maintained during this process. At this point, excess resin within the laminate is pulled out by vacuum until the point in time at which the resin gels and can no longer flow. Full vacuum is maintained until such time. After the resin completed its exotherm and has cooled to room temperature, the panel was removed for post cure and testing. During this test the following conditions were observed:
- Fiber volume Typical fiber/resin ratio ranges for vacuum infusion within the laminate (sans the infusion media) are from 40:60 to 75:35. These ranges are based on weight and are therefore very dependent upon the constituents used, both in terms of the resin and the fiber. It will accordingly be understood that this invention is in no way limited to these particular ratios.
- the spacer or Z-direction fibers retain a resiliency, there is an embedded tendency for the structure to spring back thus filling what otherwise might be undesirable voids and cavities or comparable discontinuities in the ultimate cured composite.
- This spring back is in fact aided by the lubrication introduced by the resin infusion, lowering the interactive fiber-to-fiber friction otherwise present in the dry material.
- the resultant composite therefore exhibits a higher degree of integrity and uniformity, not only in its structure but also in its ultimate strength characteristics. Significant economies in production processing are a further benefit of the use of this invention in that less wastage and off-spec products are realized.
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- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Fluid Mechanics (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Laminated Bodies (AREA)
- Moulding By Coating Moulds (AREA)
Abstract
Description
Claims
Priority Applications (8)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
MXPA04002525A MXPA04002525A (en) | 2001-09-17 | 2002-09-17 | Three-dimensional knit spacer fabric sandwich composite. |
JP2003528386A JP2006515809A (en) | 2001-09-17 | 2002-09-17 | Three-dimensional knitted spacer woven sandwich composite |
KR10-2004-7003942A KR20040047837A (en) | 2001-09-17 | 2002-09-17 | Three-dimensional knit spacer fabric sandwich composite |
BR0212737-7A BR0212737A (en) | 2001-09-17 | 2002-09-17 | Interleaved composite of three-dimensional knitted spacer fabric |
NZ532360A NZ532360A (en) | 2001-09-17 | 2002-09-17 | Three-dimensional knit spacer fabric sandwich composite |
EP20020761675 EP1432569A1 (en) | 2001-09-17 | 2002-09-17 | Three-dimensional knit spacer fabric sandwich composite |
AU2002326922A AU2002326922B2 (en) | 2001-09-17 | 2002-09-17 | Three-dimensional knit spacer fabric sandwich composite |
CNB028228367A CN1331658C (en) | 2001-09-17 | 2002-09-17 | Three-dimensional knit spacer fabric sandwich composite |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US32260201P | 2001-09-17 | 2001-09-17 | |
US60/322,602 | 2001-09-17 | ||
US10/172,053 US7048985B2 (en) | 2001-07-23 | 2002-06-17 | Three-dimensional spacer fabric resin infusion media and reinforcing composite lamina |
US10/172,053 | 2002-06-17 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2003024705A1 true WO2003024705A1 (en) | 2003-03-27 |
Family
ID=26867702
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2002/029312 WO2003024705A1 (en) | 2001-09-17 | 2002-09-17 | Three-dimensional knit spacer fabric sandwich composite |
Country Status (9)
Country | Link |
---|---|
EP (1) | EP1432569A1 (en) |
JP (1) | JP2006515809A (en) |
KR (1) | KR20040047837A (en) |
CN (1) | CN1331658C (en) |
AU (1) | AU2002326922B2 (en) |
BR (1) | BR0212737A (en) |
MX (1) | MXPA04002525A (en) |
NZ (1) | NZ532360A (en) |
WO (1) | WO2003024705A1 (en) |
Cited By (13)
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WO2004037521A1 (en) * | 2002-10-22 | 2004-05-06 | Owens Corning | Composite exterior cladding panel and method of manufacture |
WO2006033101A2 (en) * | 2004-09-22 | 2006-03-30 | Escom Composite Materials Ltd. | Textile core sandwich structures |
JP2006218821A (en) * | 2005-02-14 | 2006-08-24 | Yokohama Rubber Co Ltd:The | Connecting method of fiber-reinforced plastic panel |
JP2006247923A (en) * | 2005-03-09 | 2006-09-21 | Yokohama Rubber Co Ltd:The | Connection method of fiber reinforced plastic panels |
JP2007169841A (en) * | 2005-12-22 | 2007-07-05 | Mitsubishi Heavy Ind Ltd | Air-permeable pad for composite material formation and method for forming composite material |
JP2007530810A (en) * | 2004-03-30 | 2007-11-01 | サン−ゴバン・シンコグラス・ナムローゼ・フェンノートシャップ | Reinforcing materials, reinforcing laminates, and composite materials having these |
GB2421005B (en) * | 2003-07-29 | 2008-03-05 | Mtu Aero Engines Gmbh | Fibrous laminate and process for producing the same |
JP2008538594A (en) * | 2005-04-19 | 2008-10-30 | ヴイアールエーシー,リミテッド ライアビリテイ カンパニー | Openwork resin injection media and reinforced composite thin layer |
WO2011003629A1 (en) | 2009-07-10 | 2011-01-13 | Faurecia Innenraum Systeme Gmbh | Trim component and method for manufacturing a trim component |
EP3023235A1 (en) * | 2014-11-21 | 2016-05-25 | Airbus Defence and Space GmbH | Method for producing fibre composite components and a fiber composite component |
WO2018036821A1 (en) | 2016-08-26 | 2018-03-01 | Basf Se | Process for continuous production of fiber-reinforced foams |
US20190382952A1 (en) * | 2017-02-09 | 2019-12-19 | Evonik Degussa Gmbh | Method for producing a thermally insulating layer |
US11920735B2 (en) | 2017-06-09 | 2024-03-05 | Evonik Operations Gmbh | Method for thermally insulating an evacuable container |
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US5580412A (en) * | 1991-05-29 | 1996-12-03 | Metalleido S.R.L. | Apparatus and method for the production of a composite structure with an intermediate three-dimensional textile |
-
2002
- 2002-09-17 EP EP20020761675 patent/EP1432569A1/en not_active Withdrawn
- 2002-09-17 BR BR0212737-7A patent/BR0212737A/en not_active Application Discontinuation
- 2002-09-17 CN CNB028228367A patent/CN1331658C/en not_active Expired - Fee Related
- 2002-09-17 KR KR10-2004-7003942A patent/KR20040047837A/en not_active Application Discontinuation
- 2002-09-17 WO PCT/US2002/029312 patent/WO2003024705A1/en active IP Right Grant
- 2002-09-17 AU AU2002326922A patent/AU2002326922B2/en not_active Ceased
- 2002-09-17 JP JP2003528386A patent/JP2006515809A/en active Pending
- 2002-09-17 NZ NZ532360A patent/NZ532360A/en unknown
- 2002-09-17 MX MXPA04002525A patent/MXPA04002525A/en active IP Right Grant
Patent Citations (2)
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US4389447A (en) * | 1981-01-15 | 1983-06-21 | Hoechst Aktiengesellschaft | Dimensionally stable composite material and process for the manufacture thereof |
US5580412A (en) * | 1991-05-29 | 1996-12-03 | Metalleido S.R.L. | Apparatus and method for the production of a composite structure with an intermediate three-dimensional textile |
Cited By (17)
Publication number | Priority date | Publication date | Assignee | Title |
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WO2004037521A1 (en) * | 2002-10-22 | 2004-05-06 | Owens Corning | Composite exterior cladding panel and method of manufacture |
GB2421005B (en) * | 2003-07-29 | 2008-03-05 | Mtu Aero Engines Gmbh | Fibrous laminate and process for producing the same |
JP2007530810A (en) * | 2004-03-30 | 2007-11-01 | サン−ゴバン・シンコグラス・ナムローゼ・フェンノートシャップ | Reinforcing materials, reinforcing laminates, and composite materials having these |
WO2006033101A2 (en) * | 2004-09-22 | 2006-03-30 | Escom Composite Materials Ltd. | Textile core sandwich structures |
WO2006033101A3 (en) * | 2004-09-22 | 2006-06-01 | Escom Composite Materials Ltd | Textile core sandwich structures |
JP2006218821A (en) * | 2005-02-14 | 2006-08-24 | Yokohama Rubber Co Ltd:The | Connecting method of fiber-reinforced plastic panel |
JP2006247923A (en) * | 2005-03-09 | 2006-09-21 | Yokohama Rubber Co Ltd:The | Connection method of fiber reinforced plastic panels |
JP2008538594A (en) * | 2005-04-19 | 2008-10-30 | ヴイアールエーシー,リミテッド ライアビリテイ カンパニー | Openwork resin injection media and reinforced composite thin layer |
JP2007169841A (en) * | 2005-12-22 | 2007-07-05 | Mitsubishi Heavy Ind Ltd | Air-permeable pad for composite material formation and method for forming composite material |
JP4727416B2 (en) * | 2005-12-22 | 2011-07-20 | 三菱重工業株式会社 | Ventilation pad for molding composite material and method for molding composite material |
WO2011003629A1 (en) | 2009-07-10 | 2011-01-13 | Faurecia Innenraum Systeme Gmbh | Trim component and method for manufacturing a trim component |
DE102009032896A1 (en) | 2009-07-10 | 2011-01-13 | Faurecia Innenraum Systeme Gmbh | Covering part and method for producing a trim part |
EP3023235A1 (en) * | 2014-11-21 | 2016-05-25 | Airbus Defence and Space GmbH | Method for producing fibre composite components and a fiber composite component |
WO2018036821A1 (en) | 2016-08-26 | 2018-03-01 | Basf Se | Process for continuous production of fiber-reinforced foams |
US11787093B2 (en) | 2016-08-26 | 2023-10-17 | BASF SE (Ellwanger & Baier Patentanwälte) | Process and tool for continuous production of fiber-reinforced foams |
US20190382952A1 (en) * | 2017-02-09 | 2019-12-19 | Evonik Degussa Gmbh | Method for producing a thermally insulating layer |
US11920735B2 (en) | 2017-06-09 | 2024-03-05 | Evonik Operations Gmbh | Method for thermally insulating an evacuable container |
Also Published As
Publication number | Publication date |
---|---|
AU2002326922B2 (en) | 2007-07-05 |
JP2006515809A (en) | 2006-06-08 |
MXPA04002525A (en) | 2005-04-11 |
CN1665676A (en) | 2005-09-07 |
BR0212737A (en) | 2004-10-05 |
EP1432569A1 (en) | 2004-06-30 |
KR20040047837A (en) | 2004-06-05 |
NZ532360A (en) | 2005-12-23 |
CN1331658C (en) | 2007-08-15 |
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