Source: http://www.google.com/patents/US8214981?dq=6953794
Timestamp: 2014-03-17 17:20:03
Document Index: 525735587

Matched Legal Cases: ['Application No. 60', 'Application No. 2', 'Application No. 200380101844', 'Application No. 03768579', 'Application No. 2', 'Application No. 200380101844', 'Application No. 03768579']

Patent US8214981 - Method and apparatus for Z-direction reinforcement of composite laminates - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsA method and apparatus for Z-direction reinforcement of composite laminates is disclosed. Discrete fibers are pulled through a fiber composite preform in the Z-direction by barbed needles....http://www.google.com/patents/US8214981?utm_source=gb-gplus-sharePatent US8214981 - Method and apparatus for Z-direction reinforcement of composite laminatesAdvanced Patent SearchPublication numberUS8214981 B2Publication typeGrantApplication numberUS 13/195,129Publication dateJul 10, 2012Filing dateAug 1, 2011Priority dateNov 1, 2002Also published asCA2496817A1, CA2496817C, CN1705564A, CN100509385C, DE60325759D1, EP1560701A2, EP1560701A4, EP1560701B1, US7993477, US20060113027, US20110277937, WO2004041528A2, WO2004041528A3Publication number13195129, 195129, US 8214981 B2, US 8214981B2, US-B2-8214981, US8214981 B2, US8214981B2InventorsDonn J. Hethcock, Scott J. Drennan, Ken D. CominskyOriginal AssigneeBell Helicopter Textron Inc.Export CitationBiBTeX, EndNote, RefManPatent Citations (25), Non-Patent Citations (13), Classifications (42), Legal Events (2) External Links: USPTO, USPTO Assignment, EspacenetMethod and apparatus for Z-direction reinforcement of composite laminatesUS 8214981 B2Abstract A method and apparatus for Z-direction reinforcement of composite laminates is disclosed. Discrete fibers are pulled through a fiber composite preform in the Z-direction by barbed needles.
at least one guide rail for guiding and stabilizing the reciprocating device. Description
CROSS REFERENCE TO RELATED APPLICATIONS This application is a continuation of U.S. application Ser. No. 10/533,427, filed 17 Jan. 2006, titled �Method and Apparatus for Z-Direction Fiber Insertion of Discrete Fibers for Reinforcement of Composite Laminates,� which claims the benefit of International PCT Application No. PCT/US03/34946, filed 3 Nov. 2003, titled �Method and Apparatus for Z-Direction Reinforcement of Composite Laminates,� which claims the benefit of Provisional Application No. 60/423,641, filed 1 Nov. 2002, titled �Needled Fabric,� all of which are hereby incorporated by reference for all purposes as if fully set forth herein.
BACKGROUND 1. Field of the Present Description
Fiber composite laminates are formed by building up multiple layers of composite fibers one upon another. Each layer of fibers is oriented in a specific direction to provide particular properties to the laminate. In a typical laminate, some fibers extend parallel to the longitudinal axis, others extend transverse to the longitudinal axis, and others extend �off-axis� at various angles to the longitudinal axis. By laying up and orienting the fiber layers in certain configurations, the stiffness and other properties of the laminate can be predetermined. A �preform� is a dry fiber composite laminate. Often these preforms are �tackified,� i.e., treated with a material that binds the fibers together, so that the preforms can be more easily handled, shaped, worked, and laid up until the resin is introduced into the preform.
The composite fibers provide strength to the laminate in the plane of the material, but the only material perpendicular to that plane (the Z direction) is the resin. Thus, interlaminar delamination is a common form of failure in fiber composite laminates. Reinforcement of fiber composite laminates in the Z-direction is one way to prevent propagation of delaminations. However, Z-direction reinforcement often creates modifications, alterations, and disruptions to the basic structure of the laminate and generally weakens and softens the laminate. This reduction in strength of the laminate is commonly referred to as �knockdown.� There are several methods of providing Z-direction reinforcement, including Z-pinning, stitching, 3-dimensional weaving, and needling.
In 3-dimensional weaving, Z-direction reinforcement is provided by interweaving reinforcement fibers in the Z direction with the fibers in the X and Y directions. Although this method provides straight fibers in three directions, it is very difficult to incorporate 45� fibers, and other off-axis fibers, into the weave. Also, in 3-dimensional weaving, as with the stitching method, the stitching material is tightly woven around the composite fibers, leaving no way to join one laminate to another with Z-direction bondline reinforcement.
DESCRIPTION OF THE DRAWINGS The novel features believed characteristic of the invention are set forth in the appended claims. However, the invention itself, as well as, a preferred mode of use, and further objectives and advantages thereof, will best be understood by reference to the following detailed description when read in conjunction with the accompanying drawings, wherein:
DETAILED DESCRIPTION The present invention improves the interlaminar performance of fiber composite laminate preforms by adding through-thickness Z-direction fibers. These Z-direction fibers are introduced into the dry preform using a process referred to herein as �fiber insertion,� in which straight barbed needles are inserted into the preform in the Z direction. A mat of discrete fibers is placed on the preform. As the needles pass through the mat of discrete fibers, the barbs catch and fill up with some of the discrete fibers. As the needles are forced through the layers of the preform, the discrete fibers are pulled through the preform by the barbs. As the needles retract back through the preform, the discrete fibers are released by the barbs and left in the perform as Z-direction reinforcement fibers.
In accordance with the present invention, a layer or mat 23 of a plurality of individual discrete fibers 25 is disposed on laminate 11. Discrete fibers 25, also referred to herein as �Z-direction fibers,� are preferably S-glass fiberglass fibers in lengths of about 0.25 inches. It will be appreciated that other fiber material, such as polymer-based or graphite-based fibers, may be used to form mat 23, and that in some applications, it may be desirable to use more than one type of discrete fiber 25 or discrete fiber 25 of different lengths.
Discrete fibers 25 are pulled into and through preform 11 by one or more barbed needles 27 having flush barbs 29, as will be explained in more detail below. As needles 27 pass through mat 23 of discrete fibers 25, barbs 29 catch and fill up with discrete fibers 25. As needles 27 push through layers 13, 15, and 17 of preform 11, discrete fibers 25 are pulled through preform 11 by barbs 29. As needles 27 retract back through preform 11, discrete fibers 25 are released by barbs 29 and left in preform 11 in the Z direction, as indicated by �pulled� Z-direction fibers 31. In the preferred embodiment, needles 27 are pushed far enough through preform 11 so that barbs 29 pass through preform 11 leaving exposed loops 33 in Z-direction fibers 31 when needles 27 are retracted back through preform 11. To ensure that barbs 29 completely fill with discrete fibers 25 and do not catch, break, deform, or pull composite fibers 21, mat 23 is preferably about 0.375 inches thick in the Z direction.
A layer of resilient material 87, such a silicon rubber, may be associated with preform 11 during various steps of the present invention. Resilient material 87 may be temporarily affixed to preform 11. When used during the fiber insertion process, resilient material 87 is sandwiched between base plate 73 and fiber retaining plate 75 along with preform 11. In an alternate embodiment, resilient material 87 may be embedded in a tooling fixture to facilitate fiber insertion after �tackified� perform is formed and compressed to the final part contours on the tooling surface. Resilient material provides support for exposed loops 33. Additional functions of resilient material 87 are discussed below.
In an alternate embodiment, resilient material 87 may comprise, or may be replaced with, a thermoplastic material that wicks into Z-direction loops 33 and any loose ends of discrete fibers 31 that protrude through preform 11. This prevents the resin in any resin transfer operation from wicking into exposed Z-direction loops 33 and may be removed chemically or melted away from the cured fiber inserted preform. In another alternate embodiment, resilient material 87 comprises a soluble washout material, such as a soluble ceramic based coating similar to Cercon�, that prevents the resin from infusing into exposed Z-direction loops 33 and any loose ends of discrete fibers 25 that protrude through preform 11, but which may be removed from preform 11 after the curing process. These embodiments are particularly useful in applications in which the techniques of the present invention are used to bond one or more preforms together. These embodiments are discussed in more detail below with respect to FIGS. 13-14C.
Base plate 73 is shown in FIGS. 4A and 4B. Base plate 73 includes a plurality of apertures 93 for connecting base plate 73 to fiber retaining plate 75 and top plate 77. In addition, base plate 73 includes at least two locating pins 95 that protrude upward through fiber retaining plate 75 and through top plate 77. Locating pins 95 allow for the proper alignment of the base plate needle apertures 89 and the top plate needle apertures 91, and in conjunction with the slotted holes 97 and 99 of the fiber retaining plate 75 allow for offset movement of fiber retaining plate 75, preform 11, and resilient material 87. This offset movement, which is preferably at about 45� relative to the base plate 73, allows preform 11 to be repositioned and fiber inserted multiple times, resulting in a higher density of Z-direction fibers than is possible with a single pass of needle bank 81.
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DONN;DRENNAN, J. SCOTT;COMINSKY, KEN D.;SIGNING DATES FROM 20031104 TO 20031112;REEL/FRAME:027881/0997Owner name: BELL HELICOPTER TEXTRON INC., TEXASRotateOriginal ImageGoogle Home - Sitemap - USPTO Bulk Downloads - Privacy Policy - Terms of Service - About Google Patents - Send FeedbackData provided by IFI CLAIMS Patent Services©2012 Google