Split resistant composite laminate

Fiber-reinforced laminate composites are used in a variety of applications because they generally exhibit one or more desired characteristics, such a light weight, increased durability, and a high strength-to-weight ratio. One problem that may occur in a composite article is uncontrolled splitting along the orientation of the fibers, especially if an object strikes the composite article with sufficient mass and/or energy to create a large notch or hole which substantially or completely penetrates the composite. Although such damage may be a minor or even a major irritant in some cases, such damage may have catastrophic consequences if the composite article is, for example, the wing skin of an aircraft.

This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to be used to limit the scope of the claimed subject matter. Concepts and technologies described herein provide for an improved composite laminate, a method for making same, and at least one example of using same.

A composite laminate has numerous reinforcing fibers embedded in a matrix. In one application, a first plurality of the reinforcing fibers are generally parallel with an orientation in the range of 3 to 8 degrees, a second plurality of the reinforcing fibers are generally parallel with an orientation in the range of −3 to −8 degrees, a third plurality of the reinforcing fibers are generally parallel with an orientation in the range of 10 to 40 degrees, a fourth plurality of the reinforcing fibers are generally parallel with an orientation in the range of −10 to −40 degrees, and a fifth plurality of the reinforcing fibers are generally parallel with an orientation of approximately 90 degrees.

A method of manufacturing a composite laminate embeds reinforcing fibers in a matrix, a first plurality of the reinforcing fibers generally being parallel with an orientation in the range of 3 to 8 degrees, a second plurality of the reinforcing fibers generally being parallel with an orientation in the range of −3 to −8 degrees, a third plurality of the reinforcing fibers generally being parallel with an orientation in the range of 10 to 40 degrees, a fourth plurality of the reinforcing fibers generally being parallel with an orientation in the range of −10 to −40 degrees, and a fifth plurality of the reinforcing fibers generally being parallel with an orientation of approximately 90 degrees, the orientations being with respect to a predetermined axis.

An aircraft has a fuselage, a wing assembly operatively connected to the fuselage, and a composite laminate incorporated into at least a selected portion of the fuselage or the wing assembly. The composite laminate has reinforcing fibers embedded in a matrix, a first plurality of the reinforcing fibers generally being parallel with an orientation in the range of 3 to 8 degrees, a second plurality of the reinforcing fibers generally being parallel with an orientation in the range of −3 to −8 degrees, a third plurality of the reinforcing fibers generally being parallel with an orientation in the range of 10 to 40 degrees, a fourth plurality of the reinforcing fibers generally being parallel with an orientation in the range of −10 to −40 degrees, and a fifth plurality of the reinforcing fibers generally being parallel with an orientation of approximately 90 degrees, the orientations being with respect to a predetermined axis.

The matrix may be, for example but not limited to, an epoxy resin, a polymer, a metal, or a ceramic. In one configuration the fibers are positioned to have approximately the following general orientations: 5 degrees, −5 degrees, 30 degrees, −30 degrees, and 90 degrees. In another configuration the fibers are positioned to have approximately the following general orientations: 5 degrees, −5 degrees, 20 degrees, −20 degrees, and 90 degrees.

The features, functions, and advantages that have been discussed can be achieved independently in various configurations of the present disclosure or may be combined in other configurations, further details of which can be seen with reference to the following description and drawings.

FIG. 1 is an illustration of exemplary large notch damage in an exemplary composite panel.

FIG. 2 illustrates the relationship between the tensile strength of some composite test panels and the percentage of alpha plies or fibers.

FIG. 3 is a partial exploded isometric view of one exemplary composite laminate modified as disclosed herein to improve resistance to longitudinal splitting from large notch damage.

FIG. 4 is an illustration of an exemplary aircraft having a portion of its skin composed of a composite laminate.

The following detailed description is directed to a composite laminate, methods for making same, and uses for same. In the following detailed description, references are made to the accompanying drawings that form a part hereof, and which are shown by way of illustration, specific configurations, or examples. Like numerals represent like elements through the several figures.

A composite laminate, also known as a carbon-fiber-reinforced polymer, comprises carbon reinforcing fibers embedded in a matrix such as an epoxy resin, a polymer, a metal, or a ceramic. A polymer resin, often simply referred to as a “resin”, includes, but is not limited to, epoxy, polymer, polyester, vinyl ester, or nylon. These composite laminates provide a high strength-to-weight ratio and are often used, by way of example and not of limitation, in aerospace applications, automobiles, sailboats, sporting goods, bicycles, motorcycles, housings for electronics, and other military, industrial, and consumer applications. The fibers provide strength in a longitudinal direction, but not in a cross-fiber direction, so the laminates typically comprise layers of fibers in different directions, typically 0 degrees, ±45 degrees, and 90 degrees with respect to an axis of tension. Such composite laminates may be formed, for example, from multiple layers or plies which are bonded together, each layer being a plurality of fibers embedded in a matrix.

In an ideal environment for a composite laminate, major impacts with other objects would either be minimal or non-existent. In an actual environment, however, such as for an aircraft, significant impacts with other objects can be expected from such differing sources as weather-related meteors such as hailstones, failure of another component such as an engine, or even enemy projectiles or shrapnel therefrom. Some objects, rather than causing minor damage to a single ply, frequently cause damage to many of the plies, and may even penetrate all of the plies. For convenience of discussion, and not as a limitation, this type of damage may be referred to herein as “large notch” damage. Some traditional composite laminates exhibit a propensity to propagate large notch damage by longitudinal splitting of the laminate in a direction roughly parallel to the direction of the tension. Thus, when such large notch damage occurs, normally-present tension across the area of damage may result in complete and/or functional failure of the laminate, possibly with catastrophic results, such as the loss of the aircraft if such failure occurs in, for example, certain parts of a wing or a fuselage. For example, if the split in a skin of an aircraft wing propagates toward a stringer in an aircraft wing then the splitting may be arrested by the stringer. If, however, the split propagates parallel to the stringer then there may be nothing to arrest the splitting and the wing may fail.

U.S. Pat. No. 7,807,249 entitled “Composite Article Having Reinforcing Fibers Oriented To Suppress Or Delay Ply Splitting”, U.S. Patent Publication US2006/0222837A1 entitled “Multi-Axial Laminate Composite Structures And Methods Forming The Same”, U.S. Patent Publication US2006/0243860A1 entitled “Composite Skin And Stringer Structure And Method For Forming The Same”, and U.S. Patent Publication US2011/0045232A1 entitled “Composite Stiffeners For Aerospace Vehicles”, are by Max U. Kismarton, are assigned to The Boeing Company, Chicago, Ill., and are hereby incorporated herein by reference as entirely as if copied in full herein. These documents disclose various methods of making and using composite laminates.

FIG. 1 is an illustration of exemplary large notch damage 115 in an exemplary composite panel 100 . The panel 100 comprises multiple plies. By convention, plies having fibers primarily oriented along the axis of tension T are referred to as “alpha” plies and “alpha” fibers, plies having fibers primarily oriented at another angle with respect to that axis are referred to as “beta” plies and “beta” fibers, and plies having fibers primarily oriented at yet another angle with respect to that axis are referred to as “gamma” plies and “gamma” fibers. In one typical composite, the alpha plies have a fiber orientation angle of 0 degrees, the beta plies have fiber orientations of ±45 degrees, and the gamma ply has a fiber orientation of 90 degrees, and at least 10 percent of the plies are oriented in each of these four directions. It is also possible to place fibers having different orientations in a single ply. For example, the alpha fibers and/or the beta fibers and/or the gamma fibers could be embedded in a single ply. Also for example, fibers having different orientations could be spun into a fiber cloth. Of course, many applications require multiple plies of each orientation to achieve the desired strength or other characteristic. Multiple layers may also be bonded together, such as by, but not limited to, a resin.

As shown in FIG. 1 , an alpha layer (not shown or numbered separately) has parallel fibers 105 having an orientation which is parallel to the tensioning force T, a gamma layer (not shown or numbered separately) has parallel fibers 110 having an orientation which is perpendicular to the tensioning force T, and beta layers (not shown or numbered separately) having parallel fibers 125 A, 125 B having orientations of plus and minus 45 degrees. The beta fibers 125 are not shown in the panel 100 for convenience and clarity of illustration, but are indicated in the insert 130 .

Now assume that there is an impact with an object which causes large notch damage 115 . It will be seen that the parallel fibers 105 A have been cut at the large notch damage point 115 . If there is tension T across the panel 100 , then the tension is along the uncut parallel fibers 105 so they stretch in response to the tension. The cut parallel fibers 105 A, however, terminate at the large notch damage 115 , so they are free on that end and therefore are not subject to the tension to the same degree. As a consequence, they do not stretch, or they stretch very little. As the uncut parallel fibers 105 stretch, but the cut parallel fibers 105 A do not stretch, a shearing force develops between them and, if the tension T is sufficiently large, the differences in the lengths of the stretched fibers and the unstretched fibers cause the cut parallel fibers 105 A to be sheared away from the neighboring uncut parallel fibers 105 , as indicated by the exemplary cracks 120 . The cracks 120 can propagate along the lines of tension and can eventually propagate through the entire length of a ply, or plies, in the panel 100 . This severely degrades the strength of the panel 100 . This splitting failure mode becomes progressively more likely as the percentage of fibers parallel with the tension T increases.

One contemporary solution to large notch longitudinal splitting is to add more 45 degree fibers. The 45 degree fibers act to direct the splitting toward a stringer in an aircraft wing where the splitting will be arrested. Adding more of these 45 degree plies, however, reduces the modulus and increases the weight. A higher modulus increases some measures of structural efficiency, such as but not limited to weight, unnotched tension, filled hole tension, edge notch tension, and filled hole compression. A lower modulus can sometimes have undesired results, such as but not limited to fluttering and problems with integrating the various components of an aircraft or other vehicle or structure. Therefore, reducing the modulus is undesirable, especially while also increasing the weight.

FIG. 2 illustrates the relationship between the tensile strength of some composite test panels and the percentage of alpha plies or fibers. It will be seen from line 205 that the filled hole tension strength of a traditional laminate (0 degrees, ±45 degrees, 90 degrees) rises linearly as the percentage of alpha plies increases. A substantial portion of this line 205 cannot be used, however, because many applications, such as but not limited to wing skins, are not only at risk for longitudinal splitting in the 0 degree direction, but also must maintain the ability to carry torsion and discrete chordwise loads e.g., engine thrust loads. An increase in the percentage of alpha plies means a corresponding decrease in the number of beta and gamma plies if the same laminate thickness and weight is to be obtained, and this can result in a reduction in the torsional and chordwise capability.

Another approach is to use a modified laminate, with plies of ±5 degrees, ±45 degrees, and 90 degrees, as discussed in at least one of the above documents. As seen from a portion of line 210 , the resistance of the modified laminate to splitting also rises linearly as the percentage of alpha plies increases. Surprisingly, this approach does not give the expected results. First, it will be noted that the strength is lower, as compared to line 205 , for the same percentage of alpha plies. In addition, note that the line 210 reaches a “knee” 210 A and/or begins to flatten when the alpha ply percentage reaches around 50 percent. Thus, increasing the percentage of alpha plies can provide diminishing returns for strength in both the longitudinal direction and the spanwise direction.

It has been unexpectedly found, however, that the strength in the longitudinal direction increases substantially when the orientation of the beta plies is modified to be 10 to 40 degrees rather than 45 degrees. The strength shown by line 215 is surprisingly higher than the strength of either line 205 or line 210 for the same percentage of alpha plies. Thus, while the ±5 degree alpha plies resist longitudinal splitting in a tensioned panel that has large notch damage, these modified-beta plies also increase the longitudinal strength. For example, when the laminate contains 40 percent alpha plies, the strength of the tested traditional laminate ( 205 ) was just over 90 Ksi, but the strength of the tested alpha-modified laminate ( 210 ) was lower, around 83 Ksi. In contrast, however, the strength of the alpha- and beta-modified laminate of 215 was just over 95 Ksi, higher than either of the other laminates. The traditional laminate ( 205 ) did not reach this strength until the alpha ply percentage was near 45 percent, and the alpha-modified laminate ( 210 ) did not reach this strength until the alpha ply percentage was near 60 percent. As noted above, the higher the percentage of alpha plies, the lower the percentage of beta and gamma plies available to resist torsional and chordwise loads. In the alpha- and beta-modified laminate of 215 , however, a given percentage of alpha plies yields a higher longitudinal strength than for a traditional or an alpha-only modified laminate, and therefore allows a larger percentage of plies to be available for providing the desired spanwise strength.

FIG. 3 is a partial exploded isometric view of one exemplary composite laminate 300 modified as disclosed herein to improve resistance to longitudinal splitting in a large notch damage scenario while simultaneously increasing longitudinal strength for other key structural measures (e.g., filled hole tension, edge notch tension, and bearing-bypass). Laminate 300 has layers 305 ( 305 A, 305 B, 305 C, 305 D and 305 E), which make up a set 310 . A laminate 300 may comprise multiple sets 310 of layers 305 . For example, a typical aircraft wing may have 60 to 90 layers 305 . This number of layers is provided merely as an example and is not intended to be limiting in any manner; more layers, or fewer layers, may be used depending upon the characteristics desired for the composite laminate. Each layer 305 A- 305 E is composed of reinforcement fibers 315 A- 315 E, respectively, the fibers 315 in a layer 305 being generally parallel to each other and being imbedded in the matrix, the matrix being generally indicated as 305 M. The fibers 315 in a layer 305 in a set 310 are preferably, but not necessarily, oriented in a different direction than the fibers 315 in the other layers 305 in the set 310 . For example, the fibers 315 C in layer 305 C are oriented in a different direction than the fibers 315 A, 315 B, 315 D, 315 E in layers 305 A, 305 B, 305 D, 305 E, respectively. The orientation of the fibers 315 , as discussed herein, are with respect to the axis of tension 320 . The insert 325 provides a general view of the various fiber orientations with respect to the axis of tension 320 . The alpha plies resist longitudinal splitting, the gamma plies stabilize the laminate, increase bearing performance, and increase transverse performance, and the modified beta plies increase longitudinal performance while reducing the percentage of alpha plies needed to maintain the required laminate strength.

In one configuration, the fibers 315 A (alpha fibers) in ply 305 A have an orientation of 3 to 8 degrees, the fibers 315 B (also alpha fibers) in ply 305 B have an orientation of −3 to −8 degrees, the fibers 315 C (beta fibers) in ply 305 C have an orientation of 10 to 40 degrees, the fibers 315 D (also beta fibers) in ply 305 D have an orientation of −10 to −40 degrees, and the fibers 315 E (gamma fibers) in ply 305 E have an orientation of approximately 90 degrees. In another configuration, the alpha values are ±5 degrees. In another configuration, the beta values are ±30 degrees. In another configuration, the beta values are ±20 degrees. In another configuration, the alpha plies have orientations of ±5 degrees, the beta plies have orientations of ±30 degrees, and the gamma plies have an orientation of 90 degrees. In another configuration, the alpha plies have orientations of ±5 degrees, the beta plies have orientations of ±20 degrees, and the gamma plies have an orientation of 90 degrees.

In one configuration, the alpha plies 305 A and 305 B collectively comprise 30 to 60 percent of the volume of the laminate 300 . In another configuration, the beta plies 305 C and 305 D collectively comprise 30 to 60 percent of the volume of the laminate 300 . In another configuration, the gamma plies 305 E comprise 10 to 20 percent of the volume of the laminate 300 . In another configuration, the beta plies 305 C and 305 D collectively comprise 40 percent of the volume of the laminate 300 . In yet another configuration, the alpha plies 305 A and 305 B collectively comprise approximately 50 percent of the volume of the laminate 300 , the beta plies 305 C and 305 D collectively comprise approximately 40 percent, and the gamma plies 305 E comprise approximately 10 percent. The percentages listed herein represent the volume of the reinforcing fibers with a particular orientation as compared to the total volume of the reinforcing fibers in the laminate.

Methods of making a composite laminate are well known in the art and are not discussed in detail herein. Making a composite laminate with the particular orientations discussed herein to achieve the particular characteristics described herein is not known, however, in the art. Briefly stated, the resin and fibers having the orientations discussed herein are laid and the resulting laminate is then cured. If desired, several laminates may be made and then the laminates bonded together and cured. Preferably, the 90 degree plies are positioned away from the midplane of a laminate. Also, preferably, there should not be groups of plies having the same orientation but, preferably, plies of one orientation should be interspersed with plies of other orientations. For example, alpha plies should be interspersed with beta plies. Also, preferably, a laminate is symmetrical about its midplane. For example, if the third ply above the midplane is a −5 degree ply, then the third ply below the midplane would also be a −5 degree ply. Also, it will be appreciated that a layer may contain multiple plies of the same orientation or differing orientations.

FIG. 4 is an illustration of an exemplary aircraft having a portion of its skin composed of a composite laminate. The exemplary aircraft 400 has a fuselage 405 and at least one wing assembly 410 . The composite laminate described herein may be used as a portion, or all, of the skin on the fuselage 405 , the wing assembly 410 , or both, as desired or appropriate for a particular aircraft 400 and its expected environment. For example, in an environment wherein any large notch damage will typically be on the wing assembly 410 , then at least a portion of the skin of the wing assembly 410 will be composed of the composite laminate described herein. It should also be noted that the composite laminate described herein may also be used on only selected portions of the skin. For example, in an environment wherein any large notch longitudinal splitting will typically be in only a particular area 415 on the underside of the wing assembly 410 , then at least that area will be composed of the composite laminate described herein.

Based on the foregoing, it should be appreciated that technologies for providing a split resistant composite laminate have been disclosed herein. It is to be understood that the appended claims are not necessarily limited to the specific features, configurations, acts, or media described herein. Rather, the specific features, configurations, acts and mediums are disclosed as example forms of implementing the claims.

The subject matter described above is provided by way of illustration only and should not be construed as limiting. Various modifications and changes may be made to the subject matter described herein without following the example configurations and applications illustrated and described, and without departing from the true spirit and scope of the present disclosure, which is set forth in the following claims.