In this study, composites with discontinuous 'brick-and-mortar' architecture, consisting of conceptually stiff load-carrying bricks connected by a mortar material, were treated. The bricks were composed of unidirectional pre-impregnated tapes with a thermoplastic matrix, and a very thin interface of thermoplastic material represented the mortar. The problem was simplified to a unit cell containing a single overlap between two bricks, where the stresses between the bricks are transferred purely by shear in the mortar material. The stress-strain response of the unit cell in tension was determined by experiments and compared to predictions by a numerical model available from literature, which is based on shear-lag stress transfer. The results showed that it is possible to create a highly non-linear stress-strain response with this ordered discontinuous architecture. The effect of the interface shear strength and fracture toughness and the influence of the brick geometry on the achievable tensile strength were discussed.

Current applications of composite materials have been focussing on the use in thin shells and continuous profiles, commonly being manufactured on the approach of a layered structure. The aim of this work was to evaluate the eligibility of a process based on compression moulded thermoplastic chopped tapes as a candidate to replace complex CNC machined metal parts for load introduction elements in aircrafts. Due to their discontinuous character, such materials are subject to scale effects, which are discussed in detail and interpreted in respect to the combination of failure modes leading to fracture.