Method of making a fibrous structure having a separate layer of a deployment portion and the resulting fibrous structure

Abstract

A method of forming a three-dimensional woven fiber structure (200) from a plurality of warp yarns and a plurality of weft yarns includes weaving a first section (230) and at least one second section (250) longitudinally adjacent to the first section. All weft yarn layers in the first section are joined by the plurality of warp yarns, and the second section includes a base portion (251) and an expanded portion (252) separated by a first non-interlocking zone (261). The expanded portion (252) is separated into at least a first ply (2520) and a second ply (2521) in a thickness direction (DE), and the first ply and the second ply are not joined by a non-interlocking zone (280) extending into the second section (250) of the fiber structure in a longitudinal direction (D L ) that is not parallel to the thickness direction (DE). The first ply (2520) and the second ply (2521) each include at least one warp yarn and at least one weft yarn from the plurality of warp yarns in the first section of the fiber structure.

Description

Technical Field

[0001] This invention relates to the manufacture of composite material components, and more particularly to the preparation of fiber-reinforced structures for such components by three-dimensional (3D) weaving. Background Technology

[0002] One application area of ​​this invention is the manufacture of structural composite material components, namely components with fiber-reinforced structures and matrix densification, such as organic matrix composite (OMC), carbon-based composite (C / C), and ceramic matrix composite (CMC) components. In certain sections of turbine engines, OMC, C / C, and CMC have replaced metal components. Their application helps optimize aircraft performance, particularly by improving turbine engine efficiency, reducing overall turbine engine weight, and significantly reducing harmful environmental emissions (CO, CO2, NO). x (etc.) and fuel consumption.

[0003] The present invention specifically relates to a fiber-reinforced structure obtained by three-dimensional (3D) weaving, which includes one or more unfolded sections, i.e., sections that need to be unfolded during the fiber structure forming process.

[0004] One example of such fiber structures is a confining structure used to manufacture fiber reinforcements for composite turbine ring sections, as described in document US2012027572.

[0005] Figure 1 shows the fiber structure 10 used to form the fiber reinforcement of the turbine ring section of the composite material. This structure 10 is formed by three-dimensional weaving of multiple warp and weft yarns, with the warp yarns along the longitudinal direction D. L Extend, the weft yarn along the transverse direction D T Extension. The weft yarn is woven in multiple rows, with row C... T Indicates. Weft yarn row C T Along the longitudinal direction D L Each weft yarn is spaced apart from the others, with the weft yarns in each weft row perpendicular to the longitudinal direction D. L The stacking direction D S10 They are arranged side by side in the thickness direction of the fiber structure.

[0006] Structure 10 includes a maximum of 12 for forming the base of the ring segment, and an upper portion 14 connected to the lower portion 12 via a central portion 16. The upper portion 14 includes two extended portions 141, 142 located at opposite ends of the central portion 16, which are not connected to the lower portion 12. In other words, the fiber structure 10 includes two non-interlocking regions 18 at two opposite laterally positioned edges to form two freely extending portions.

[0007] Figure 2 illustrates the forming process of fiber structure 10: the unfolded portions 141 and 142 are bent 90° towards the central portion 16, and after densification, they form the ring section attachment flange on the inner ring support structure of the turbine. After bending, the stacking direction of the weft yarns in the unfolded portions 141 and 142 changes. Specifically, the weft yarn stacking direction DS of the weft yarns in the unfolded portions 141 and 142 changes. 141 DS 142 Relative to the initial stacking direction DS 10 A significant angular change occurs. The shear angle β of the weft yarn rows within the unfolding sections 141 and 142 is between 45° and 60°. This angular change originates from the shear force applied to the unfolding sections 141 and 142 during the unfolding process, due to the inner radius R. INT The path is shorter than the outer radius R EXT The path.

[0008] Angle offset of the weft yarns will cause the fiber structure to be at the corner radius (mainly the inner radius R). INT Layering occurs, and at the outer radius R EXT Material shortages in certain areas are detrimental to finished parts, as they create areas without fiber reinforcement.

[0009] Furthermore, due to the use of three-dimensional weaving, angular deviations can cause weft yarn shearing, which in turn can lead to misalignment of related parts, potentially damaging the impregnation properties of the obtained preform and altering the preset mechanical properties. Summary of the Invention

[0010] Therefore, there is an urgent need for a fiber structure manufacturing solution that can overcome the above-mentioned defects.

[0011] Therefore, this invention proposes a method for manufacturing a fiber structure, which is woven from multiple layers of warp yarns and multiple layers of weft yarns. The warp yarns extend longitudinally, and the weft yarns extend laterally. The weft yarns are woven in multiple rows, spaced apart from each other longitudinally, and each row of weft yarns is arranged side by side along the thickness direction of the fiber structure. The fiber structure includes: a first section: all weft yarn layers are connected by multiple layers of warp yarns through three-dimensional or multi-layer weaving; at least one second section adjacent to the first section longitudinally: the second section includes a base and a spread section, which are separated by a first non-interlocking region; the first non-interlocking region extends longitudinally from the non-interlocking bottom end of the fiber structure adjacent to the first section into the second section of the fiber structure.

[0012] Its features are:

[0013] The unfolded portion of the at least one second segment of the fiber structure is divided into at least a first layer and a second layer along the thickness direction, and the layers are not connected to each other through a second non-interlocking region; the second non-interlocking region extends longitudinally into the second segment of the fiber structure from the non-interlocking bottom end adjacent to the first segment; wherein the first layer and the second layer each contain at least one warp yarn and at least one weft yarn in the multiple warp yarns of the first segment of the fiber structure, and the warp yarns of the at least one warp yarn and the weft yarns of the at least one weft yarn are woven together.

[0014] The resulting fiber structure comprises one or more unfolded sections, each consisting of multiple independent layers (i.e., unconnected layers). Compared to a single three-dimensional woven block, this effectively releases stress. The shear force in the unfolded sections is significantly reduced, particularly improving the filling effect at the inner and outer radii. Forming non-interlocking layers in the unfolded sections also enhances the positioning accuracy during preform molding, as each layer is easier to position than a single three-dimensional woven block.

[0015] According to a specific feature of the method of the present invention, the first layer and the second layer each comprise at least three warp yarns and at least three weft yarns in a multi-layered warp yarn of a first segment of fiber structure; the at least first layer and the second layer are formed by three-dimensional or multi-layered weaving of the at least three warp yarns and the at least three weft yarns.

[0016] Because each layer is 3D woven, the unfolded part retains the 3D woven characteristics, and each layer has excellent anti-delamination properties.

[0017] According to another specific feature of the method of the invention, each sheet comprises up to four warp layers from a first segment of the fiber structure and four weft layers. This helps to further reduce the shear force experienced by each sheet in the relevant unfolding section.

[0018] According to another specific feature of the method of the present invention, each layer adopts one of the following multi-layer weaving methods: interlocking weaving, multi-layer satin weaving, multi-layer twill weaving, and multi-layer plain weaving.

[0019] The present invention also provides a method for manufacturing composite material components, comprising:

[0020] Weaving fiber structures according to the weaving method of the present invention;

[0021] Bending one or more unfolded sections shapes the fiber structure, resulting in a fiber preform.

[0022] The fiber preform is densified using a matrix.

[0023] The composite material component manufacturing method of the present invention can be used to manufacture turbine ring sections, reinforcing ribs, turbine engine stationary blades or moving blades.

[0024] The present invention also provides a fiber structure comprising multiple layers of warp yarns and multiple layers of weft yarns, wherein the warp yarns extend longitudinally and the weft yarns extend transversely; the fiber structure includes multiple rows of weft yarns arranged longitudinally at intervals, each row of weft yarns being arranged side-by-side in the fiber structure along the thickness direction of the fiber structure; the fiber structure includes: a first segment: all weft yarn layers are connected by the warp yarns of multiple layers of warp yarns through three-dimensional or multi-layer weaving; at least one second segment adjacent to the first segment longitudinally: the second segment includes a base and a spread portion, the base and the spread portion being separated by a first non-interlocking region; the first non-interlocking region extends from the non-interlocking bottom end of the fiber structure adjacent to the first segment along... A second segment extending longitudinally into the fiber structure; characterized in that: the unfolded portion of the at least one second segment of the fiber structure is divided into at least a first layer and a second layer along the thickness direction, the first layer and the second layer are not connected to each other through a second non-interlocking region; the second non-interlocking region extends longitudinally into the second segment of the fiber structure from the non-interlocking bottom end adjacent to the first segment; and the first layer and the second layer each contain at least one warp yarn and at least one weft yarn from the multiple warp yarns of the first segment of the fiber structure, and the warp yarns of the at least one warp yarn and the weft yarns of the at least one weft yarn are woven together.

[0025] According to a specific feature of the fiber structure of the present invention, the first layer and the second layer each comprise at least three warp yarns and at least three weft yarns in a first segment of the fiber structure, wherein the at least first layer and the second layer are formed by three-dimensional weaving or multi-layer weaving of the warp yarns of the at least three warp yarn layers and the weft yarns of the at least three weft yarn layers.

[0026] According to another specific feature of the fiber structure of the present invention, each sheet comprises up to four warp layers from the multi-layered warp layers of the first segment of the fiber structure, and four weft layers.

[0027] According to another specific feature of the fiber structure of the present invention, each layer adopts one of the following multi-layer weaving methods: interlocking weaving, multi-layer satin weaving, multi-layer twill weaving, and multi-layer plain weaving.

[0028] The present invention also relates to a composite material component comprising a matrix-densified fiber reinforcement, characterized in that the fiber reinforcement comprises the fiber structure described in the present invention.

[0029] According to a specific feature of the component of the present invention, the component is a turbine ring section, a reinforcing rib, or a turbine engine stationary / moving blade.

[0030] Brief description of the attached figures

[0031] Figure 1 A schematic three-dimensional diagram of the fiber structure of existing technology.

[0032] Figure 2 for Figure 1 Schematic front view of the fiber structure after molding

[0033] Figure 3 A schematic perspective view of a jacquard loom used to manufacture the fiber structure of the present invention.

[0034] Figure 4 This is a schematic front view of a fiber structure according to an embodiment of the present invention.

[0035] Figure 5 Figure 4 shows the weaving planar diagram of the fiber structure.

[0036] Figure 6 Figure 4 shows a schematic front view of the fiber structure after molding. Detailed Implementation

[0037] The present invention is generally applicable to the manufacture of fiber structures or connecting weft layers by three-dimensional (3D) or multi-layer weaving between warp and weft layers, wherein the fiber structure includes at least one part that needs to be unfolded during the forming process.

[0038] "Three-dimensional weaving" or "3D weaving" refers to a weaving method in which at least some weft yarns connect to multiple layers of warp yarns, or vice versa. An example of three-dimensional weaving is "interlocking weaving." Interlocking weaving refers to a weaving method in which each layer of warp yarns connects to multiple layers of weft yarns, and all yarns in the same warp row move in the same direction within the weaving plane.

[0039] "Multi-layer weaving" refers to three-dimensional weaving with multiple layers of weft yarns. Each basic layer of weaving is equivalent to conventional two-dimensional fiber fabric weaving, but the weaving includes some organizational points that connect the weft yarn layers. Known multi-layer weavings that can be used in this invention are specifically described in documents US2007007386 and US2009186547.

[0040] The yarn used in this article may be carbon fiber yarn or ceramic fiber yarn, such as silicon carbide (SiC) fiber. This invention is not limited to the above-mentioned yarn types.

[0041] Figure 3 shows a loom 100 equipped with a jacquard loom 101, which consists of... Figure 1The upper structure support is not shown. The loom 100 also includes a heald frame 110, which consists of a heald plate 111 and control yarns (healds) 113; one end of each heald 113 is connected to a control hook 1010 of the jacquard loom 101, and the other end is connected to a return spring 102 fixed to the frame 103 of the loom 100. Each heald 113 has a heald eye 114 for threading the warp yarns 203. The associated heald 113 and its heald eye 114 extend into a region in which the heald 113 and heald eye 114 are driven to perform a substantially vertical reciprocating motion, indicated by a double arrow F. The heald 113 is subjected to the tension of the control hook 1010 and the return spring 102, respectively. The heald 113 lifts a portion of the warp yarns 203 according to a preset weaving program. By raising a portion of the warp yarns 203, the heddles 113 form a shed, which allows the introduction of weft yarns 204 for three-dimensional or multi-layer weaving of the ribbon or strip fiber fabric 200. The warp yarns 203 are organized into multiple warp layers C1 to Cn. The reed 120, located upstream of the shed, tightens each introduced weft yarn by moving from upstream to downstream until the corresponding position of shed closure is reached. The warp yarns 203 are supported by a bobbin cassette positioned upstream of the jacquard loom 101 of the loom 100. Figure 3 (Not shown in the image) The cylinder supply.

[0042] The following describes a method for manufacturing a fiber structure 200 according to an embodiment. In this example, the fiber structure 200 is used to form a fiber reinforcement in a composite turbine ring section. As shown in FIG4, the woven fiber structure 200 includes: a first section 230 corresponding to the central section of the fiber structure; and a second section 240 along the longitudinal direction D. L Adjacent to the first segment 230, forming the first end of the fiber structure 200; the third segment 250: along the longitudinal direction D L Adjacent to the first section 230, it forms the second end of the fiber structure 200. Within the central section 230, all weft yarn layers are connected to multiple warp yarn layers through 3D or multi-layer weaving.

[0043] The fiber structure 200 has a lower portion 210 for forming the base of a ring segment, and an upper portion 220 connected to the lower portion 210 via a first segment 230. The second segment 240 includes a base 241 located at the lower portion 210 of the fiber structure 200, and a spread portion 242 located at the upper portion of the fiber structure and adjacent to the first side end 231 of the first segment 230. Similarly, the third segment 250 includes a base 251 located at the lower portion 210 of the fiber structure 200, and a spread portion 252 located at the upper portion of the fiber structure and adjacent to the second side end 232 of the first segment 230.

[0044] The unfolded portions 242 and 252 are not connected to the base portions 241 and 251 of the lower portion 210, respectively. During weaving, two non-interlocking areas 260 and 261 are provided at the two opposite edges of the fiber structure to keep the unfolded portions 242 and 252 free. The two non-interlocking areas 260 and 261 extend longitudinally along D from the non-interlocking bottom ends 2600 and 2610 adjacent to the first section 230 of the fiber structure. L The second and third sections 240 and 250 extend into the fiber structure 200. Non-interlocking sections 260 and 261 extend along the transverse direction D. T extend.

[0045] The sheet comprises at least one warp layer and at least one weft layer, which are a first segment of a fiber structure, and the warp yarns of the one or more warp layers are woven together with the weft yarns of the one or more weft layers. When the sheet comprises one warp layer and one weft layer, the warp and weft yarns are combined in a two-dimensional weave.

[0046] When a sheet contains two layers of warp yarns and / or two layers of weft yarns, the warp and weft yarns are combined in a multi-layered weave.

[0047] When the sheet comprises at least three layers of warp yarns and at least three layers of weft yarns, the warp yarns and weft yarns are preferably combined in 3D or multi-layer weaving.

[0048] Therefore, the warp yarns remain continuous within the first, second, and third sections 230, 240, and 250 of the fiber structure (especially the independent layers in the unfolded portion), ensuring that the fiber reinforcement made from the fiber structure of the present invention has good strength.

[0049] In this example, the unfolded portion 242 of the second segment 240 of the fiber structure 200 is divided into four independent layers 2420, 2421, 2422, and 2423 by three non-interlocking regions 270, 271, and 272; each non-interlocking region 270, 271, and 272 extends longitudinally along D from the non-interlocking bottom ends 2700, 2710, and 2720 adjacent to the first segment 230 of the fiber structure. L The second segment 240 extends into the fiber structure. Non-interlocking regions 270, 271, and 272 extend along transverse direction D. T The extension 252 of the second segment 250 of the fiber structure 200 is divided into four independent sheets 2520, 2521, 2522 and 2523 by three non-interlocking regions 280, 281 and 282; each non-interlocking region 280, 281 and 282 extends longitudinally along D from the non-interlocking bottom ends 2800, 2810 and 2820 of the fiber structure adjacent to the first segment 230. L The third segment 250 extends into the fiber structure. Non-interlocking regions 280, 281, and 282 extend along transverse direction D. T extend.

[0050] The fiber structure of this invention can be specifically 3D or multi-layered woven using interlocking weaving, multi-layer satin weaving, multi-layer plain weaving, or multi-layer twill weaving.

[0051] "Multi-layer satin weave or fabric" refers to 3D or multi-layer weave with multiple layers of weft yarns. Each basic layer of weave is equivalent to a regular satin weave, but the weave includes some weaving points that connect the weft yarn layers.

[0052] "Multi-layer plain weave or fabric" refers to 3D or multi-layer weave with multiple layers of weft yarns. Each basic layer of weave is equivalent to regular plain weave, but the weave includes some weaving points that connect the weft yarn layers.

[0053] "Multi-layer twill weave or fabric" refers to 3D weave with multiple layers of weft yarns. Each basic layer of weave is equivalent to a regular twill weave, and the weave includes some weaving points that connect the weft yarn layers.

[0054] As a non-limiting example, the fiber texture of the present invention can be 3D woven using the multi-layer satin weave shown in Figure 5.

[0055] Figure 5 shows the multi-layer satin weave planar cross-sections of the first segment 230 and the third segment 250 of the corresponding fiber structure 200. In this example, the fiber structure 200 contains 28 layers of warp yarns C in the first and third segments 230 and 250. C1 To C C28 It contains at least 28 layers of weft yarn C within the first section 230. T1 To C T28 Except for some warp yarns on the surface of the fiber structure and inside the individual layers 2520, 2521, 2522, and 2523, each warp yarn 203 periodically deflects from its path above a weft layer to alternately: grab a weft yarn of that weft layer; and jointly grab a weft yarn of that weft layer and a weft yarn in the same column of the adjacent lower weft layer. This forms alternating classic single-weft satin weave points PS1 and double-weft satin weave points PS2, which connect the yarns of two adjacent weft layers, thereby ensuring the bonding between the weft layers.

[0056] See Figure 5:

[0057] • The 28 layers of weft yarn C that constitute the first section 230 T1 To C T28 Composed of 28 layers of warp C C1 To C C28 Warp 203 is connected;

[0058] • The 10 layers of weft yarns C that make up base 251 T19 To C T28 Composed of 10 layers of warp C C19 To C C28 Warp 203 is connected;

[0059] • The 4 layers of weft yarns that make up the 2520 layer T14 To C T17 Composed of 5 layers of warp C C14 To C C18 coupling;

[0060] • The four weft yarns C that make up layer 2521 T9 To C T12 Composed of 5 layers of warp C C9 To C C13 coupling;

[0061] • The three weft yarns C that make up layer 2522 T5 To C T7 Composed of 4 layers of warp C C5 To C C8 coupling;

[0062] • The three weft yarns C that make up layer 2523 T1 To C T3 Composed of 4 layers of warp C C1 To C C4 coupling.

[0063] warp C C19 To C C28 Not extending into the weft layer C T14 To C T17 And warp C C14 To C C18 Not extending into the weft layer C T19 To C T28 This ensures the formation of a non-interlocking area 261 separating the base 251 and the lamination 2520. Warp C C14 To C C18 Not extending into the weft layer C T9 To C T12 And warp C C9 To C C13 Not extending into the weft layer C T14 To C T17 This ensures the formation of a non-interlocking area 280 separating layer 2520 and layer 2521. Warp C C9 To C C13 Not extending into the weft layer CT5 To C T7 And warp C C5 To C C8 Not extending into the weft layer C T9 To C T12 This ensures the formation of a non-interlocking area 281 separating layer 2521 and layer 2522. Warp C C5 To C C8 Not extending into the weft layer C T1 To C T3 And warp C C1 To C C4 Not extending into the weft layer C T5 To C T7 This ensures the formation of a non-interlocking region 282 separating the layers 2522 and 2523.

[0064] In this example, the weft layer C T4 C T8 C T13 C T18 The weft yarns in the fiber structure 200, third section 250, corresponding to the non-interlocking areas 261, 280, 281, and 282 respectively, do not participate in the weaving. The weft yarns in the non-interlocking areas may also not be removed, meaning the number of weft yarns remains the same between sections 230 and 250.

[0065] Figure 5 shows the weaving plane along the transverse direction D. T Repeated on multiple continuous weave planes, single satin weave point PS1 and double satin weave point PS2 are along the longitudinal direction D. L The fabric is staggered from one woven plane to the next.

[0066] The second section 240, which is made of fiber structure using a similar multi-layer satin weave, has independent layers 2420, 2421, 2422 and 2423 in its base 241 and unfolding section 242.

[0067] The same weaving logic can be applied to interlocking, multi-layer plain weave, and multi-layer twill weaves to create fiber structure 200. In one implementation variation, the warp yarns within the first section 230 can be along the thickness direction E P It bends upwards and downwards, crossing at the non-interlocking bottom end to reinforce it.

[0068] In addition, the individual layers of each unfolded section can be woven in a 3D or multi-layered manner, different from the rest of the fiber structure.

[0069] After weaving, the fiber structure 200 shown in Figure 4 is obtained.

[0070] Figure 6 shows the preform 300 obtained after the fiber structure 200 is formed (i.e. bent): on the one hand, the individual sheets 2420, 2421, 2422 and 2423 of the unfolded portion 242 of the second section 240 are bent at 90° relative to the base 241; on the other hand, the individual sheets 2520, 2521, 2522 and 2523 of the unfolded portion 252 of the third section 250 are bent at 90° relative to the base 251.

[0071] Because each unfolding section has multiple non-interlocking layers, the overlapping direction D of the inner weft yarn rows in unfolding sections 242 and 252... S242 and D S252 The angle change is much smaller than that of the integral unfolded section (not divided into multiple non-interlocking layers) shown in Figures 1 and 2. The shear force is smaller during the bending process of the unfolded section, and the shear angle α of the inner weft yarn rows in unfolded sections 242 and 252 is less than 45°. The fiber structure within the inner radius R... I242 and R I252 and outer radius R E242 and R E252 The delamination phenomenon is significantly reduced, and the fiber structure can better fill the rounded corner areas.

[0072] The offset of the weft yarns in the unfolded section is further reduced, thereby improving the impregnation performance of the preform and better detecting the preset mechanical properties.

[0073] The above examples relate to fiber structures with multiple spread sections, which are woven simultaneously with the base and are not interlocked. This invention is, of course, applicable to fiber structures with different (especially simpler) architectures. The weaving method of this invention can be applied to the weaving of fiber structures that include a base along the longitudinal direction, the base extending from a spread section for bending during fiber structure forming to form an L-shaped preform, for example, suitable for the fabrication of composite material reinforcing ribs.

[0074] The fiber preform 300 is then densified to form a composite component, in this example, a gas turbine ring section. Densification of the fiber preform used to manufacture the fiber reinforcement of the component to be processed includes filling all or part of the preform pores with the material constituting the matrix. This densification can be achieved using methods known per se, including liquid phase (CVL), gas phase (CVI), ceramic filler injection (slurry casting), silicon alloy impregnation (MI or RMI), or a combination of one or more of these methods.

[0075] The liquid-phase method involves impregnating a preform with a liquid composition containing a matrix material precursor. The precursor is typically in polymer form, such as a high-performance epoxy resin, and can be diluted with a solvent. The preform is placed in a sealable mold, the mold cavity conforming to the final molded blade shape. The mold is closed, and the liquid matrix precursor (such as resin) is injected into the entire cavity, impregnating all fibrous areas of the preform.

[0076] The conversion of the precursor to the matrix (i.e. polymerization) is achieved through heat treatment, typically by heating the mold. After removing any possible solvents and crosslinking the polymer, the preform remains in the mold, with a shape consistent with the part to be manufactured.

[0077] For carbon-based or ceramic-based molding, heat treatment involves pyrolyzing the precursor to transform the matrix into a carbon or ceramic matrix, depending on the precursor used and the pyrolysis conditions. For example, liquid ceramic precursors (especially SiC or SiCN) can be polycarbosilane (PCS), polytitanium carbosilane (PTCS), or polysilazane (PSZ) resins; liquid carbon precursors can be resins with high carbon residue, such as phenolic resins. Multiple continuous cycles from impregnation to heat treatment can be performed to achieve the desired degree of densification.

[0078] Especially for organic matrix molding, the densification of fiber preforms can be achieved using known resin transfer molding (RTM) methods. According to the RTM method, the fiber preform is placed into a mold having the external shape of the part to be manufactured. Thermosetting resin is injected into the internal space of the mold containing the fiber preform. Typically, a pressure gradient is established in the internal space between the resin injection point and the outlet to control and optimize the impregnation of the preform by the resin.

[0079] Preform densification can also be achieved through polymer impregnation pyrolysis (PIP) or slurry impregnation (e.g., containing SiC and organic binders) followed by liquid silicon infiltration (melt infiltration).

[0080] Densification of fiber preforms can also be achieved using known vapor-phase methods, namely chemical vapor infiltration (CVI) of the matrix. A fiber preform corresponding to the fiber reinforcement of the component to be manufactured is placed in a furnace, and a reactive gas phase is introduced. The furnace pressure, temperature, and gas phase composition are selected to allow the gas phase to diffuse into the pores of the preform, generating a solid substance through component decomposition or multi-component reactions, which is then deposited in the core of the material in contact with the fibers to form the matrix. This differs from the specific pressure and temperature conditions of chemical vapor deposition (CVD), which can only achieve deposition on the material surface.

[0081] The SiC matrix can be prepared by methyltrichlorosilane (MTS), which decomposes to generate SiC; the carbon matrix can be prepared by hydrocarbon gases (such as methane and / or propane), which crack to generate carbon.

[0082] Alternatively, a densification method combining liquid-phase and gas-phase methods can be used, which is easy to implement, reduces costs and manufacturing cycles, while meeting the performance requirements for the intended use.

[0083] The aforementioned densification method can be used to manufacture organic matrix composite (OMC), carbon-based composite (C / C), and ceramic matrix composite (CMC) components primarily from the fiber structure of this invention. These OMC, C / C, and CMC components replace metal parts in certain areas of turbine engines. Using them helps optimize aircraft performance, particularly by improving turbine engine efficiency, reducing overall turbine engine weight, and significantly reducing harmful environmental emissions (CO, CO2, NO). x (etc.) and fuel consumption.

[0084] After densification, composite material parts are obtained.

[0085] The fiber structure and manufacturing method of the present invention can be used in particular for manufacturing turbine ring sections, reinforcing ribs, or turbine engine stationary / moving blades.

Claims

1. A method for manufacturing a fiber structure (200) by weaving multiple layers of warp yarns (203) and multiple layers of weft yarns (204), wherein the warp yarns are woven along the longitudinal direction (D... L ) extends, the weft yarn along the transverse direction (D T ) Extension; weft yarns (204) are woven in multiple rows spaced apart along the longitudinal direction, with each row of weft yarns along the thickness direction of the fiber structure (D E The weft yarns are arranged side-by-side in the fiber structure; the fiber structure includes all weft layers (C) woven in three dimensions or multiple layers. T1 -C T28 ) is composed of multiple layers of warp yarns (C C1 -C C28 The first segment (230) connected, and along the longitudinal direction (D) L At least one second segment (250) adjacent to the first segment; the second segment includes a base (251) and a spread (252) separated by a first non-interlocking region (261), the first non-interlocking region extending longitudinally (D) from the non-interlocking bottom end (2610) of the first segment (230) adjacent to the fiber structure. L ) extends into the second segment (250) of the fiber structure (200); Its features are, The unfolded portion (252) of the at least one second segment (250) of the fiber structure along the thickness direction (D) E The fiber structure is divided into at least a first layer and a second layer (2520, 2521), which are not connected to each other by a second non-interlocking region (280), which extends longitudinally (D) from the non-interlocking bottom end (2800) of the first segment (230) adjacent to the fiber structure. L The first layer (2520) and the second layer (2521) each contain at least one warp and at least one weft yarn in the multilayer warp yarns of the first layer of the fiber structure, and the warp yarns of the at least one layer of warp yarns and the weft yarns of the at least one layer of weft yarns are woven together.

2. The method according to claim 1, wherein, The first layer (2520) and the second layer (2521) each contain at least three layers of warp yarns and at least three layers of weft yarns in the first segment of the fiber structure; the at least first layer and the second layer are formed by three-dimensional or multi-layer weaving of the at least three layers of warp yarns and the at least three layers of weft yarns.

3. The method according to claim 2, wherein, The at least first layer (2520) and the second layer (2521) each contain up to four warp layers and four weft layers in the multi-layered warp yarns of the first segment of the fiber structure.

4. The method according to claim 2 or 3, wherein, The at least first layer (2520) and the second layer (2521) adopt one of the following multi-layer weaving methods: interlocking weaving, multi-layer satin weaving, multi-layer twill weaving, and multi-layer plain weaving.

5. A method for manufacturing a composite material component, comprising: • Weave a fiber structure (200) according to the weaving method of any one of claims 1 to 4; • Bending at least one unfolded portion (252) shapes the fiber structure, resulting in a fiber preform (300). • The fiber preform (300) is densified using a matrix.

6. The composite material component manufacturing method of claim 5 is used for manufacturing turbine ring sections, reinforcing ribs, or turbine engine stationary / moving blades.

7. A fiber structure (200) comprising multiple layers of warp yarns (203) and multiple layers of weft yarns (204), wherein the warp yarns are along the longitudinal direction (D... L ) extends, the weft yarn along the transverse direction (D T ) Extension; the fiber structure includes multiple rows of weft yarns spaced apart longitudinally, each row of weft yarns being along the thickness direction (D) of the fiber structure. E ) arranged side by side; the fiber structure includes all weft layers (C) woven in three dimensions or multiple layers. T1 -C T28 ) is composed of multiple layers of warp yarns (C C1 -C C28 The first section (230) of the warp yarn connection, and along the longitudinal direction (D) L At least a second segment (250) adjacent to the first segment; the second segment includes a base (251) and a spread (252) separated by a first non-interlocking region (261), the first non-interlocking region extending longitudinally (D) from the non-interlocking bottom end (2610) adjacent to the first segment (230) of the fiber structure. L ) Extends into the second section (250) of the fiber structure (200); Its features are, The unfolded portion (252) of the second segment (250) of the at least one fiber structure is divided into at least a first layer (2520) and a second layer (2521) along the thickness direction (DE). The first layer and the second layer are not connected to each other through a second non-interlocking region (280). The second non-interlocking region extends longitudinally (D) from the non-interlocking bottom end (2800) adjacent to the first segment (230) of the fiber structure. L The first layer (2520) and the second layer (2521) each contain at least one warp yarn and at least one weft yarn in the multilayer warp yarns of the first layer of the fiber structure, and the warp yarns of the at least one layer of warp yarns and the weft yarns of the at least one layer of weft yarns are woven together.

8. The fiber structure according to claim 7, wherein, The first layer (2520) and the second layer (2521) each contain at least three layers of warp yarns and at least three layers of weft yarns in the first segment of the fiber structure; the at least first layer and the second layer are formed by three-dimensional or multi-layer weaving of the at least three layers of warp yarns and the at least three layers of weft yarns.

9. The fiber structure according to claim 8, wherein, The at least first layer (2520) and the second layer (2521) each contain up to four warp yarns and four weft yarns in the multi-layered warp yarns of the first segment of the fiber structure.

10. The fiber structure according to claim 8 or 9, wherein, The at least first layer (2520) and the second layer (2521) adopt one of the following multi-layer weaving methods: interlocking weaving, multi-layer satin weaving, multi-layer twill weaving, and multi-layer plain weaving.

11. A composite material component comprising a matrix-densified fiber reinforcement, characterized in that, The fiber reinforcement comprises the fiber structure as described in any one of claims 8 to 10.

12. The component according to claim 11, wherein, The component is a turbine ring section, a reinforcing rib, or a turbine engine stationary / moving blade.

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