Three Dimensional Braid Tow Ladder Intertwining
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Solution Overview
Problem
Conventional three-dimensional braids lack effective intertwining in the radial or cross-thickness direction, resulting in limited load transfer between layers, which is typically reliant on resin encasing, and often compromise in-plane strength due to the methods used in their formation.
Innovation Solution
A braided structure featuring tow ladder substructures with a specific pattern of intersecting plaits oriented at positive and negative angles, allowing for simultaneous intertwining in both radial and in-plane directions, enhancing load transfer and structural consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional three-dimensional braiding methods are used, then some cross-thickness load transfer is achieved, but radial strength and in-plane strength are compromised due to limited intertwining and reliance on resin
Solution Approach 1:
The patent transitions from conventional two-dimensional fabric layers to a true three-dimensional braid structure where tows intertwine in the radial direction. This dimensional change enables load transfer across thickness without relying on resin bonding between separate layers, achieving both radial strength and structural integrity through spatial reconfiguration of the braid architecture.
Solution Approach 2:
The patent implements nested tow configurations where inner tows are surrounded by outer tows in a concentric arrangement. This nesting enables multiple tows to work together in a hierarchical structure, with inner tows providing core structural support and outer tows providing additional load paths and stability, thereby enhancing radial strength without excessive complexity.
2Reliability
If stitching or sewing is used to intertwine layers, then some cross-thickness load transfer is achieved, but the structure becomes pseudo three-dimensional with materials distinct from in-thickness materials
Solution Approach 1:
The patent merges the functions of structural reinforcement and load transfer into a single integrated braid structure. Instead of using separate stitching materials to connect layers, the same continuous tows that form the braid body also provide the intertwining paths for load transfer, eliminating the need for distinct stitching materials and simplifying the overall structure.
Solution Approach 2:
The braid structure performs multiple functions simultaneously: it provides in-plane structural support, enables cross-thickness load transfer, and maintains radial integrity all through the same intertwined tow configuration. This multi-functionality eliminates the need for separate stitching operations and achieves reliable load transfer through the universal braid architecture itself.
3Manufacturing precision
If conventional braiding methods are used, then in-plane strength is maintained, but crimp density variability increases and consistency in crimp orientation deteriorates
Solution Approach 1:
The patent optimizes braid formation parameters including tow spacing, braid angle, and tension control to achieve consistent crimp orientation. By carefully controlling these parameters during the braiding process, the patent achieves uniform crimp density and orientation without sacrificing production efficiency, as the optimized parameters enable smoother tow feeding and more stable braid formation.
Data Source
AI summary
A three dimensional braid includes a plurality of first plaits adjacent one another oriented in a first direction and a plurality of second plaits adjacent one another oriented in a transverse second direction intertwined forming a braid with each first plait intersecting each of the plurality of second plaits in succession. Each first plait includes a first group of tows and a second group of tows, each of the tows in the first group of tows corresponding to one of the tows in the second group of tows in pairs of first plait tows. Each second plait includes a plurality of tows. For each first plait, one of the first plait pairs crosses over a subset of second plait tows at each intersection of the first plait and successive second plaits forming a series of braid points along the first plait.