3D Composite Preform Weaving via Interlayer Reinforcement
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Solution Overview
Problem
Existing methods for manufacturing fiber-reinforced composite materials with complex three-dimensional shapes are time-consuming and costly, requiring expensive molds and manual labor for fabric arrangement, leading to high production costs and difficulties in automating the process.
Innovation Solution
A system and method for three-dimensional weaving of composite preforms by stacking layers of two-dimensional fiber fabric and connecting them with interlayer fibers, allowing for arbitrary topologies and shapes, including non-convex and disjoint forms, to create complex composite structures without the need for rigid molds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If molds and rigid structures are used to support fiber preforms, then manufacturing precision and shape accuracy are improved, but device complexity and production cost increase
Solution Approach 1:
The patent uses a drapeable membrane instead of rigid molds to support and define the shape of fiber preforms. The membrane can be conformally draped over complex three-dimensional shapes and adjusted during the process, eliminating the need for complex rigid tooling while maintaining manufacturing precision for custom and low-volume production
Solution Approach 2:
The membrane system is made dynamic and adjustable rather than fixed and rigid. The membrane can be tensioned, relaxed, and repositioned during the manufacturing process, allowing for flexibility in accommodating different preform shapes and sizes without requiring new rigid molds for each configuration
2Manufacturing precision
If manual fabric arrangement is performed in molds, then manufacturing precision is improved, but productivity decreases and automation becomes difficult
Solution Approach 1:
Fibers are pre-formed into tubes or ribbons with controlled architectures before being integrated into the preform. This preliminary structuring allows for more systematic and automated assembly processes while maintaining precision in the final fabric arrangement, reducing reliance on manual manipulation
Solution Approach 2:
The patent transitions from two-dimensional fabric layup in rigid molds to three-dimensional fiber assembly using drapeable membranes. This dimensional change enables automated placement and arrangement of fibers in complex spatial configurations, improving both productivity and automation capability while maintaining manufacturing precision
3Manufacturing precision
If custom molds are created for each part shape, then manufacturing precision is improved, but loss of time and production cost increase
Solution Approach 1:
The drapeable membrane system serves multiple functions and can be reused across different part configurations. A single membrane system can be adjusted and reconfigured to produce various custom shapes, eliminating the need to create new rigid molds for each part design and significantly reducing tooling time and cost
Solution Approach 2:
The membrane system allows for dynamic adjustment of geometric parameters such as tension, curvature, and boundary conditions during manufacturing. This parametric flexibility enables the same physical membrane to adapt to different part shapes and sizes, reducing the need for custom tooling while maintaining manufacturing precision
Data Source
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AI summary
Methods creating composite preforms with a three-dimensional weaving pattern include stacking material layers and then connecting them with interlayer reinforcements. First and second layers are aligned and separated by a first layer spacing. First interlayer reinforcements are then inserted through at least the first and the second layers. At least a third layer is aligned with at least the first and second layers. Second interlayer reinforcements are inserted through at least the second and third layers, using the first layer spacing between the first and second layers to manipulated the second interlayer reinforcements during insertion. Following the insertion of at least the second interlayer reinforcement, this layer spacing is closed to bring the first and second layers into contact. Further layers and interlayer reinforcements may be added, using additional layer spacings to manipulate additional interlayer reinforcements to form complex three-dimensionally woven composite preforms.