3D Textile Preform for Composite Stiffeners
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Solution Overview
Problem
Forming unitary composite parts in vehicles, such as aircraft skin and stiffeners, poses challenges due to limitations in fiber layer formability, leading to defects, voids, and increased manufacturing complexity.
Innovation Solution
The use of a three-dimensional (3D) textile preform comprising a flange portion and a stiffener portion with specific geometrical features, such as wall portions and a web, which are integrated into a composite part with a cured polymer matrix, eliminating the need for void fillers like noodles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional laminar composite structures are used with fiber layers bonded together, then manufacturing process is established, but fiber layer formability is limited causing defects, voids, and distortion
Solution Approach 1:
The patent transitions from traditional two-dimensional laminar composite structures to three-dimensional textile preforms. The 3D preforms incorporate through-thickness fiber architecture that allows the material to conform to complex geometries without the limitations of layered 2D fabrics, eliminating the need for radius fillers and reducing void formation at curved intersections.
Solution Approach 2:
The invention uses 3D textile preforms with integrated through-thickness reinforcement as a composite material structure. This 3D composite architecture combines the benefits of laminar composites with the formability of woven structures, creating a material that can be molded into complex shapes while maintaining structural integrity and eliminating delamination issues.
2Manufacturing precision
If radius fillers are employed at intersections to prevent distortion, then surrounding material distortion is reduced, but manufacturing complexity and time increase
Solution Approach 1:
The patent removes the need for radius fillers and additional reinforcement elements at curved intersections. The 3D textile preform's inherent through-thickness fiber architecture provides the necessary structural support and stress distribution directly within the preform structure, eliminating the need for separate radius filler components and their associated installation steps.
3Strength
If multiple fiber layers are bonded together to form composite structures, then structural strength is achieved, but delamination and interlaminar fracturing resistance is reduced
Solution Approach 1:
The 3D textile preform introduces through-thickness fiber reinforcement that bridges multiple traditional layers, creating a integrated three-dimensional load-bearing structure. This vertical fiber architecture prevents delamination by providing continuous reinforcement through the thickness direction, while maintaining the horizontal strength provided by the woven fabric layers.
Data Source
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AI summary
Examples are disclosed herein that relate to vehicles, composite parts, and three-dimensional (3D) textile preforms for composite parts. In one example, a 3D textile preform (300) for a composite part comprises a flange portion (302) and a stiffener portion (304) extending upwardly from the flange portion (302). The stiffener portion comprises a first wall portion (306) that extends from the flange portion and a second wall portion (308) that extends from the flange (302) portion at a location spaced from the first wall portion (306). A connecting portion (336) connects the first wall portion (306) and the second wall (308) portion at a location spaced from the flange portion (302).