3D Woven Composite Fabric for Higher Interlaminar Strength
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Solution Overview
Problem
Traditional two-dimensional layup designs for composite components in gas turbine engines face challenges in manufacturing, including high labor costs, assembly difficulties, and limited interlaminar strength, particularly in components subject to impact loading conditions.
Innovation Solution
The development of three-dimensional woven fabrics with interlocking fiber tows that pass through the thickness of the fabric, enhancing interlaminar loading capability and providing improved structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional two-dimensional layup designs are used for composite components, then manufacturing process is simpler, but interlaminar strength is limited and assembly is more difficult
Solution Approach 1:
The patent transitions from traditional two-dimensional layup designs to three-dimensional woven fabrics by incorporating through-thickness fiber tows that extend in the thickness direction. This dimensional change enables interlaminar reinforcement while maintaining manufacturing feasibility through automated weaving processes.
Solution Approach 2:
The invention uses composite fiber architectures combining warp fiber tows, weft fiber tows, and through-thickness fiber tows in a single woven structure. This composite approach integrates multiple fiber orientations to achieve enhanced interlaminar strength without proportionally increasing manufacturing complexity.
2Ease of manufacture
If traditional two-dimensional layup designs are used, then manufacturing costs are lower, but labor costs increase and assembly is more difficult
Solution Approach 1:
By implementing three-dimensional weaving with through-thickness fiber tows, the patent creates a self-interlocking structure that reduces assembly complexity. The 3D architecture provides built-in alignment and positioning features that simplify the manufacturing and assembly processes compared to traditional 2D layups.
3Strength
If three-dimensional woven fabrics with interlocking fiber tows are used, then interlaminar loading capability is enhanced, but manufacturing complexity increases
Solution Approach 1:
The patent employs composite fiber tows including warp, weft, and through-thickness fibers all integrated in one woven structure. This composite approach achieves enhanced interlaminar loading capability while the unified structure avoids the complexity of assembling multiple separate reinforcement layers.
Data Source
AI summary
A method of manufacturing a woven fabric for a composite component for a turbine engine. The method includes arranging a plurality of warp fiber tows to extend in the warp direction. The plurality of warp fiber tows is arranged in a thickness direction to form a plurality of warp fiber layers and is arranged in a weft direction to form a plurality of warp fiber columns. The method also includes weaving the plurality of weft fiber tows with the plurality of warp fiber tows. The plurality of weft fiber tows includes a multi-layer weft fiber tow. The multi-layer weft fiber tow is woven with a multi-layer portion that extends two or more warp fiber layers of the plurality of warp fiber layers.