3D Woven Composite Preform with Through-Thickness Reinforcement
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Solution Overview
Problem
Two-dimensional woven composite structures face limitations in strength, labor-intensive pre-forming, and susceptibility to delamination when multiple layers are used, particularly in applications requiring multi-directional reinforcement and high load-bearing capabilities.
Innovation Solution
A three-dimensional woven preform with a central interwoven column and independently woven layers at the ends, incorporating bias plies and through-thickness reinforcement to enhance strength and damage tolerance, allowing for quasi-isotropic or multi-directional reinforcement at the ends and unidirectional reinforcement in other areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple layers are laminated together to increase strength, then the strength of the composite structure is improved, but delamination occurs between layers reducing reliability
Solution Approach 1:
The patent merges multiple fabric layers into a single integrated three-dimensional woven structure where fibers from different layers are interwoven together. This eliminates the interfaces between separate layers that cause delamination, while maintaining the strength benefits of multi-directional reinforcement. The fabrics are woven simultaneously to create a monolithic structure with improved reliability.
2Reliability
If multiple fabric layers are sewn together to prevent delamination, then delamination resistance is improved, but many woven fibers are damaged during sewing reducing strength
Solution Approach 1:
The patent extracts the need for post-weaving assembly operations (sewing or tacking) by integrating multiple fabric layers into a single woven structure during the weaving process itself. This eliminates the harmful sewing operation that damages fibers, while still achieving delamination resistance through the interwoven architecture. The solution removes the problematic step rather than trying to mitigate its effects.
3Ease of manufacture
If simple two-dimensional woven fabrics are used, then ease of manufacture is improved, but strength and stretch-resistance are limited in directions other than 0° and 90° axes
Solution Approach 1:
The patent transitions from two-dimensional woven fabrics to three-dimensional woven structures by adding through-thickness reinforcement and interlacing multiple fabric layers in the Z-direction. This dimensional enhancement provides strength and stretch-resistance in additional directions (including ±45° bias directions) while maintaining manufacturing simplicity through integrated weaving processes that produce the 3D structure in a single operation.
4Strength
If bias fibers are added to two-dimensional weave to improve multi-directional strength, then strength in intermediate angles is improved, but the complexity of pre-forming increases
Solution Approach 1:
The patent combines bias fibers with the primary warp and weft fibers into a single integrated three-dimensional woven structure. Instead of adding bias fibers as a separate post-weaving step or complex multi-layer laminate, the bias fibers are woven simultaneously with the main fabric layers, creating a unified structure that provides multi-directional strength without increasing pre-form complexity. The different fiber directions are integrated into one weaving operation.
Data Source
AI summary
A woven preform used to reinforce a composite structure which includes a central portion having a plurality of interwoven layers. The preform also includes first and second end portions having a plurality of independent woven layers that are integrally woven with the plurality of interwoven layers in the central portion and which extend along the entire length the preform. Interspersed between the plurality of independent woven layers in the first and second end portions are bias plies. The first and second end portions can have through thickness reinforcements comprising reinforcement fibers that traverse through the independent woven layers and the bias plies, locking them together.