3D Woven Composite Preforms 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 use of three-dimensional woven fabrics with interlocking fiber tows that pass through the thickness of the fabric, enhancing interlaminar loading capability and providing increased strength in composite components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional two-dimensional layup designs are used for composite components, then manufacturing processes are simpler, but interlaminar strength is limited and labor costs are high
Solution Approach 1:
The patent transitions from traditional two-dimensional fiber reinforcement to three-dimensional woven fabrics. The fabric structure includes warp fiber tows arranged in multiple layers in the thickness direction and weft fiber tows that interlock these layers, creating a true 3D structure. This dimensional change provides through-thickness reinforcement and significantly improves interlaminar strength while maintaining manufacturing feasibility through integrated weaving processes
2Ease of manufacture
If traditional two-dimensional layup designs are used, then assembly processes are easier, but manufacturing costs are high due to labor requirements
Solution Approach 1:
The patent merges multiple fiber layers and reinforcement functions into a single integrated three-dimensional woven fabric structure. The warp and weft fiber tows are woven together to create a monolithic preform that combines structural support, reinforcement, and shaping functions. This integration eliminates the need for separate layup operations and reduces assembly steps, thereby improving manufacturing efficiency and reducing labor costs
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 three-dimensional weaving where warp fiber tows are arranged in multiple layers in the thickness direction and weft fiber tows pass through these layers to interlock them. This 3D architecture creates direct through-thickness load paths and mechanical interlocking between layers, significantly enhancing interlaminar loading capability. The complexity is managed through established weaving technologies and process integration
Data Source
Figure 1
Figure 2A~2B
Figure 2C~2D
AI summary
A method of manufacturing a woven fabric (400, 500, 602, 604, 700) for a composite component for a turbine engine (100). The method includes arranging a plurality of warp fiber tows (210) to extend in the warp direction. The plurality of warp fiber tows (210) is arranged in a thickness direction to form a plurality of warp fiber layers (212) and is arranged in a weft direction to form a plurality of warp fiber columns (214). The method also includes weaving the plurality of weft fiber tows (220) with the plurality of warp fiber tows (210). The plurality of weft fiber tows (220) includes a multi-layer weft fiber tow (410, 652, 654, 674, 710). The multi-layer weft fiber tow (410, 652, 654, 674, 710) is woven with a multi-layer portion (412, 616, 626, 712) that extends two or more warp fiber layers (212) of the plurality of warp fiber layers (212).