3D Woven Integrally Stiffened Panel for Composite Joints
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Solution Overview
Problem
Existing methods for joining composite components to form reinforced structures often result in weak joints due to reliance on adhesives or mechanical fasteners, which can lead to separation under tension and introduce distortions when folding two-dimensional woven preforms into three-dimensional shapes, compromising the structural integrity and surface quality.
Innovation Solution
An integrally woven three-dimensional preform is constructed using multiple woven fabrics with interwoven yarns to create stiffeners in two directions, allowing for folding into a three-dimensional shape without separate stitching or adhesives, ensuring a strong and uniform joint by locking components together with interwoven fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If separate composite components are joined using adhesives or mechanical fasteners, then the structural assembly can be formed, but the joint strength is reduced and separation can occur under tension
Solution Approach 1:
The patent merges separate composite components into a single integral structure by weaving reinforcement fibers continuously across component boundaries during the molding process. This eliminates adhesive bonds or mechanical fasteners entirely, creating a unified structure where load transfers directly through the continuous fiber network, thereby maximizing joint strength and reliability under tension.
Solution Approach 2:
The patent utilizes composite materials with reinforcement fibers (such as carbon, glass, or aramid) embedded in a matrix material to create structures with superior joint properties. The continuous fiber reinforcement across joint regions provides enhanced tensile strength and reliability, eliminating the weak bond lines inherent in adhesive-jointed structures.
2Shape
If two-dimensional woven preforms are folded into three-dimensional shapes, then complex structures can be formed, but distortions occur at fold lines compromising surface quality
Solution Approach 1:
The patent transitions from two-dimensional woven preforms to three-dimensional structures by incorporating through-thickness reinforcement fibers and creating multi-layered woven architectures. This dimensional enhancement allows the structure to accommodate folding and shaping while maintaining surface quality, as the additional fiber layers distribute stresses and prevent distortion at fold lines.
Solution Approach 2:
The patent modifies the physical and structural parameters of the reinforcement preform, including fiber orientation, layer stacking sequences, and material properties, to enable distortion-free folding. By carefully controlling these parameters, the preform can be transformed into complex three-dimensional shapes while maintaining high manufacturing precision and surface quality at fold lines.
3Strength
If separate components are joined to form stiffened structures, then structural reinforcement is achieved, but additional manufacturing steps and complexity are introduced
Solution Approach 1:
The patent combines multiple manufacturing operations into a single integral molding process. Reinforcement fibers are woven into the desired three-dimensional configuration and molded directly into the final stiffened structure in one step, eliminating separate steps for component fabrication, assembly, and joining. This integration maintains structural reinforcement while dramatically reducing manufacturing process complexity.
Data Source
AI summary
An integrally woven three-dimensional preform with stiffeners in two directions constructed from a woven base fabric having first, second and third woven fabrics. A plurality of yarns are interwoven over a region between the first and second fabrics such that the first fabric is foldable relative to the second fabric. An additional plurality of yarns are interwoven over a region between the second and third fabrics such that the third fabric is foldable relative to the second fabric. Upon folding of the woven base fabric, the integrally woven three-dimensional preform with stiffeners in two directions is formed.