3D Woven Composite Flange and Counter-Flange Integration
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Solution Overview
Problem
Conventional methods for manufacturing composite parts with flanges and counter-flanges, especially in turbomachines, face issues such as localized force distribution, material mismatch, and weight optimization due to the use of separate metal counter-flanges, which can lead to contact faults and increased mass.
Innovation Solution
A fibrous structure with a three-dimensional weave design, where the edge forms both the flange and counter-flange, allowing for integral formation within the composite part, eliminating the need for separate machining and reducing material density by using composite materials with comparable mechanical properties to titanium.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal counter-flange is used to reinforce the composite flange, then the mechanical strength and force distribution are improved, but the weight of the composite part increases significantly
Solution Approach 1:
The patent merges the flange and counter-flange into a single integrated composite structure. The fibrous structure includes both the flange portion and the counter-flange portion as one continuous piece, eliminating the need for separate metal counter-flanges. This integration maintains mechanical strength while achieving weight reduction since both components are made from lightweight composite materials with comparable mechanical properties to titanium.
Solution Approach 2:
The patent uses composite materials for both the flange and counter-flange portions, replacing traditional metal counter-flanges. The fibrous structure is made from composite materials that have mechanical properties comparable to titanium but significantly lower density, thus reducing weight while maintaining the required strength and force distribution capabilities.
2Strength
If separate metal counter-flanges are manufactured and assembled, then the force distribution is improved, but the manufacturing complexity and assembly steps increase
Solution Approach 1:
The patent combines the manufacturing of the flange and counter-flange into a single integrated process. The fibrous structure is manufactured as one continuous piece using three-dimensional weaving and densification techniques, eliminating the need for separate manufacturing and assembly operations. This reduces manufacturing complexity while maintaining the force distribution function of the counter-flange.
Solution Approach 2:
The integrated fibrous structure serves multiple functions simultaneously: it provides the main flange structure, the counter-flange reinforcement, and the bonding interface all in one component. This multi-functionality eliminates the need for separate parts and assembly steps, reducing manufacturing complexity while maintaining structural integrity.
3Ease of manufacture
If the fibrous structure edge is folded to form the counter-flange, then the manufacturing process is simplified, but the structural integrity during folding must be maintained
Solution Approach 1:
The patent incorporates the counter-flange portion into the fibrous structure during the initial three-dimensional weaving process, before densification. This preliminary formation of the folded structure ensures that the fibers are properly positioned and oriented to maintain structural integrity during the subsequent densification and curing processes, while still achieving manufacturing simplification through the integrated design.
Data Source
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Figure 5~7
AI summary
Fibrous structure (10) for producing a composite part comprising a matrix reinforced by said fibrous structure (10), said fibrous structure (10) being produced by three-dimensional weaving and having a main portion (12) and a rim (14) adjacent to the main portion (12). Said rim (14) has a thickness greater than the thickness of the main portion (12), and the rim (14) comprises a first portion (16) placed so as to be continuous with the main portion (12) and a second portion (18) placed on top of the first portion (16), forming an overthickness, said rim (14) thus being configured so as to be bent on the side of the second portion (18) in such a way that said first and second portions (16, 18) form a flange and a counter-flange respectively, in order to fix said part.