Composite Preform Joining With Through-Thickness Reinforcement
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Solution Overview
Problem
Existing methods for joining composite preform components introduce stress concentrations and potential failure points due to fastening or bonding, which are not suitable for complex composite structures with aerodynamic and thermal requirements.
Innovation Solution
Joining composite preform components via through thickness reinforcement (TTR) using methods such as needling, stitching, or z-pinning, followed by densification, to create a holistic composite structure without fasteners or bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fastening or bonding methods are used to join composite preform components, then the components can be connected, but stress concentrations and potential failure points are introduced
Solution Approach 1:
The patent merges the joining function and reinforcement function into a single through-thickness reinforcement operation. The reinforcement elements serve both to join the preform components together and to reinforce the structure, eliminating the need for separate fastening or bonding operations that would create stress concentrations.
Solution Approach 2:
The patent changes the physical state and distribution of reinforcement elements by inserting them through the thickness of the preform components. This transforms the reinforcement from a surface-level operation to a through-thickness operation, distributing stresses more evenly and avoiding the stress concentrations associated with fastening or bonding.
2Ease of manufacture
If traditional joining methods are used, then components can be assembled, but the process is not suitable for complex composite structures with aerodynamic and thermal requirements
Solution Approach 1:
The patent segments the complex composite structure into multiple preform components that can be independently manufactured and then joined through through-thickness reinforcement. This segmentation allows each component to be optimized for specific aerodynamic and thermal requirements while maintaining ease of assembly through the standardized joining process.
Solution Approach 2:
The patent applies local quality by allowing different regions of the composite structure to have different reinforcement patterns, material compositions, and densities. This enables each local area to be optimized for its specific functional requirements (aerodynamic, thermal, structural) while using the same through-thickness reinforcement joining method.
3Device complexity
If multiple preform components are joined together, then complex composite structures can be created, but stress concentrations occur at the joints
Solution Approach 1:
The patent transitions from two-dimensional surface-level joining to three-dimensional through-thickness reinforcement. By inserting reinforcement elements through the entire thickness of the preform components, the joining occurs in the third dimension, distributing stresses throughout the volume rather than concentrating them at surface joints.
Solution Approach 2:
The patent uses composite reinforcement elements that combine different materials or structures to achieve both joining and reinforcement functions. These composite reinforcement elements are designed to match the mechanical properties of the preform components, reducing stress concentrations at the interfaces between joined components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances mechanical properties and reduces stress concentrations, enabling the creation of complex composite structures with improved integrity and reduced cycle time.
Implementation Method 1
fibers of the first surface of the first composite preform component are pushed into the first surface of the second composite preform component
Data Source
AI summary
A manufacturing method is provided. The manufacturing method arranges a first surface of a first composite preform component to align with a first surface of a second composite preform component; attaches the first surface of the first composite preform component to the first surface of the second composite preform component to form a complex composite structure; and densifies the complex composite structure as one, complete complex composite structure.