Woven Corner Fitting Preform with Unwoven Hinge Joints
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Solution Overview
Problem
Existing reinforced composite materials face challenges in creating strong corner joints for complex shapes, as traditional methods like adhesives and mechanical coupling weaken the structure, and 3D preforms are expensive and prone to distortion when folded into curved or angled shapes.
Innovation Solution
A woven corner fitting preform with continuous warp yarns that can be folded around corners without darting, using specially engineered unwoven areas as hinges to maintain continuous reinforcement, allowing the preform to be woven on a conventional loom and integrated into composite structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional adhesive or mechanical coupling methods are used to join reinforcement preforms at corners, then the joining process is simple, but the structural strength and integrity of the corner joint deteriorates
Solution Approach 1:
The patent merges two separate preforms into a single integral woven structure by interlacing their reinforcement layers at the corner region. The first preform's reinforcement layers extend into and are interlaced with the second preform's reinforcement layers, creating a unified corner fitting that eliminates the need for separate joining operations while maintaining continuous fiber reinforcement throughout the joint.
2Shape
If 3D preforms are used to create curved or angled shapes, then shape complexity is improved, but manufacturing cost increases and distortion occurs during folding
Solution Approach 1:
The patent segments the corner fitting into multiple discrete reinforcement layers (first reinforcement layer, second reinforcement layer, third reinforcement layer, fourth reinforcement layer) that are woven in sequence. Each layer is positioned and interlaced to contribute to the final corner geometry, allowing complex three-dimensional corner shapes to be constructed from simpler two-dimensional woven layers that can be manufactured on conventional looms without distortion.
3Adaptability or versatility
If reinforcement preforms are joined at angles to create complex shapes, then shape versatility is improved, but the continuity of fiber reinforcement is interrupted creating weak links
Solution Approach 1:
The patent incorporates the corner fitting reinforcement layers into the preform structure before the actual corner joint is formed. The reinforcement layers are pre-positioned and interlaced during the weaving process, so that when the preforms are joined at angled configurations, the fiber continuity is already established in advance, eliminating weak links that would otherwise occur at the joint interfaces.
Data Source
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AI summary
A corner fitting preform (100) and a method of forming a corner fitting preform including steps integrally weaving a base (10) or parent material with one or more flanges or legs (20) that extend from the base (10) is disclosed. The flat woven preform includes specially engineered areas within the legs or flanges (20) that have continuous warp yarns which are not woven. The unwoven areas (28) provide a hinge which allows the flanges (20) of the preform to fold around a corner. After folding, the excess unwoven warp yarns are pulled back through the woven portion of the legs or flanges to produce a preform with continuous warp yarn reinforcement around the corner.