3D Fibrous Weaving Starting Block for Precision Spacing Control
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Solution Overview
Problem
Existing 3D or multilayer weaving techniques for composite materials result in a loose portion without cohesion at the start of the fibrous structure, leading to uncontrolled spacing between frame columns, significant material loss, and increased manufacturing costs.
Innovation Solution
A process involving a high intertwining rate 'starting block' portion at the beginning of the weaving, which prevents the shift of subsequent frame wires and ensures controlled spacing, thereby maintaining the defined weaving armor and minimizing material loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional weaving is used without a starting block, then the weaving process is simpler and shorter, but the spacing between weft columns is uncontrolled and material loss is significant
Solution Approach 1:
A starting block with high interlacing rate is woven preliminarily at the beginning of the fibrous structure. This starting block establishes a stable foundation that enables precise control of weft column spacing from the very first column, eliminating the need to discard initial loose portions and thereby reducing overall weaving time while maintaining precision.
Solution Approach 2:
The fibrous structure is segmented into two distinct portions: a starting block portion with high interlacing rate and a main body portion with the desired weaving pattern. This segmentation allows the starting block to serve its specific function of establishing spacing control, while the main body optimizes for the final application requirements, resolving the contradiction between precision and time.
2Manufacturing precision
If conventional weaving is used without a starting block, then the weaving process is faster, but material loss increases due to uncontrolled spacing
Solution Approach 1:
The starting block is woven in advance as a necessary preparatory step that establishes controlled spacing from the first weft column. This preliminary action ensures that all subsequently woven columns maintain precise spacing, eliminating the material loss that would otherwise occur from discarding uncontrolled initial portions.
Solution Approach 2:
The interlacing rate parameter is changed in the starting block portion, using a higher interlacing rate compared to the main body. This parameter change creates a stable foundation that enables precise spacing control, thereby reducing material loss without compromising the overall weaving efficiency.
3Manufacturing precision
If a starting block with high interlacing rate is used, then spacing control and material utilization improve, but the weaving process becomes more complex
Solution Approach 1:
The weaving process is segmented into two portions with different interlacing rates. The starting block uses high interlacing for spacing control, while the main body uses the desired pattern for final application. This segmentation allows each portion to be optimized independently, managing complexity while achieving precision.
Solution Approach 2:
Different interlacing rates are applied to different portions of the fibrous structure based on local requirements. The starting block has high interlacing quality for spacing control, while the main body has the quality needed for its specific application. This local differentiation achieves precision without unnecessarily complicating the entire weaving process.
Data Source
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AI summary
A fibrous structure (400) intended to form the fibrous reinforcement of a part made of composite material comprises a fibrous reinforcement densified by a matrix, the fibrous structure having a three-dimensional or multilayer weave between a plurality of layers of warp threads (201) and a plurality of layers of weft threads (202). The fibrous structure comprises at least a first portion (411) having a first type of weave and a second portion (412), continuing on from the first portion, having a second type of weave, the warp threads and the weft threads exhibiting a degree of interweaving in the first type of weave that is greater than the degree of interweaving of the warp threads and the weft threads exhibited by the second type of weave.