Integral 3D Woven Preform Sidewall Formation
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Solution Overview
Problem
Existing methods for creating reinforced composite structures with integral sidewalls face challenges such as delamination, weight addition, and distortion when using adhesives or mechanical coupling, and require multiple steps or additional fibers, limiting the strength and integrity of the joints.
Innovation Solution
An integrally woven three-dimensional preform with multiple layers, where fibers in different directions are interwoven and cut/folded to form integral sidewalls, eliminating the need for separate panels and additional fibers, thus enhancing joint strength and reducing distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesives or mechanical coupling are used to join substrate and sidewalls, then assembly is simplified, but joint strength decreases and delamination occurs
Solution Approach 1:
The substrate and sidewalls are merged into a single integral woven structure where reinforcement fibers continuously interweave between the substrate and sidewall regions. This eliminates separate joining operations and creates a unified structure where the reinforcement itself forms both components and their connection, preventing delamination while maintaining manufacturing efficiency.
Solution Approach 2:
The invention uses composite reinforcement structures with fibers oriented in multiple directions (0°, 90°, and ±45°) that are integrally woven together. The reinforcement preform combines substrate and sidewall regions into a single composite structure where fibers transition continuously between regions, providing superior joint strength compared to adhesive or mechanical connections.
2Reliability
If separate panels and additional fibers are used to create sidewalls, then structural integrity is improved, but device complexity increases
Solution Approach 1:
The substrate and sidewalls are merged into a single integral woven structure where reinforcement fibers continuously interweave between the substrate and sidewall regions. This eliminates separate joining operations and creates a unified structure where the reinforcement itself forms both components and their connection, preventing delamination while maintaining manufacturing efficiency.
3Ease of manufacture
If conventional weaving methods are used, then manufacturing process is simple, but distortion occurs when folding into three-dimensional shape
Solution Approach 1:
The reinforcement preform incorporates localized variations in fiber orientation and density to accommodate different functional requirements. The weave pattern is designed with specific local characteristics in substrate regions versus sidewall regions, with transition zones that facilitate distortion-free folding into three-dimensional configurations while maintaining overall manufacturing simplicity.
4Strength
If multiple layers are interwoven to form integral sidewalls, then joint strength is improved, but manufacturing complexity increases
Solution Approach 1:
The reinforcement preform is segmented into distinct functional regions (substrate and sidewalls) with specific fiber orientations in each region. The weave pattern uses systematic segmentation of fiber directions (0°, 90°, ±45°) to achieve superior joint strength while maintaining a manageable weave structure that can be produced with conventional looms.
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
The present invention generally relates to an integrally woven three-dimensional preform with at least one sidewall (12) in at least one direction constructed from a woven base fabric comprising two or more layers, and a method of forming thereof. A plurality of fibers (1) in a first direction is interwoven between at least the top layer and a second layer, such that top layer is foldable relative to the other layers and form, upon folding, an integral sidewall (12). A plurality of fibers may also be interwoven between the second-from-the-top layer and a second layer, such that the second-from-the-top layer is foldable relative to the other layers, upon folding, form a second integral sidewall (13) perpendicular to the first integral sidewall (12). The preform may optionally comprise a plurality of non-integral sidewalls formed by folding portions of the topmost layer.