Method for manufacturing a ring sector
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Solution Overview
Problem
Current weaving technologies for ceramic matrix composite (CMC) parts result in structurally dependent layers with unnecessary thickness variations, leading to excessive use of expensive fibrous material and difficulty in producing small preforms due to the fragility of SiC fibers, which traditional trimming methods weaken.
Innovation Solution
A three-dimensional weaving method that varies the warp-weft ratio by adjusting the spacing between weft planes and local insertion/disengagement of weft threads, allowing structurally independent portions to achieve variable thickness without trimming, specifically by increasing spacing and reducing weft threads in certain parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional constant warp-weft ratio weaving is used, then structural simplicity and ease of manufacture are maintained, but unnecessary thickness increases in the central portion and excessive fibrous material consumption occur
Solution Approach 1:
The patent applies local quality by varying the warp-weft ratio in different portions of the fibrous structure. The central portion uses a first warp-weft ratio to achieve greater thickness, while the first and second portions use a second warp-weft ratio to achieve lesser thickness. This localized variation in weaving parameters allows each region to have the optimal thickness for its functional requirements, reducing overall material consumption while maintaining structural integrity.
Solution Approach 2:
The patent implements parameter changes by modifying the warp-weft ratio parameter during the weaving process. By changing the ratio between warp and weft threads in different sections, the thickness of the fibrous structure is controlled locally. This parameter variation enables the central portion to be thicker than the side portions, optimizing material usage without requiring post-manufacturing trimming or removal of excess material.
2Quantity of substance
If trimming methods are used to reduce thickness, then material consumption decreases, but the fragility of SiC fibers causes structural weakening
Solution Approach 1:
The patent applies preliminary action by incorporating the thickness variation directly into the weaving process itself. Instead of producing a uniform thickness structure and then trimming excess material afterward, the desired variable thickness profile is created during the initial weaving stage by adjusting the warp-weft ratio. This preliminary formation of the final thickness distribution eliminates the need for subsequent trimming operations that would weaken the fragile SiC fibers.
3Quantity of substance
If variable thickness is achieved through traditional weaving, then material efficiency improves, but manufacturing precision and structural independence deteriorate
Solution Approach 1:
The patent applies segmentation by dividing the fibrous structure into distinct portions with different thickness requirements. The central portion is woven with a first warp-weft ratio to achieve a greater thickness, while the first and second portions are woven with a second warp-weft ratio to achieve a lesser thickness. This segmentation allows each region to be independently optimized for its specific functional needs, achieving both material efficiency and manufacturing precision through controlled local variation in the weaving parameters.
Data Source
Figure 1~4
Figure 5
AI summary
The invention relates to a three-dimensionally woven multi-layer fibrous structure (20) having the same number of warp threads woven at any level in the warp direction, the fibrous structure (20) comprising, in the warp direction, a first portion (22) and a second portion (24), the first portion (22) having a thickness, measured in a direction perpendicular to the warp and weft directions, which is greater than that of the second portion (24), characterised in that the spacing between two weft planes in the warp direction is greater in the second portion than that in the first portion (22), and in that the number of weft threads is smaller in the second portion (24) than in the first portion (22).