Omega-Section Woven Preform Binding Core and Sole

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Solution Overview

Problem

Existing methods for creating omega-shaped reinforcement stiffeners in the aeronautical field often result in reduced mechanical strength due to inadequate binding between the core and sole, leading to adhesion failures under traction, and require significant workforce and material waste with non-optimized fiber orientation.

Innovation Solution

A woven dry preform with an omega-section is developed, featuring interlocking weft and warp yarns that provide a strong binding between the core and sole, allowing for continuous weaving and resin impregnation to create a homogeneous assembly with controlled fiber orientation, enhancing mechanical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If separate preforms are made for the skin and stiffener, then manufacturing flexibility is improved, but binding strength between core and sole deteriorates

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidbinding strength between core and sole

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent merges the core and sole into a single continuously woven preform structure. The weaving process creates an intimate binding where weft yarns cross common warp yarns, physically integrating the core and sole portions. This eliminates the need for separate preforms while maintaining manufacturing flexibility through the weaving process itself.

Inventive Principle:

Principle #5Merging (Combining)

2Strength

If hand-made drapings are used to incorporate stiffener into skin, then binding strength is improved, but workforce requirement and cost increase

Engineering Contradiction:

Improvebinding strengthVSAvoidworkforce efficiency

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The weaving process automatically creates the binding between core and sole through the interlacing of weft and warp yarns. The structure self-assembles during the weaving process without requiring manual draping operations. The weft yarns naturally cross the warp yarns at the junction between core and sole, creating the binding structure as an inherent part of the weaving process.

Inventive Principle:

Principle #25Self-service

3Quantity of substance

If flat fabrics are used for stiffener incorporation, then material availability is improved, but fiber orientation optimization deteriorates

Engineering Contradiction:

Improvematerial availabilityVSAvoidfiber orientation optimization

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The patent changes the fundamental parameter of fabric structure from flat 2D fabrics to a 3D omega-shaped woven preform. This structural transformation allows fibers to be oriented optimally throughout the entire stiffener geometry, including the curved core and flat sole portions, during the weaving process itself, rather than requiring subsequent cutting and reorientation operations.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11473225B2Woven preform for producing a circumferential or toroidal reinforcement having an omega-shaped cross-section

Publication Date: 2022.10.18 SAFRAN NACELLES

AI summary

A method of manufacturing a preform including a core and a sole includes contour weaving the preform on a lap roller having a groove or an outgrowth allowing shape weaving of the core and the sole of the preform. At least one portion of the core and at least one portion of the sole include weft yarns which cross each other on common warp yarns.