Pi-Shaped Preform With Non-Linear Legs For Distortion-Free Folding
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Solution Overview
Problem
Existing reinforced composite materials face challenges in creating complex shapes with non-uniform cross-sections and variable thickness, leading to distortion when folded, and existing methods either rely on adhesives or mechanical coupling, which are not optimal for structural integrity and weight considerations.
Innovation Solution
A method for weaving fiber preforms with non-linear legs and variable width clevises, allowing for the creation of complex shapes like 'Pi' and 'T' configurations without distortion, by adjusting fiber lengths during weaving to ensure smooth folding and using weft fibers for layer-to-layer interlocking, enabling the formation of strong, three-dimensional structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional weaving methods are used to create complex shapes with non-uniform cross-sections, then the preform can be manufactured, but distortion occurs when folded into final shape
Solution Approach 1:
The patent applies dynamics by making the leg positioning adjustable during the weaving process. The leg position can be dynamically changed along the length of the preform, allowing non-linear and non-uniform configurations. This dynamic adjustment capability enables the preform to be woven in a flat state with predetermined fold lines, which then fold into complex three-dimensional shapes without distortion because the fiber lengths are optimized for the final folded configuration.
Solution Approach 2:
The patent utilizes parameter changes by varying the leg position parameter along the length of the preform. The leg position can be changed continuously or in steps, creating non-uniform cross-sections and variable thickness regions. This parameter variation allows the preform to accommodate complex geometries while maintaining proper fiber length relationships that prevent folding distortion.
2Strength
If adhesive bonding is used to join reinforcement preforms at angles, then structural assembly is achieved, but structural integrity and weight optimization are compromised
Solution Approach 1:
The patent merges multiple reinforcement preforms into a single integrated woven structure. Instead of joining separate preforms with adhesives or mechanical fasteners, the invention weaves multiple layers and orientations of reinforcement fibers into one continuous preform that inherently forms the desired angular or complex configuration. This integration eliminates the need for additional joining materials and processes, thereby reducing weight while maintaining or enhancing structural integrity through continuous fiber reinforcement across what would otherwise be joint locations.
3Ease of manufacture
If uniform cross-section preforms are used, then manufacturing is simplified, but complex shapes and variable thickness cannot be achieved
Solution Approach 1:
The patent applies dynamics by making the leg positioning adjustable during the weaving process. The leg position can be dynamically changed along the length of the preform, allowing non-linear and non-uniform configurations. This dynamic adjustment capability enables the preform to be woven in a flat state with predetermined fold lines, which then fold into complex three-dimensional shapes without distortion because the fiber lengths are optimized for the final folded configuration.
Solution Approach 2:
The patent utilizes parameter changes by varying the leg position parameter along the length of the preform. The leg position can be changed continuously or in steps, creating non-uniform cross-sections and variable thickness regions. This parameter variation allows the preform to accommodate complex geometries while maintaining proper fiber length relationships that prevent folding distortion.
Data Source
Figure 1
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AI summary
A woven preform (200) for a reinforced composite material, which may be woven flat and folded into shape. The preform has a three-dimensional weave architecture with weft fibers (214) woven to provide layer-to-layer interlocking of layers of warp fiber (216) as well as interlocking of fibers within each layer. One or more legs (225, 235) extend from a base (220), the base (220) and legs (225, 235) each having at least two layers of warp fibers (216).The legs move along a sine wave in the warp and/or weft direction and may be parallel or angled to each other.The outer ends of the base and/or the legs preferably have tapers formed from terminating layers of warp fibers in a stepped pattern.