3D Woven Preform Integrated Gap Filler Structural Integrity
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Solution Overview
Problem
Existing 3D woven preforms formed into shapes like 'T' suffer from structural integrity issues due to gaps that require filling with additional materials, leading to increased weight and localized thickness, which compromises their performance in load-bearing applications.
Innovation Solution
A method of forming 3D woven preforms with integrated gap fillers by folding and compressing woven layers to create triangular gaps that are then filled with compressed fibers, eliminating the need for external materials and maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gaps in T-shaped preforms are filled with additional external materials, then structural integrity at gap locations is improved, but weight and localized thickness increase
Solution Approach 1:
The patent merges the gap-filling function with the existing preform structure by using integrated gap fillers that are formed as part of the continuous preform manufacturing process. This eliminates the need for separate external materials and maintains weight efficiency while providing structural reinforcement at gap locations.
Solution Approach 2:
The gap fillers are prepared and positioned in advance during the preform manufacturing process, before the preform is cured and assembled. This preliminary action ensures proper placement and integration of gap-filling material without requiring additional weight or thickness modifications to the final structure.
2Reliability
If gaps in T-shaped preforms are filled with additional external materials, then structural integrity at gap locations is improved, but localized thickness increases
Solution Approach 1:
The patent applies local quality by providing gap fillers only at specific gap locations where structural reinforcement is needed, rather than uniformly increasing thickness throughout the preform. The integrated gap fillers are strategically positioned to maintain local structural integrity without adding unnecessary volume elsewhere.
3Reliability
If conventional gap filling methods are used, then gap locations are reinforced, but continuity of the preform is compromised
Solution Approach 1:
The integrated gap fillers are formed as a continuous integral part of the preform structure, merging the gap-filling function with the preform's continuous composition. This eliminates discontinuities that would result from adding separate external materials, maintaining both structural reinforcement and preform continuity.
4Reliability
If additional materials are added to fill gaps, then gap reinforcement is achieved, but manufacturing complexity increases
Solution Approach 1:
The gap fillers are prepared and integrated during the initial preform manufacturing process using continuous fiber placement and consolidation techniques. This preliminary action eliminates the need for separate gap-filling operations, reducing manufacturing complexity while achieving gap reinforcement.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution allows for 3D woven preforms with integrated gap fillers that maintain structural integrity without adding weight or thickness, enhancing their performance in load-bearing applications by ensuring continuous fiber reinforcement throughout the structure.
Implementation Method 1
the at least one middle section is compressed or crumpled in a gap formed between the at least two outer sections
Data Source
Figure 1A~1B
Figure 2A~2C
Figure 3A~3B
AI summary
A three-dimensional gap-filled preform and a method of forming a three-dimensional gap-filled preform. The preforms comprise a base section (200) of all integrally woven layers, a portion of that base separated into three sections, the outer two sections (212,214) comprising integrally woven layers, and the middle section (210) comprising an integrated gap filler. The integrated gap filler may comprise a center section of one woven layer, independently woven layers, integrally woven layers, or a plurality of layers of warp fibers that are not interwoven with weft fibers. The layers of the integrated gap filler compress or crumple up in the middle section and fill the formed gap or gaps, while the woven layers of the outer sections are folded to form the shape of the preform.