Shaped Woven Composite Preforms Without Cutting or Darting
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Solution Overview
Problem
Existing reinforced composite materials face challenges in achieving uniform strength and stiffness across complex geometries, particularly in non-axisymmetric configurations, due to distortions and labor-intensive processes like cutting and darting, which compromise structural integrity and increase production costs.
Innovation Solution
The use of multidirectionally reinforced shaped woven preforms, combining techniques like bi-axial braiding, tri-axial braiding, polar weaving, warp steering, and three-dimensional weaving, allows for the creation of composite structures that maintain fiber orientation and geometry without cutting or darting, providing continuous reinforcement in multiple directions and adapting to complex curvatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If cutting and darting procedures are used to shape reinforcement preforms, then complex geometries can be achieved, but structural integrity is compromised and production costs increase
Solution Approach 1:
The preform is pre-shaped into the desired complex geometry during the weaving process itself, rather than requiring subsequent cutting and darting operations. The weaving machine is configured to produce the final shaped preform directly, eliminating the need for post-weaving modification and preserving structural integrity.
Solution Approach 2:
The reinforcement preform is divided into multiple fabric layers with different fiber orientations (0°, 90°, ±45°) that are woven together to create the desired complex shape. Each layer contributes to specific structural requirements, allowing the overall structure to achieve complex geometries without compromising strength through cutting and darting.
2Shape
If cutting and darting procedures are used to shape reinforcement preforms, then complex geometries can be achieved, but production costs increase
Solution Approach 1:
The shaping operation is performed preliminarily during the weaving process itself, eliminating the need for subsequent cutting and darting operations. This integration of shaping into the weaving process reduces labor requirements and production steps, thereby lowering production costs.
Solution Approach 2:
The weaving process and shaping process are merged into a single operation. The weaving machine simultaneously produces the fabric structure and the desired complex geometry, combining what were previously separate steps (weaving flat fabric, then cutting and darting to shape) into one integrated process that reduces overall manufacturing cost.
3Ease of manufacture
If conventional weaving techniques are used, then simple geometries can be produced, but fiber distortions occur in non-axisymmetric configurations
Solution Approach 1:
The weaving machine employs dynamic adjustment of warp yarn tension and take-up rates during the weaving process to accommodate non-axisymmetric geometries. This dynamic control allows the warp yarns to maintain their intended orientation and length even when producing complex three-dimensional shapes, preventing fiber distortions that occur with conventional static weaving techniques.
Solution Approach 2:
Different regions of the preform are given different fiber orientations (0°, 90°, ±45°) to match the local structural requirements of the complex geometry. This local optimization of fiber orientation ensures that each area of the preform has the appropriate reinforcement direction, maintaining manufacturing precision even in non-axisymmetric configurations.
Data Source
AI summary
The present invention relates to multidirectionally reinforced fiber preforms that conform easily to complex curvatures, such as, composite turbine fan cases, jet engine containment rings, aircraft fuselage frames, aircraft window frames, and flanged rings for attaching nacelles to aircraft engines. The present invention provides multidirectionally reinforced shape woven preforms with improved strength for composite structures that are axisymmetric as well as non-axisymmetric in nature. The invention is a preform used to reinforce a composite structure which includes a contour woven fabric portion, bi-axially braided, tri-axially braided or bias fabric portion, and/or a polar woven fabric portion, and a method of making thereof. The preform may optionally include a three-dimensionally woven portion. The combination of different forms of fabrics allows the preform to be produced without cutting and darting of the individual plies. Eliminating these cuts and darts improves the strength and performance of the resulting structure.