2D Fabric with Shortened Reinforcing Threads for 3D Composites
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of three-dimensional composite parts from two-dimensional fabrics faces challenges in achieving desired strength and shape while minimizing material waste, as existing methods require extensive cutting and manual effort, leading to inefficiencies and high costs due to the need for precise cutting of reinforcing yarns.
Innovation Solution
A two-dimensional fabric with reinforcing weft and warp threads made from high-tensile yarns, where some threads are shortened to fit specific three-dimensional shapes, allowing for improved drapability and reduced waste by predetermining thread lengths and positions during weaving, and a binding system to hold these threads in place without direct binding, optimizing the arrangement for minimal cutting and material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the two-dimensional fabric is cut to size to match the desired preform shape, then the fabric can be adapted to the specific three-dimensional shape, but a large proportion of material waste is generated and a lot of manual effort is required
Solution Approach 1:
The reinforcing yarns are pre-positioned and pre-cut to specific lengths during the weaving process itself, rather than cutting them later. The loom is configured with multiple yarn supplies that feed yarns of different lengths to create a fabric where reinforcement yarns extend only where needed for the specific three-dimensional shape, eliminating post-weaving cutting operations and reducing material waste
2Strength
If the reinforcing yarns are made longer to ensure coverage, then the strength requirements are met, but the amount of expensive reinforcing yarn material increases
Solution Approach 1:
Different lengths of reinforcing yarns are used in different locations within the fabric. The loom is equipped with multiple yarn supplies, each providing yarns of specific lengths tailored to the requirements of particular zones in the final three-dimensional component. This ensures that expensive reinforcing yarns are used only where structurally necessary, rather than uniformly throughout the entire fabric
3Strength
If the fabric is designed with full-width reinforcement threads, then the structural integrity is maintained, but the drapability and ability to conform to complex three-dimensional shapes is reduced
Solution Approach 1:
The fabric is constructed with reinforcement yarns that are segmented into different length categories, with some yarns extending across the full fabric width and others extending only partially. This segmentation allows the fabric to maintain structural integrity in critical areas while having shorter, more flexible yarns in other areas that improve drapability and conformability to complex three-dimensional shapes
Data Source
Figure 1~2
Figure 3~5
Figure 6~8
AI summary
The invention relates to a two-dimensional fabric (20) and to a method for the production thereof. The two-dimensional fabric (20) is used to produce a three-dimensional composite part. The two-dimensional fabric has a binding system (21) having binding warp threads (23) and/or binding weft threads (24) and a reinforcing system (22) having reinforcing weft threads (25) and/or reinforcing warp threads (26). At least some of the introduced reinforcing threads (25) are embodied as shortened reinforcing weft threads (25a) and/or shortened reinforcing warp threads (26a). The thread length (L) thereof is less than the binding weft threads (24) or binding warp threads (23). The shortened reinforcing thread (25a), (26a) extends between its free ends, which are located in a respective thread end position (30) and (31). The respective thread length (L) and the respective thread end positions (30), (31) of a shortened reinforcing thread (25a), (26a) are predetermined in a two-dimensional fabric (20) by the three-dimensional shape of the composite part to be produced. In this way, waste cuttings in the production of preforms and cutting effort for the reinforcing threads (25), (26) can be reduced.