Continuous Spiral Fiber Preform for Conical Shell Manufacturing
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Solution Overview
Problem
Conventional methods for producing conical shells from fiber reinforced composites face limitations such as non-aligned fiber directions with the principal directions of the cone, discontinuous seams, size restrictions, and material wastage, especially when using 2D fabrics or polar weaving.
Innovation Solution
A fiber preform is created using a continuous spiral fabric in the shape of an Archimedes spiral, woven on a loom with a differential take-up mechanism, allowing for uniform fiber alignment and distribution in the circumferential and axial directions, eliminating seams and enabling larger sizes with reduced material waste, using a single piece of fabric.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If 2D fabric is used to form conical shells, then manufacturing is simpler, but fiber directions are not aligned with the principal directions of the cone resulting in non-uniform strength
Solution Approach 1:
The patent transitions from 2D fabric to 3D woven structure with spiral yarn paths. The yarns are woven in a continuous spiral pattern around the cone axis, allowing fiber directions to align with the principal stress directions of the conical shell while maintaining structural integrity. This three-dimensional weaving approach enables uniform strength distribution without requiring complex assembly of multiple 2D panels.
2Strength
If polar weaving is used to align fiber directions, then fiber alignment improves, but discontinuous seams and joint weaknesses are created
Solution Approach 1:
The patent implements continuous spiral yarn paths that wrap around the cone in an unbroken sequence. The weaving process creates a continuous fabric structure where yarns follow spiral trajectories from base to apex without interruption. This eliminates discontinuous seams and joints, ensuring uniform load distribution and structural reliability throughout the entire conical shell.
3Ease of manufacture
If conventional weaving methods are used, then standard loom equipment can be employed, but size restrictions and material wastage occur
Solution Approach 1:
The patent employs a dynamic weaving system where the loom can adjust yarn tension, spacing, and spiral pitch during the weaving process. This dynamic control allows the fabric to be woven in a continuous spiral pattern that efficiently utilizes material while adapting to the conical geometry. The system can accommodate larger sizes by continuously adjusting parameters during weaving, eliminating the size restrictions of static conventional looms and reducing material waste through optimized yarn placement.
Data Source
AI summary
A woven fiber preform, a fiber reinforced composite incorporating the preform, and methods of making thereof are disclosed. The woven preform includes a plurality of warp and weft yarns or fibers interwoven to form a continuous spiral fabric. The spiral fabric may take the shape of an Archimedes spiral. The weft yarns in the preform may have a uniform or variable pick spacing, or a uniform or variable angular separation. The spiral fabric of the Archimedes spiral may be assembled or wrapped to form a conical shell structure, which could be a portion of a spinner or an exit cone. The spiral fabric may be woven on a loom equipped with a differential take-up mechanism.