Variable Thickness 3D Weaving Fibrous Structure
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Solution Overview
Problem
Conventional 3D weaving techniques struggle to produce fibrous structures with significant variations in thickness perpendicular to the warp and weft directions, often requiring cutting which reduces mechanical strength and is inefficient, or increasing yarn cross-sections which becomes difficult beyond a certain limit.
Innovation Solution
A method of multilayer three-dimensional weaving that adjusts the number of warp or weft planes and layers without changing the number of yarns, allowing for varying thickness by grouping or dividing warp planes and adding or subtracting layers, while using yarns of different titers and textures to maintain structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If cutting is used to obtain variable thickness from a uniform thick fibrous structure, then the desired thickness variation is achieved, but material is wasted and mechanical strength is reduced
Solution Approach 1:
The invention performs preliminary action by varying the number of warp yarn layers during the weaving process itself to create the desired thickness variation directly in the fibrous structure. This avoids the need for subsequent cutting operations, thereby preventing material waste and preserving mechanical strength. The thickness variation is built into the structure during manufacturing rather than being created by removing material afterward.
2Shape
If the yarn count is increased to reduce thickness reduction during weaving, then thickness variation capacity improves, but weaving becomes difficult or impossible beyond a certain point
Solution Approach 1:
The invention applies segmentation by dividing the fibrous structure into multiple sections along the warp direction, each with a different number of warp yarn layers. This allows independent control of thickness in each section without requiring an overall increase in yarn count. The structure is segmented into first and second parts with different thickness characteristics, achieved by selectively adding or removing warp yarn layers in specific zones during the weaving process.
3Shape
If the number of warp planes is decreased and warp yarn layers are increased to achieve greater thickness, then thickness variation is achieved, but the number of warp yarns remains constant requiring reconfiguration
Solution Approach 1:
The invention applies dynamics by making the number of warp planes and warp yarn layers variable along the warp direction rather than fixed throughout. The system dynamically adjusts the configuration by decreasing the number of warp planes and increasing the number of warp yarn layers in sections where greater thickness is required. This dynamic reconfiguration allows the fibrous structure to adapt its thickness locally without changing the total number of warp yarns.
Data Source
Figure 1~8
Figure 2~5
Figure 3A~3C
AI summary
The invention relates to a fibrous structure produced by multi-layer three-dimensional weaving with variable thickness, in a direction perpendicular to the warp (C) and weft (T) directions, in the warp direction while keeping the same number of woven warp threads at every point of the fibrous structure in the warp direction. During a transition to warp direction from a first portion of the fibrous texture to a second portion of the fibrous texture having a greater thickness than that of the first portion, the number of warp planes is reduced and the number of warp thread layers is increased without changing the number of warp threads, constituting at least one warp plane (Pl,...) in the second portion with warp threads from at least two different warp planes (Pl, P2,...) in the first portion.