Weave Control Grid for Reproducible 3D Composite Structures
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Solution Overview
Problem
Existing methods struggle to manipulate planar woven structures into complex, three-dimensional shapes with varying contours, particularly for components like ceramic matrix composite (CMC) or organic matrix composite (OMC) components used in jet engines, due to difficulties in forming three-dimensional woven structures within molds with non-planar geometries.
Innovation Solution
A weaving method utilizing a weave control grid affixed to a base, combined with positional controllers and warp fiber arms, allows for precise control and repositioning of warp fibers to form complex shapes, enabling the creation of woven structures with controlled spacing and reproducibility, using a robotic weaving assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional planar weaving methods are used, then the manufacturing process is simple, but the ability to form three-dimensional structures with varying contours is limited
Solution Approach 1:
The base is made movable relative to the weave control grid, allowing dynamic repositioning during the weaving process. This enables the formation of three-dimensional structures with varying contours by changing the spatial relationship between the base and grid throughout manufacturing, resolving the contradiction between forming complex 3D shapes and maintaining simple manufacturing processes.
Solution Approach 2:
A movable base is introduced as an intermediary component between the weave control grid and the warp fibers. The base provides a reference surface that can be repositioned relative to the grid, enabling precise control of warp fiber positioning for complex geometries while maintaining the simplicity of the grid structure itself.
2Manufacturing precision
If warp fibers are manually positioned, then flexibility in forming complex shapes is possible, but manufacturing precision and consistency are reduced
Solution Approach 1:
The weave control grid with its opening pattern provides self-positioning guidance for the warp fibers. The grid structure itself serves as the positioning mechanism, eliminating the need for complex manual positioning operations while maintaining high precision and consistency in warp fiber placement.
Solution Approach 2:
The manual mechanical positioning process is replaced by a controlled grid system with openings that guide fiber placement. This substitution maintains positioning precision while significantly reducing operational complexity and manual intervention requirements.
3Adaptability or versatility
If a fixed grid pattern is used, then manufacturing consistency is maintained, but adaptability to varying mold contours is limited
Solution Approach 1:
The base is made movable relative to the weave control grid, allowing dynamic repositioning during the weaving process. This enables the formation of three-dimensional structures with varying contours by changing the spatial relationship between the base and grid throughout manufacturing, resolving the contradiction between forming complex 3D shapes and maintaining simple manufacturing processes.
Solution Approach 2:
The weaving system is segmented into independent components: a movable base and a stationary weave control grid. This segmentation allows the base to be repositioned independently to accommodate varying mold contours while the grid maintains its spacing consistency, enabling both adaptability and precision simultaneously.
Data Source
Figure 1
Figure 2A~2C
Figure 3~4
AI summary
Disclosed is a weaving method including placing a first section of a fill fiber 30 between warp fibers 42, forming a pick 58, moving a base 22 to reposition the warp fibers, and placing a second section of the fill fiber between the warp fibers to form a woven structure 14, wherein at least a portion of the warp fibers are introduced to the woven structure using a weave control grid 100. Also disclosed is a weaving assembly including a base 22, a base positional controller 54, a weave control grid 100, warp fiber arms 26, a warp fiber arm positional controller 50 and a fill fiber wand 18.