3D Woven Casing Preform With Deployable Stiffeners for Vibration Loads

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

Existing methods for manufacturing composite material casings for aeronautical engines face challenges in reinforcing the casing to withstand vibratory stresses and dynamic excitations, particularly in turbomachines, while ensuring the casing does not excite harmful vibrational eigenmodes, and the reinforcement regions are difficult to connect to the composite structure.

Innovation Solution

A fibrous web with a three-dimensional weave structure featuring deployable portions that form integral stiffeners and attachment flanges, eliminating the need for additional stiffener attachment by integrating these features directly into the casing preform during manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If reinforcement regions are added to the casing to withstand vibratory stresses, then the mechanical strength is improved, but the device complexity increases due to the need for additional connection steps

Engineering Contradiction:
Improvemechanical strengthVSAvoiddevice complexity
Core Design Contradiction:
StrengthVSDevice complexity

Solution Approach 1:

The patent integrates reinforcement regions directly into the fibrous web structure used to manufacture the casing. The reinforcement zones are woven into the same fibrous web that forms the casing body, eliminating the need for separate reinforcement components and their associated attachment steps. This merging of functions resolves the contradiction by improving mechanical strength through integrated reinforcement while reducing device complexity by removing additional connection mechanisms.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The reinforcement regions are prepared and positioned within the fibrous web during the manufacturing process itself, before the casing is completed. The fibrous web with integrated reinforcement zones is wound around the mandrel and then impregnated with matrix material in a single continuous process. This preliminary integration of reinforcement structures eliminates subsequent attachment operations, resolving the contradiction between strength improvement and complexity reduction.

Inventive Principle:
Principle #10Preliminary action

2Strength

If reinforcement regions are added to the casing, then the mechanical strength is improved, but the manufacturing process becomes more difficult

Engineering Contradiction:
Improvemechanical strengthVSAvoidease of manufacture
Core Design Contradiction:
StrengthVSEase of manufacture

Solution Approach 1:

The patent combines the reinforcement regions with the main casing structure by integrating them into the same fibrous web. This single integrated web is wound around the mandrel and impregnated with matrix material in one continuous manufacturing process, eliminating the need for separate attachment operations. This merging approach improves mechanical strength while maintaining ease of manufacture by simplifying the production process.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The patent uses a fibrous web composed of composite material structure with reinforcement zones integrated into the weave pattern. The fibrous web itself is a composite structure that provides both the casing body and reinforcement regions. This composite material approach allows simultaneous improvement of mechanical strength and ease of manufacture by enabling both functions to be achieved through a single material system and manufacturing process.

Inventive Principle:
Principle #40Composite materials

3Ease of manufacture

If the casing structure is simplified to reduce manufacturing complexity, then the ease of manufacture is improved, but the ability to withstand vibratory stresses deteriorates

Engineering Contradiction:
Improveease of manufactureVSAvoidmechanical strength
Core Design Contradiction:
Ease of manufactureVSStrength

Solution Approach 1:

The patent implements local quality by creating reinforcement zones with specific structural characteristics at predetermined locations within the fibrous web. These localized reinforcement regions have higher fiber density or different weave patterns tailored to withstand vibratory stresses at critical areas. This local quality approach maintains overall manufacturing simplicity while providing targeted strength enhancement where needed, resolving the contradiction between ease of manufacture and mechanical strength.

Inventive Principle:
Principle #3Local quality

Data Source

PatentUS20260008241A1Aeronautical casing preform comprising a fibrous web with two deployable portions
Publication Date: 2026.01.08 SAFRAN AIRCRAFT ENGINES SAS
  • US20260008241A1 patent drawing
  • US20260008241A1 patent drawing
  • US20260008241A1 patent drawing

AI summary

A fibrous web extending between a proximal edge and a distal edge, between a first side edge and a second side edge, and between an inner face and an outer face, the fibrous web including a distal portion present between an intermediate part and the distal edge in the longitudinal direction, the distal portion including, in the direction of its thickness, an inner portion and an outer portion, wherein the outer portion is connected to the inner portion by at least one linking portion, the outer portion comprising a first deployable portion separated from the inner portion by a first non-interlinked area, and a second deployable portion separated from the inner portion by a second non-interlinked area.