3D Woven Composite Fiber Structure for Complex Shapes
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Solution Overview
Problem
The challenge lies in fabricating complex composite material parts with minimal scrap material while maintaining good mechanical properties, as current methods often require significant cutting and result in excessive waste of expensive fiber reinforcement.
Innovation Solution
A fiber reinforcing structure is woven as a single piece, comprising independent fiber substructures with multilayer weaving, where adjacent warp yarns of one substructure interlink with warp yarns of another, allowing for continuous weaving and minimizing scrap by enabling parts to be shaped closer to the final form without interruption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If portions are cut off to make complex shapes, then the part shape complexity is improved, but large amounts of scrap material are generated
Solution Approach 1:
The fiber reinforcement is divided into multiple independent sub-structures (first sub-structure, second sub-structure, etc.) that can be manufactured separately as single-pieced reinforcements matching the complex geometry of different parts. This segmentation allows each sub-structure to be optimized for its specific shape without requiring cutting from a larger piece, thereby reducing scrap material while maintaining shape complexity.
Solution Approach 2:
The invention transitions from traditional 2D flat fiber reinforcement to 3D multilayer woven sub-structures with multiple layers of warp and weft yarns. This dimensional change enables the fiber reinforcement to conform to complex three-dimensional part geometries, allowing the reinforcement to be shaped closer to the final part form and reducing the need for cutting and scrap generation.
2Shape
If portions are cut off to make complex shapes, then the part shape complexity is improved, but the manufacturing cost increases
Solution Approach 1:
By segmenting the fiber reinforcement into independent sub-structures that match the complex geometry of different parts, the invention eliminates the need for expensive cutting operations and scrap disposal. Each sub-structure is manufactured as a single-pieced reinforcement, reducing manufacturing steps and costs while enabling complex shapes.
Solution Approach 2:
The fiber sub-structures are pre-formed and pre-assembled before the molding process. This preliminary action of creating ready-to-use three-dimensional fiber reinforcements with precise geometries eliminates the need for post-molding cutting and finishing operations, thereby reducing manufacturing cost while achieving complex part shapes.
3Strength
If fiber substructures are assembled by substituting weft yarns with warp yarns, then the interlinking between substructures is improved, but the weaving complexity increases
Solution Approach 1:
The weaving process is segmented into two independent stages: first, manufacturing individual sub-structures with their own warp and weft yarns; second, assembling sub-structures by substituting weft yarns with warp yarns at interfaces. This segmentation simplifies each weaving stage while achieving strong interlinking, as each sub-structure can be woven independently using standard looms without requiring complex multilayer multiaxial weaving equipment.
4Strength
If single-pieced fiber reinforcement is used, then the mechanical force distribution is improved, but the adaptability to complex shapes is reduced
Solution Approach 1:
The invention segments the fiber reinforcement into multiple single-pieced sub-structures, each optimized for a specific part geometry. This segmentation maintains the force distribution benefits of single-pieced reinforcement within each sub-structure while enabling adaptation to complex overall part shapes through the assembly of multiple sub-structures with different geometries.
Solution Approach 2:
By transitioning from 2D flat reinforcement to 3D multilayer woven sub-structures, the invention enables single-pieced fiber reinforcements to adapt to complex three-dimensional shapes. Each sub-structure is woven in three dimensions with multiple layers, allowing it to conform to the specific geometry of its corresponding part while maintaining continuous fiber paths for effective force distribution.
Data Source
AI summary
A reinforcing fiber structure woven as a single piece for fabricating a composite material part and including: first and second fiber substructures, each fiber substructure including at least one independent portion obtained by multilayer weaving between a plurality of layers of warp yarns and a plurality of layers of weft yarns that are independent from the other substructure; and an assembly portion between the least first and second fiber substructures in which a plurality of adjacent layers of warp yarns of the first fiber substructure are interlinked by at least some of the warp yarns of the second fiber substructure.