Woven Composite Junctions with Integrated Noodle Reinforcement
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Solution Overview
Problem
Existing woven composite structures face challenges in forming complex shapes with multiple members due to difficulties in joining woven structures at junctions, leading to reduced fibre volume fraction and poor integration of noodle elements, which complicates handling and manipulation during component formation.
Innovation Solution
A woven composite component design where fibre-reinforcement tows cross each other around a noodle element within the woven structure, integrating the noodle element to enhance fibre volume fraction and guide the profile of the junction, ensuring proper fibre reinforcement and smooth outer surface formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If woven preforms are used in sheets to form complex shapes with multiple members, then structural integrity is improved, but joining difficulties at junctions reduce manufacturing precision
Solution Approach 1:
A noodle element is introduced as an intermediary component at the junction between feeder portions and compound members. This noodle element facilitates the joining process by providing a central structure around which warp tows are woven, enabling accurate junction formation while maintaining the structural integrity of the multi-member composite component
2Quantity of substance
If noodle elements are placed at junctions to maintain fibre volume fraction, then fibre reinforcement is improved, but integration difficulties complicate handling and manipulation
Solution Approach 1:
The noodle element is integrated directly into the woven preform structure during manufacturing, merging it with the warp tows and feeder portions. This integration ensures proper fibre reinforcement and maintains fibre volume fraction at junctions, while the unified structure eliminates handling difficulties associated with separate noodle elements
3Adaptability or versatility
If warp tows are crossed at junctions to form multiple members, then complex shapes are achieved, but fibre volume fraction decreases
Solution Approach 1:
The noodle element provides localized fibre concentration at the junction region where complex shaping occurs. This local quality enhancement ensures that fibre volume fraction is maintained specifically at the junction between feeder portions and compound members, while allowing the rest of the structure to achieve complex shapes through tow crossing
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
A woven composite component 100 for an aerospace structure or machine, comprising: a compound member 102 extending from a junction 104 with a feeder member 106, a noodle element 114 extending in a weft direction through the junction. The feeder member comprises first and second feeder portions 108, 110 either side of the junction, each feeder portion comprising warp tows extending towards the junction. There is a compound set of warp tows 112 extending from the first and second feeder portions, each turning at the junction to define warp tows for the compound member. There is a crossing set of warp tows belonging to the compound set, the crossing set comprising warp tows from the first feeder portion and warp tows from the second portion which cross each other at the junction to pass around the noodle element. There is also disclosed a method of manufacturing a preform for a woven composite component.