Woven Composite Junction Structure With Noodle-Bound Warp Tows
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Solution Overview
Problem
Challenges exist in joining woven composite structures at junctions between members, particularly in forming complex shapes, as woven preforms are difficult to manipulate and integrate noodle elements effectively.
Innovation Solution
A woven composite component design where warp tows from opposing feeder portions cross each other around a noodle element, binding it within the structure and defining its location, with capping plies providing a smooth outer profile, and a method of manufacturing this preform using a computer-controlled loom to create a multi-layer weave.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If woven preforms are used to form complex shapes with multiple members, then structural integrity is improved, but ease of manufacture deteriorates due to difficulty in joining at junctions
Solution Approach 1:
The noodle element is inserted into the woven preform before the final forming process, allowing it to be positioned and integrated in advance. This preliminary action enables the junction structure to be prepared beforehand, simplifying the subsequent joining process and improving ease of manufacture while maintaining structural integrity
Solution Approach 2:
The noodle element acts as an intermediary component at the junction between feeder portions and compound members. It facilitates the connection by providing a central structure around which warp tows are woven, enabling easier joining while maintaining the structural integrity of the complex shape
2Quantity of substance
If noodle elements are inserted to reinforce junctions, then fibre volume fraction is improved, but device complexity increases
Solution Approach 1:
The noodle element is integrated with the woven preform structure by weaving warp tows around it, merging the reinforcement function with the structural framework. This combining approach increases fibre volume fraction at junctions while avoiding excessive complexity by unifying the reinforcement and structural elements into a single integrated system
3Strength
If warp tows are made to cross around the noodle element, then structural integrity at junctions is improved, but manufacturing precision requirements increase
Solution Approach 1:
The weaving process itself provides the positioning and alignment function for the warp tows around the noodle element. As the loom operates, the warp tows naturally cross and interlace around the noodle in a self-organizing manner, reducing the need for external positioning mechanisms and lowering manufacturing precision requirements while maintaining structural integrity
Data Source
AI summary
A woven composite component for an aerospace structure or machine, comprising: a compound member extending from a junction with a feeder member, a noodle element extending in a weft direction through the junction. The feeder member comprises first and second feeder portions either side of the junction, each feeder portion comprising warp tows extending towards the junction. There is a compound set of warp tows 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.