3D Woven Composite Skin Core Structure
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Solution Overview
Problem
The production of composite material parts with fibrous reinforcement structures faces challenges such as surface irregularities, inhomogeneous densification, and the need to maintain three-dimensional structure continuity, especially in thin parts like turbomachine blade trailing edges, which affect mechanical properties and require additional processing steps.
Innovation Solution
A fibrous reinforcing structure woven in a single piece with a three-dimensional core and a satin-type skin weave, allowing for easier access during chemical vapor infiltration and minimizing surface irregularities, while varying yarn counts and weaves between core and skin to achieve desired fiber content, permeability, and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a three-dimensional interlock weave is used in the core, then access to the gaseous phase is improved, but surface irregularities increase
Solution Approach 1:
The fibrous structure is divided into two distinct parts: a core region with three-dimensional interlock weave for gas access and a skin layer with two-dimensional satin weave for surface quality. This segmentation allows each region to be optimized for its specific function without compromising the other.
Solution Approach 2:
Different weave structures are applied to different regions of the fibrous structure. The core has a three-dimensional interlock weave that facilitates gaseous phase access, while the skin has a two-dimensional satin weave that provides a smooth surface. This local differentiation resolves the contradiction by giving each region the quality it needs.
2Stability of the object's composition
If multiple superposed layers are bonded together, then structural continuity is improved, but surface irregularities increase
Solution Approach 1:
The structure is segmented into a multi-layered core for structural continuity and a single-layer skin for surface quality. The core maintains structural integrity through bonding of multiple layers, while the skin provides a smooth outer surface without the irregularities that would result from bonding multiple surface layers.
Solution Approach 2:
The skin layer is applied locally at the surface region where smoothness is critical, while the internal core regions maintain their multi-layered bonded structure for structural continuity. This local application of different structural qualities resolves the contradiction.
3Quantity of substance
If yarn counts are varied between core and skin, then fiber content control is improved, but manufacturing complexity increases
Solution Approach 1:
Different yarn counts are used in different regions: the core uses yarn counts optimized for structural integrity and gas permeability, while the skin uses yarn counts optimized for surface quality and smoothness. This local differentiation allows precise control of fiber content in each region.
Solution Approach 2:
The yarn count parameter is changed between the core and skin regions to achieve the desired fiber content distribution. By varying this physical parameter locally, the invention optimizes both structural and surface properties without requiring fundamentally different manufacturing processes.
Data Source
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Figure 5~5H
AI summary
A woven fibrous structure embodied in one piece, used for producing a composite material part and comprising an internal part or a core (72) and a part adjacent to the external surface thereof or a skin (74, 76), is formed by three-dimensional core weaving with at least one weave selected from interlock and multilayer weaves and by skin weaving with a weave which differs from the core weave and selected from a multilayer weave and a two-dimensional weave. It can be also formed by three-dimensional weaving with at least one core interlock weave (72) and weaving with a fabric-, satin or skin twill-type weave, wherein skin weaving is of a multilayer or two-dimensional type. .