Woven Preform with Closed Perimeter Cells for Composite Structures
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Solution Overview
Problem
Current methods for producing woven preforms for reinforced composite materials often result in open cells at the outer edges, which are weaker under internal pressure loads, and require complex assembly processes, limiting the size and shape of structures that can be produced and increasing manufacturing costs.
Innovation Solution
A method of machine weaving fiber preforms with closed perimeters and multiple intersecting members, using a single weft yarn to create continuous hoop reinforcement in each cell, allowing the preform to be woven flat and then folded into its final shape, eliminating the need for resin layers and reducing assembly labor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional weaving methods are used to produce reinforcement preforms, then the preforms can be manufactured with standard processes, but the outer edges result in open cells that are weaker under internal pressure loads
Solution Approach 1:
The patent inverts the traditional weaving approach by making the weft yarn continuous through the entire preform structure rather than having it repeat at each warp intersection. This inversion creates closed perimeter cells at the outer edges while maintaining manufacturability through a modified but still standard weaving process.
Solution Approach 2:
The patent implements continuity of useful action by using a single continuous weft yarn that traverses the entire length of the preform, creating uninterrupted hoop reinforcement around each cell. This continuous action eliminates the open cell structures at edges that occur with traditional repeating weft patterns, while the weaving process itself remains a continuous manufacturing operation.
2Shape
If individual layers of fabric are assembled to form complex shapes, then the desired geometry can be achieved, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent applies segmentation by designing the preform to be woven flat in a simplified configuration and then folded or shaped into the final complex geometry. This divides the manufacturing process into two stages: a simple weaving stage that produces the reinforcement structure, and a subsequent forming stage that creates the final shape, thereby reducing assembly complexity.
Solution Approach 2:
The patent uses dimensionality change by transitioning from a 2D flat woven structure to a 3D complex shape through folding and forming operations. This allows the preform to achieve complex geometries without complex weaving patterns, as the final shape is created by manipulating the already-woven flat structure in additional spatial dimensions.
3Reliability
If multiple resin layers are used to join fabric layers, then the structural integrity can be maintained, but the manufacturing time and costs increase
Solution Approach 1:
The patent merges the reinforcement function and the joining function into a single integrated structure. The continuous weft yarn creates hoop reinforcement that inherently joins the fabric layers together at the intersections, eliminating the need for separate resin layers to provide both reinforcement and joining functions. This consolidation maintains structural integrity while reducing manufacturing steps.
Solution Approach 2:
The patent extracts the joining function from the resin layers and transfers it to the woven fabric structure itself. The continuous weft yarn creates inherent joints at the intersections that provide structural integrity without requiring additional resin layers, thereby removing the harmful effect of increased manufacturing time and cost associated with multiple resin application and curing cycles.
4Reliability
If the preform is woven with closed perimeters and continuous hoop reinforcement, then the damage tolerance is improved, but the weaving process becomes more complex
Solution Approach 1:
The patent inverts the traditional approach by making the weft yarn continuous through the entire preform rather than having it repeat at each intersection. This inversion achieves closed perimeter cells and continuous hoop reinforcement while actually simplifying the weaving process, as it eliminates the need for complex yarn routing and rethreading operations required by traditional methods.
Data Source
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Figure 3(a)~3(c)
AI summary
The present invention generally relates to a woven preform for reinforced composite materials and a method of making thereof. Specifically, the present invention is a method of machine weaving fiber preforms for polymer matrix composites that consist of closed perimeters with multiple intersecting members in their interiors. More specifically, the invention is a woven preform and a method of forming thereof with closed cells at the outer edges with continuous hoop reinforcement in each cell of the preform. The woven preform is woven flat in both the warp and weft directions, and then unfolded to achieve the final shape of the structure, and can be processed into composite structural components using known methods such as resin transfer molding or chemical vapor infiltration. Thus, complicated shapes of all sizes can be woven on a conventional loom using the instant method.