Integrally Woven 3D Preform with Off-Axis Stiffeners
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing reinforced composite materials face limitations in creating strong, lightweight structures that can withstand high out-of-plane loads and require complex geometric shapes, with prior methods either relying on weak adhesive joints or mechanical coupling that adds weight and introduces thermal expansion issues.
Innovation Solution
An integrally woven preform with stiffeners in multiple directions, such as 0°, ±60°, and ±45°, is developed using a conventional loom, where fibers exchange positions to create a hexagonal or diamond pattern, enhancing structural integrity and allowing for the formation of complex shapes without the need for adhesives or mechanical fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive joints or mechanical fasteners are used to join reinforcement preforms, then the structural integrity and strength are improved, but the weight increases and thermal expansion issues are introduced
Solution Approach 1:
The patent merges multiple reinforcement preforms into a single integrated woven structure with interlaced fibers. The fibers from different preforms are interwoven together at the joints, creating a unified composite structure that eliminates the need for separate adhesive joints or mechanical fasteners, thereby reducing weight while maintaining structural integrity
Solution Approach 2:
The patent uses composite fiber structures where reinforcement fibers from multiple preforms are interlaced and combined with matrix material. This composite approach allows the joint regions to have enhanced properties through the intermingling of fibers from different directions, providing both strength and weight efficiency
2Strength
If adhesive joints are used to join reinforcement preforms, then the structural integrity is improved, but thermal expansion mismatches and reliability issues occur
Solution Approach 1:
The patent merges multiple reinforcement preforms into a single integrated woven structure with interlaced fibers. The fibers from different preforms are interwoven together at the joints, creating a unified composite structure that eliminates the need for separate adhesive joints or mechanical fasteners, thereby reducing weight while maintaining structural integrity
Solution Approach 2:
The patent achieves homogeneity by interlacing fibers from multiple preforms together, creating a uniform distribution of reinforcement materials at the joint regions. This homogeneous fiber arrangement ensures consistent thermal and mechanical properties throughout the structure, eliminating thermal expansion mismatches that would occur with heterogeneous adhesive joints
3Adaptability or versatility
If complex geometric shapes are created using multiple joined preforms, then the shape adaptability is improved, but the manufacturing complexity and number of joints increase
Solution Approach 1:
The patent applies segmentation by creating a modular woven structure where different sections of the composite can be independently designed and manufactured. The interlaced fiber architecture allows the structure to be divided into functional segments while maintaining continuity through the interwoven fiber paths, enabling complex shapes without requiring multiple separate joints
Solution Approach 2:
The patent uses another dimension by implementing fiber interlacing in the through-thickness direction. This three-dimensional fiber arrangement allows the structure to achieve complex geometric shapes and structural features without requiring additional joints in the planar directions, thereby reducing manufacturing complexity while maintaining shape adaptability
4Ease of manufacture
If conventional loom weaving is used to create multi-directional stiffeners, then the manufacturing ease is improved, but achieving off-axis reinforcement patterns is difficult
Solution Approach 1:
The patent applies dynamics by implementing a flexible fiber routing system where fibers can change direction and orientation dynamically throughout the weaving process. This allows the conventional loom to produce off-axis reinforcement patterns by dynamically adjusting fiber paths during weaving, maintaining manufacturing simplicity while achieving versatile stiffener orientations
Solution Approach 2:
The patent uses parameter changes by varying the weaving pattern parameters to achieve different stiffener orientations. By changing the interlacing sequence, fiber angles, and weave density parameters during the weaving process, the conventional loom can produce off-axis reinforcement patterns without requiring complex mechanical modifications to the loom itself
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
An integrally woven three-dimensional preform with stiffeners in two or more directions constructed from a woven fabric having a first, second and optional third woven fabric layer. A plurality of yarns are interwoven over a region between the first and second fabric layers such that the first fabric layer is foldable relative to the second fabric layer. An additional plurality of yarns are interwoven over a region between the second and third fabric layers such that the third fabric layer is foldable relative to the second fabric layer. Upon folding of the woven fabric layers, the integrally woven three-dimensional preform with stiffeners in two or more directions is formed.