Multidirectional Reinforced Shape Woven Preforms for Composite Structures
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Solution Overview
Problem
Existing reinforced composite materials face challenges in achieving uniform strength and stiffness across complex geometries, particularly in non-axisymmetric configurations, due to fiber distortions and labor-intensive cutting and darting processes, which compromise structural integrity and efficiency.
Innovation Solution
The use of multi-directional reinforcement techniques such as bi-axial braiding, tri-axial braiding, polar weaving, warp steering, and three-dimensional weaving to create preforms that maintain fiber orientation and geometry without cutting or darting, allowing for complex shape conformance and uniform material distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If cutting and darting processes are used to conform preforms to complex geometries, then shape conformance is improved, but structural integrity and manufacturing efficiency deteriorate
Solution Approach 1:
The preform is designed and manufactured with built-in geometric features that match the final desired shape before assembly. This preliminary shaping eliminates the need for subsequent cutting and darting operations, preserving fiber continuity and structural integrity while achieving complex geometry conformance.
Solution Approach 2:
The preform is divided into multiple fabric layers with different fiber orientations (0°, 90°, ±45°) that are assembled to create complex three-dimensional shapes. This segmentation allows each layer to be manufactured separately with optimal fiber alignment, avoiding distortion from cutting and darting while achieving overall shape conformance.
2Shape
If cutting and darting processes are used to conform preforms to complex geometries, then shape conformance is improved, but manufacturing efficiency and labor requirements deteriorate
Solution Approach 1:
The preform is designed and manufactured with built-in geometric features that match the final desired shape before assembly. This preliminary shaping eliminates the need for subsequent cutting and darting operations, preserving fiber continuity and structural integrity while achieving complex geometry conformance.
Solution Approach 2:
Multiple fabric layers with different fiber orientations are combined into a single integrated preform structure. This merging allows complex geometries to be achieved through the combination of simpler manufactured layers, improving manufacturing efficiency by eliminating post-processing operations.
3Ease of manufacture
If conventional weaving techniques are used, then manufacturing simplicity is maintained, but fiber orientation control in complex geometries deteriorates
Solution Approach 1:
Different regions of the preform are constructed with different fiber orientations (0°, 90°, ±45°) to match the local structural requirements. This local quality approach allows conventional weaving techniques to be used for each layer while achieving precise fiber orientation control in the final complex geometry through strategic layer arrangement.
Data Source
AI summary
The present invention relates to mutidirectionally reinforced fiber preforms that conform easily to complex curvatures, such as, composite turbine fan cases, jet engine containment rings, aircraft fuselage frames, aircraft window frames, and flanged rings for attaching nacelles to aircraft engines. The present invention provides mutidirectionally reinforced shape woven preforms with improved strength for composite structures that are axisymmetric as well as non-axisymmetric in nature. The invention is a preform used to reinforce a composite structure which includes a contour woven fabric portion, bi-axially braided, tri-axially braided or bias fabric portion, and/or a polar woven fabric portion, and a method of making thereof. The preform may optionally include a three-dimensionally woven portion. The combination of different forms of fabrics allows the preform to be produced without cutting and darting of the individual plies. Eliminating these cuts and darts improves the strength and performance of the resulting structure.