Patent application number | Description | Published |
20080261474 | Hybrid Three-Dimensional Woven/Laminated Struts for Composite Structural Applications - A woven preform used to reinforce a composite structure which includes a central portion having a plurality of interwoven layers. The preform also includes first and second end portions having a plurality of independent woven layers that are integrally woven with the plurality of interwoven layers in the central portion and which extend along the entire length the preform. Interspersed between the plurality of independent woven layers in the first and second end portions are bias plies. The first and second end portions can have through thickness reinforcements comprising reinforcement fibers that traverse through the independent woven layers and the bias plies, locking them together. | 10-23-2008 |
20090149100 | Method for Weaving Closed Structures with Intersecting Walls - 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. | 06-11-2009 |
20090163100 | Method for Weaving Substrates with Integral Sidewalls - The present invention generally relates to an integrally woven three-dimensional preform with at least one sidewall in at least one direction constructed from a woven base fabric comprising two or more layers, and a method of forming thereof. A plurality of fibers in a first direction is interwoven between at least the top layer and a second layer, such that top layer is foldable relative to the other layers and form, upon folding, an integral sidewall. A plurality of fibers may also be interwoven between the second-from-the-top layer and a second layer, such that the second-from-the-top layer is foldable relative to the other layers, upon folding, form a second integral sidewall perpendicular to the first integral sidewall. The preform may optionally comprise a plurality of non-integral sidewalls formed by folding portions of the topmost layer. | 06-25-2009 |
20090202763 | Multidirectionally Reinforced Shape Woven Preforms for Composite Structures - The present invention relates to multidirectionally 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 multidirectionally 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. | 08-13-2009 |
20090247034 | Fiber Architecture for Pi-Preforms - A woven preform for a reinforces composite material, which may be woven flat and folded into a shape. The preform has a three-dimensional weave architecture with fill fibers woven to provide layer-to-layer interlocking of layers of warp fiber as well as interlocking of fibers within each layer. At least two legs extend from a base, the base and legs each having at least two layers of warp fibers. The legs can be connected at a symmetrical or asymmetrical, distributed-column intersection, with an even or odd number of columns of warp fibers being located between the legs. The outer ends of the base and/or legs preferably have tapers formed from terminating layers of warp fibers in a stepped pattern. | 10-01-2009 |
20090311462 | HYBRID THREE-DIMENSIONAL WOVEN/LAMINATED STRUTS FOR COMPOSITE STRUCTURAL APPLICATIONS - A woven preform used to reinforce a composite structure which includes a central portion having a plurality of interwoven layers. The preform also includes first and second end portions having a plurality of independent woven layers that are integrally woven with the plurality of interwoven layers in the central portion and which extend along the entire length the preform. Interspersed between the plurality of independent woven layers in the first and second end portions are bias plies. | 12-17-2009 |
20090325443 | Fabricating symmetric and asymmetric shapes with off-axis reinforcement from symmetric preforms - A device for obtaining off-axis reinforcement of a woven object. The device is made up of a fixed mandrel and a rotating mandrel. The rotating mandrel is connected to the fixed mandrel by a shaft that rotates through the middle of the fixed mandrel. The shaft allows the rotating mandrel to move up and down in relation to the fixed mandrel. A portion of the woven object can be clamped to the fixed mandrel while a second portion of the woven object can be clamped to the rotating mandrel. When rotated, the rotating mandrel causes the warp fibers in the woven object to twist off the 0° direction while fill or hoop fibers remain substantially parallel to the 90° direction. | 12-31-2009 |
20100105268 | Pi-Preform with Variable Width Clevis - A woven preform for a reinforced composite material, which may be woven flat and folded into shape. The preform has a three-dimensional weave architecture with fill fibers woven to provide layer-to-layer interlocking of layers of warp fiber as well as interlocking of fibers within each layer. At least two legs extend from a base, the base and legs each having at least two layers of warp fibers. The legs may be parallel or angled to each other, or may have a variable width clevis in between. The outer ends of the base and/or the legs preferably have tapers formed from terminating layers of warp fibers in a stepped pattern. | 04-29-2010 |
20100105269 | Pi-Shaped Preform - A woven preform for a reinforced composite material, which may be woven flat and folded into shape. The preform has a three-dimensional weave architecture with weft fibers woven to provide layer-to-layer interlocking of layers of warp fiber as well as interlocking of fibers within each layer. One or more legs extend from a base, the base and legs each having at least two layers of warp fibers. The legs may be parallel or angled to each other and/or may move along a sine wave in the warp and/or weft direction. The outer ends of the base and/or the legs preferably have tapers formed from terminating layers of warp fibers in a stepped pattern. | 04-29-2010 |
20100167007 | Woven Preform with Integral Off Axis Stiffeners - 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. | 07-01-2010 |
20100167616 | Quasi-Isotropic Three-Dimensional Preform and Method of Making Thereof - A quasi-isotropic three-dimensional preform and a method of making thereof are disclosed. The preform includes a plurality of woven elements that are braided with each other. The woven elements have one or more integrally woven stiffeners or walls in a direction perpendicular to the plane of the woven element. The preform may be used in forming a fiber reinforced composite. | 07-01-2010 |
20110086565 | Woven Preform, Composite, and Method of Making Thereof - A three dimensional woven preform, a fiber reinforced composite incorporating the preform, and methods of making thereof are disclosed. The woven preform includes two or more warp steered fabrics. The warp steered fabrics include a darted portion and an un-darted portion. The darted portions of the warp steered fabrics are joined to un-darted portions of one another so as to provide continuous fiber in the circumferential and radial directions of all portions of the preform. An un-darted portion in one steered fabric reinforces a darted portion in the other. The warp steered fabrics can be woven on a loom equipped with a differential take-up mechanism. The warp steered fabrics can be single or multilayer fabrics. The final preform can be a portion of an aircraft window frame. | 04-14-2011 |
20110086566 | Woven Preform, Composite, and Method of Making Thereof - A three dimensional woven preform, a fiber reinforced composite incorporating the preform, and methods of making thereof are disclosed. The woven preform includes one or more layers of a warp steered fabric. A portion of the warp steered fabric is compressed into a mold to form an upstanding leg. The preform includes the upstanding leg and a joggle in a body portion. The body portion and upstanding leg are integrally woven so there is continuous fiber across the preform. A portion of the warp steered fabric includes stretch broken carbon fibers in the warp direction, and another portion includes conventional carbon fibers. The warp steered fabric can be woven on a loom equipped with a differential take-up mechanism. The warp steered fabric can be a single or multilayer fabric. The preform or the composite can be a portion of an aircraft window frame. | 04-14-2011 |
20110097526 | FIBER PREFORM, FIBER REINFORCED COMPOSITE, AND METHOD OF MAKING THEREOF - A woven fiber preform, a fiber reinforced composite incorporating the preform, and methods of making thereof are disclosed. The woven preform includes a plurality of warp and weft yarns or fibers interwoven to form a continuous spiral fabric. The spiral fabric may take the shape of an Archimedes spiral. The weft yarns in the preform may have a uniform or variable pick spacing, or a uniform or variable angular separation. The spiral fabric of the Archimedes spiral may be assembled or wrapped to form a conical shell structure, which could be a portion of a spinner or an exit cone. The spiral fabric may be woven on a loom equipped with a differential take-up mechanism. | 04-28-2011 |
20110111664 | REINFORCEMENT FOR DARTED PI PREFORMS - A reinforcement for a darted three-dimensional Pi or T-shaped preform, a method of making thereof and a composite structure including the reinforcement is disclosed. The reinforcement is a steered fabric having a width, a length, a first face surface and a second face surface separated by a thickness. The first face surface of the steered fabric is affixed to a darted component of the preform. The steered fabric reinforcement can be a single layer or multilayer fabric, which can be woven using a programmable take up system. | 05-12-2011 |
20110217893 | METHOD FOR WEAVING SUBSTRATES WITH INTEGRAL SIDEWALLS - The present invention generally relates to an integrally woven three-dimensional preform with at least one sidewall in at least one direction constructed from a woven base fabric comprising two or more layers, and a method of forming thereof. A plurality of fibers in a first direction is interwoven between at least the top layer and a second layer, such that top layer is foldable relative to the other layers and form, upon folding, an integral sidewall. A plurality of fibers may also be interwoven between the second-from-the-top layer and a second layer, such that the second-from-the-top layer is foldable relative to the other layers, upon folding, form a second integral sidewall perpendicular to the first integral sidewall. The preform may optionally comprise a plurality of non-integral sidewalls formed by folding portions of the topmost layer. | 09-08-2011 |
20120100321 | WOVEN PREFORMS, FIBER REINFORCED COMPOSITES, AND METHODS OF MAKING THEREOF - Preforms for use in fiber-reinforced composites, fiber-reinforced composites, and methods for making thereof are disclosed. One method includes interweaving a plurality of warp yarns with a single weft yarn so as to form a tubular woven structure with a central axis. The preform can be woven using an endless or tubular weaving technique, and can be woven so as to have two or more diameters along a length thereof. The preform can include one or more layers of a fabric formed on or attached to one or both surfaces of the tubular woven structure. The end structure can be a part of a window frame, a wheel rim, or a combustor in a jet engine. | 04-26-2012 |
20120189798 | PREFORM AND METHOD FOR REINFORCING WOVEN FIBER NODES - Preforms including fiber reinforced nodes for use in fiber reinforced composite structures and methods for making fiber reinforced composite structures. Preforms with woven fabric elements extending radially from a common node include at least one reinforcing fiber interwoven between at least two elements and passing through the node. A method of assembling preform structures using the preforms to provide a structure with reinforced nodes. | 07-26-2012 |
20120251793 | CORNER FITTING PREFORMS AND METHOD OF MAKING THEREOF - A corner fitting preform and a method of forming a corner fitting preform including steps integrally weaving a base or parent material with one or more flanges or legs that extend from the base is disclosed. The flat woven preform includes specially engineered areas within the legs or flanges that have continuous warp yarns which are not woven. The unwoven areas provide a hinge which allows the flanges of the preform to fold around a corner. After folding, the excess unwoven warp yarns are pulled back through the woven portion of the legs or flanges to produce a preform with continuous warp yarn reinforcement around the corner. | 10-04-2012 |
20130108422 | COMPOSITE MATERIAL TURBOMACHINE ENGINE BLADE OR VANE, COMPRESSOR STATOR SEGMENT OR TURBINE NOZZLE SEGMENT INCORPORATING SUCH VANES AND METHOD FOR MANUFACTURING SAME | 05-02-2013 |
20130216770 | PI-SHAPED PREFORM WITH BIAS FIBERS - A woven preform for a reinforced composite material, which may be woven flat and folded into shape. The preform has off-axis reinforcement with one or more legs and/or base extending in an off axis or bias (non 0/90 degree) orientation with respect to the warp/weft fibers. One or more legs extend from a base, the base and legs each having at least two layers of warp fibers. The legs may be parallel or angled to each other. The outer ends of the base and/or the legs may have tapers formed from terminating layers of warp fibers in a stepped or angled pattern. | 08-22-2013 |
20140113088 | CIRCUMFERENTIAL STIFFENERS FOR COMPOSITE FANCASES - Woven preforms, for example those used for jet aircraft engine fancases, may need additional stiffeners to improve the strength and/or dynamic performance of the preform assembly, as well as to serve as attachment points. The present invention describes several improved woven preforms that include circumferential or axial stiffeners, as well as methods of manufacturing the same. One embodiment includes circumferential stiffeners added to a woven preform. Another embodiment includes sub-preforms with integral flanges that combine to make integral stiffeners. A further embodiment includes an intermediate stiffener wrapped onto a base sub-preform wrap, wherein the intermediate stiffener wrap incorporates intermediate stiffeners. Another embodiment incorporates bifurcations in one or more layers of an outermost wrap of a multi-layer fabric composite that forms a preform, wherein the bifurcated outer wrap is folded to form stiffeners that may be oriented circumferentially or axially. | 04-24-2014 |
20140120296 | Preform and Method for Reinforcing Woven Fiber Nodes - Preforms including fiber reinforced nodes for use in fiber reinforced composite structures and methods for making fiber reinforced composite structures. Preforms with woven fabric elements extending radially from a common node include at least one reinforcing fiber interwoven between at least two elements and passing through the node. A method of assembling preform structures using the preforms to provide a structure with reinforced nodes. | 05-01-2014 |
20140178645 | THREE-DIMENSIONAL WOVEN CORNER FITTING WITH LAP JOINT PREFORMS - A three-dimensional corner lap joint preform and a method of forming a three-dimensional corner lap joint preform including a woven flange with one or more legs that extend from the flange. The legs may include one or more independently woven portions which allow formation of a corner without darting the leg or adding additional reinforcement. The independently woven portions may include warp fibers which are not woven into the preform. The unwoven area allows removal of a portion of the leg prior to formation of the corner, allowing the portions of the leg to overlap and form a lap joint. | 06-26-2014 |
20140220295 | Preform and Method for Reinforcing Woven Fiber Nodes - Preforms including fiber reinforced nodes for use in fiber reinforced composite structures and methods for making fiber reinforced composite structures. Preforms with woven fabric elements extending radially from a common node include at least one reinforcing fiber interwoven between at least two elements and passing through the node. A method of assembling preform structures using the preforms to provide a structure with reinforced nodes. | 08-07-2014 |
20140315457 | 3D WOVEN FIBER STRUCTURE, A FIBER PREFORM OBTAINED FROM SUCH A FIBER STRUCTURE, AND A COMPOSITE MATERIAL PART INCLUDING SUCH A PREFORM - A fiber preform is formed by a fiber structure woven by three-dimensional weaving with a plurality of layers of warp yarns interlinked by weft yarns of a plurality of layers of weft yarns, the fiber preform having a first portion and a second portion that extend one another in the weft direction and that are at an angle to each other. In the fold zone and in each weft plane of the fiber structure, two weft yarns situated in a region adjacent to an outside face of the fiber structure situated on the inside of the corner present paths that cross, so that less curvature is imposed on these yarns. | 10-23-2014 |
20140322485 | FIBER PREFORM OF PI-SHAPED SECTION, IN PARTICULAR FOR A FAN PLATFORM MADE OF COMPOSITE MATERIAL - A fiber preform of π-shaped section, the preform including a base with a first face and an opposite second face, legs extending from the second face, and a fiber structure woven as a single piece by three-dimensional weaving with a plurality of layers of warp or weft yarns linked interlinked by weft or warp yarns in a plurality of layers of weft or warp yarns. In each plane of the preform, the weft or warp yarns of a first group of weft or warp yarns extend continuously through the base between two opposite edges thereof, and weft or warp yarns of a second group of weft or warp yarns extend continuously from an end of one of the legs to an end of the other leg, passing via the base, with the yarns of the first group and the yarns of the second group presenting two mutual crossings. | 10-30-2014 |
20140334935 | FIBROUS REINFORCEMENT STRUCTURE FOR COMPOSITE MATERIAL PART HAVING A REDUCED THICKNESS PORTION - A fiber structure reinforcing a composite material part woven as a single piece by multilayer weaving between plural first and second layers of yarns. The fiber structure includes a portion of decreasing thickness that presents: plural yarn withdrawal parts in surface continuity, with yarns interrupted from the first plural layers of yarns underlying the layer of yarns of the first plural layers of yarns situated in the surface of the structure; and plural yarn withdrawal parts in surface discontinuity, with yarns interrupted from the first plural layers of yams situated at the surface of the structure, each interrupted yarn replaced in the surface of the structure by a yarn of a layer of yarns underlying the first plural layers of yarns. The yarns of the second plural layers of yarns situated in the surface of the fiber structure are continuous over at least the entire portion of decreasing thickness. | 11-13-2014 |
20140349538 | FIBER STRUCTURE WOVEN AS A SINGLE PIECE BY 3D WEAVING AND APPLICATION TO THE MANUFACTURING OF COMPOSITE MATERIAL PART - In a fiber structure woven as a single piece by three-dimensional weaving, first weft yarns interlink layers of warp yarns in a first portion of the fiber structure adjacent to a non-interlinked zone and also warp yarns of a second portion of the fiber structure beyond the non-interlinked zone, and second weft yarns interlink layers of warp yarns of the second portion of the fiber structure adjacent to the non-interlinked zone and also layers of warp yarns of the first portion of the fiber structure beyond the non-interlinked zone, such that the paths of the first and second weft yarns cross in at least one transition zone extending within the fiber structure from the end of the non-interlinked zone, the transition zone extending in the weft direction over a distance greater than the pitch between adjacent warp columns. | 11-27-2014 |
20140369847 | FIBROUS STRUCTURE HAVING VARIABLE NUMBERING YARNS - A fiber structure for reinforcing a composite material part, the structure being woven as a single piece by multilayer weaving between a first plurality of layers of yarns extending in a first direction and a second plurality of layers of yarns extending in a second direction. The second plurality of layers of yarns includes at least one layer of variable-weight yarns, each variable-weight yarn including a separable assembly of individual yarns, each having a determined weight. The fiber structure includes at least one portion of reduced thickness in which the variable-weight yarn presents a weight that is less than the weight that it presents prior to the reduced thickness portion. | 12-18-2014 |