3D woven preforms with channels

Abstract

A three-dimensional (3D) woven preform with channels in the through thickness direction developed for applications such as forming light weight preforms with an increased thickness.

Claims

1. A three-dimensional (3D) woven preform comprising: a plurality of groups of warp yarns; a plurality of groups of weft yarns, the warp yarns woven with the weft yarns to form a mock leno structure having a plurality of layers of the 3D woven preform, wherein a first group of weft yarns in a particular layer includes at least two first weft edge yarns and a first set of at least one weft central yarn, the first set of at least one weft central yarn binds warp yarns in the particular layer to warp yarns in a subsequent layer and the at least two first weft edge yarns include one disposed on each side of the first set of the at least one weft central yarn, and wherein a second group of weft yarns in the particular layer includes at least two second weft edge yarns and a second set of at least one weft central yarn, the first set of at least one weft central yarn binds warp yarns in the particular layer to warp yarns in a preceding layer and the at least two second weft edge yarns include one disposed on each side of the second set of the at least one weft central yarn, such that through thickness channels are formed in the multilayer preform.

2. The 3D woven preform of claim 1, wherein a first group of warp yarns in the particular layer includes a first set of at least one warp central yarn that binds weft yarns in the particular layer to weft yarns in the subsequent layer and at least two first warp edge yarns, one on each side of the first set of the at least one warp central yarn, and wherein a second group of warp yarns in the particular layer includes a second set of at least one warp central yarn that binds weft yarns in the particular layer to weft yarns in the preceding layer and at least two second warp edge yarns, one on each side of the second set of the at least one warp central yarn.

3. The 3D woven preform of claim 2, wherein the first and second weft edge yarns are woven over the first set of at least one warp central yarn and under the second set of at least one warp central yarn in the particular layer, and wherein the first and second warp edge yarns are woven over the first set of at least one weft central yarn and under the second set of at least one weft central yarn in the particular layer.

4. A composite comprising: a three-dimensional (3D) woven preform of claim 1, wherein the preform is impregnated with matrix material.

5. A composite comprising: a three-dimensional (3D) woven preform of claim 3, wherein the preform is impregnated with matrix material.

6. A method of forming a three-dimensional (3D) woven preform comprising: forming groups of warp yarns in a plurality of layers of the 3D woven preform; forming groups of weft yarns in the plurality of layers of the 3D woven preform; forming a mock leno structure by weaving the warp yarns in the warp groups with weft yarns in the weft groups, wherein a first group of weft yarns in a particular layer includes at least two first weft edge yarns and a first set of at least one weft central yarn, the first set of at least one weft central yarn binds warp yarns in the particular layer to warp yarns in a subsequent layer and the at least two first weft edge yarns include one disposed on each side of the first set of the at least one weft central yarn, and wherein a second group of weft yarns in the particular layer includes at least two second weft edge yarns and a second set of at least one weft central yarn, the first set of at least one weft central yarn binds warp yarns in the particular layer to warp yarns in a preceding layer and the at least two second weft edge yarns include one disposed on each side of the second set of the at least one weft central yarn, such that through thickness channels are formed in the multilayer preform.

7. The 3D woven preform of claim 6, wherein a first group of warp yarns in a particular layer includes at least two first warp edge yarns and a first set of at least one warp central yarn, the first set of at least one warp central yarn binds weft yarns in the particular layer to weft yarns in a subsequent layer and the at least two first warp edge yarns include one disposed on each side of the first set of the at least one warp central yarn, and wherein a second group of warp yarns in the particular layer includes at least two second warp edge yarns and a second set of at least one warp central yarn, the first set of at least one warp central yarn binds weft yarns in the particular layer to weft yarns in a preceding layer and the at least two second warp edge yarns include one disposed on each side of the second set of the at least one warp central yarn.

8. The 3D woven preform of claim 7, wherein the first and second weft edge yarns are woven over the first set of at least one warp central yarn and under the second set of at least one warp central yarn in the particular layer, and wherein the first and second warp edge yarns are woven over the first set of at least one weft central yarn and under the second set of at least one weft central yarn in the particular layer.

9. A method of forming a composite comprising: forming three-dimensional (3D) woven preform of claim 6, impregnating the 3D woven preform with matrix material.

10. A method of forming a composite comprising: forming three-dimensional (3D) woven preform of claim 8, impregnating the 3D woven preform with matrix material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1A illustrates an example of a related art single-layer mock leno weave fabric structure wherein both the warp and the weft yarns are grouped in threes.

(2) FIG. 1B illustrates another example of a related art single-layer mock leno weave fabric structure wherein both the warp and the weft yarns are grouped in threes.

(3) FIG. 1C illustrates another example of a related art single-layer mock lend weave fabric structure.

(4) FIG. 2 illustrates another example of a related art single-layer mock leno weave fabric structure wherein both the warp and the weft yarns are grouped in fours.

(5) FIGS. 3A-3H illustrate sections along the warp yarns in the single-layer mock leno weave fabric structure shown in FIG. 2.

(6) FIG. 4A illustrates a top view of an example of a 3D woven preform with channels of the present disclosure.

(7) FIG. 4B illustrates an oblique view of the 3D woven preform with channels.

(8) FIGS. 5A-5H illustrate sections along the warp yarns in the 3D woven preform of the present disclosure.

(9) FIG. 6 illustrates the plans used to generate the top of a 3D woven preform with channels

(10) of the present disclosure.

(11) FIG. 7 illustrates other examples of 3D woven preforms of the present disclosure.

DETAILED DESCRIPTION

(12) FIG. 4A illustrates a top view of an example of 3D woven preform with channels of the present disclosure. FIG. 4B illustrates an oblique view of the 3D woven preform with channels. As shown in FIGS. 4A-4B, the 3D woven preform with channels of the present disclosure includes a multi-layer mock leno weave fabric structure wherein both the warp and the weft-yarns are grouped in fours.

(13) The 3D woven preform may comprise two kinds of 3D mock leno weave patterns, i.e., 3D mock leno weave pattern I, and 3D mock leno weave pattern II. FIGS. 5A-5D show an example of 3D mock leno weave pattern I, and FIGS. 5E-5H show an example of 3D mock leno weave pattern II. Both of the 3D mock leno weave patterns I and II are formed by a group of four warp yarns and a group of four weft yarns in a plurality of layers. Each group of four warp yarns includes a first edge warp yarn, two central warp yarns, and a second edge warp-yarn, the edge yarns on opposite sides of the central yarns. Similarly, each group of four weft yarns includes a first edge weft yarn, two central weft yarns, and a second edge weft yarn, the edge yarns on opposites of the central yarns.

(14) A 44 (4 warp yarns in each group and 4 weft yarns in each group) mock leno weave pattern is illustrated and described, However, it should be appreciated that there do not necessarily have to be an equal number of yarns in the warp and weft yarn groups. Moreover, it is not necessary to have 4 yarns in a group as long as there is at least one central yarn and at least one edge yarn on either side of the central yarn in each warp and weft group.

(15) In the 44 3D mock leno weave patterns I shown in FIGS. 5A-5D, there are two central warp yarns in the warp yarn group in a particular layer, e.g. layer n, that alternate between being woven over all of the four yarns in the weft yarn group in the same layer n, and then woven under all of the four yarns in the weft yarn group in the next layer n+1, which is under this particular layer n in the through-thickness direction.

(16) In the 3D mock leno weave patterns II shown in FIGS. 5E-5H, there are two central warp yarns in the warp yarn group in a particular layer, e.g. layer n, that alternate between being woven under all of the four yarns in the warp yarn group in the same layer n, and then woven over all of the four yarns in the warp yarn group in the upper layer n1, which is over this particular layer n in the through-thickness layers of the fabric.

(17) In more detail, FIGS. 5A-5H illustrate sections along two groups of warp yarns in the 3D woven preform which structure has, for example, 12 layers. As shown in FIGS. 5A-5H, the two groups of warp yarns include warp yarns 11-14 of a first warp group and warp yarns 15-18 of a second warp group in the first layer of the 3D preform. Also illustrated are warp yarns 21-24 and 25-28 of first and second warp groups of the second layer. This pattern continues to warp yarns 111-114; 115-118 of first and second warp groups of the eleventh layer, and warp yarns 121-124 and 125-128 of first and second warp groups of the twelfth layer.

(18) FIGS. 5A-5H also show two groups of 4 weft yarns each that includes weft yarns 54, 69, 78, and 93 in a first weft yarn group and weft yarns 49, 63, 73, and 87 in a second weft yarn group on the first layer of the 3D woven preform, and two groups of 4 weft yarns that includes weft yarns 56, 67, 80, and 91 in a first weft yarn group and weft yarns 52, 71, 76, and 95 in a second weft yarn group on the second layer. The weft groupings continue in a similar manner to two groups of weft yarns 58, 65, 82, and 89 in a first weft yarn group 59, 64, 83, and 88 in a second weft yarn group in the tenth layer, weft yarns 60, 62, 84, and 86 in a first weft yarn group and weft yarns 51, 61, 75, and 85 in a second weft yarn group in the eleventh layer.

(19) In the following discussion the term subsequent layer is used for convenience of discussion only. However, subsequent layer as used herein means another layer not necessarily a layer lower or deeper in the 3D preform than a particular layer. Indeed, a subsequent layer could be above or higher in the 3D preform than the particular layer, The term preceding layer is only used to describe a layer in a direction opposite to that of the subsequent layer.

(20) As shown in FIGS. 5A and 5D there are 4 yarns in a first group of warp yarns: warp yarns 11, 14, one on either side of central yarns 12, 13. During the weaving of the 3D mock leno weave pattern I, the first edge warp yarn 11 and the second edge warp yarn 14 are woven under the first edge weft yarn 54 of the first weft yarn group of the first layer, then over all the central weft yarns 69 and 78, and finally under the second weft edge yarn 93 in the weft yarn group. Edge warp yarns 11, 14 are then woven over the first edge weft yarn 49 of the first layer, then under all the central weft yarns 63 and 73, and finally over the second weft edge yarn 87. Edge warp yarns 11, 14 alternate the over/under in this manner for subsequent columns of weft yarns.

(21) As shown in FIGS. 5B and 5C, the two central warp yarns 12 and 13 of the warp yarn group 11-14 in the first layer are woven over all of the four weft yarns 54, 69, 78, and 93 of the first layer and under the four weft yarns 52, 71, 76, and 95 of the second layer. Therefore, the first layer and the second layer are tied to each other.

(22) In a similar manner, the first edge warp yarn 21 and second edge warp yarn 24 of the warp yarn group 21-24 in the second layer are woven under the first edge weft yarn 56 of the first weft yarn group of the second layer, then over the central weft yarns 67 and 80, and under the second weft edge yarn 91. And the first edge warp yarn 21 and the second edge warp yarn 24 are woven over the first edge weft yarn 52 of the second weft yarn group of the second layer, then under the central weft yarns 71 and 76, and finally over the second weft edge yarn 95.

(23) The two central warp yarns 22 and 23 of the warp yarn group 2124 in the second layer are woven over all of the four weft yarns 56, 67, 80, and 91 of the second layer and under all four weft yarns 53, 70, 77, and 94 in the third layer. Therefore, the second layer and the third layer are tied to each other.

(24) As shown in FIGS. 5E and 5H there are 4 yarns in a second group of warp yarns: edge warp yarns 15, 18, one on either side of central yarns 16, 17. During the weaving of the 3D mock leno weave pattern II, the first edge warp yarn 15 and the second edge warp yarn 18 are woven over the first edge weft yarn 54 of the first weft yarn group of the first layer, then under all the central weft yarns 69 and 78, and finally over the second weft edge yarn 93 in the weft yarn group. And edge warp yarns 15, 18 are then woven under the first edge weft yarn 49 of the first layer, then over all the central weft yarns 63 and 73, and finally under the second weft edge yarn 87, Edge warp yarns 15, 18 alternate the over/under in this manner for subsequent columns of weft yarns.

(25) As shown in FIGS. 5F and 5G, the two central warp yarns 16 and 17 of the warp yarn group 15-18 in the first layer are woven under all of the four weft yarns 54, 69, 78, and 93 of the first layer and over the four weft yarns 50, 72, 74, and 76 of the layer above the first layer. Therefore, the first layer and the layer above the first layer are tied to each other.

(26) In a similar manner, the first edge warp yarn 25 and second edge warp yarn 28 of the warp yarn group 25-28 in the second layer are woven over the first edge weft yarn 56 of the first weft yarn group of the second layer, then under the central weft yarns 67 and 80, and over the second weft edge yarn 91. And the first edge warp yarn 25 and the second edge warp yarn 28 are woven under the first edge weft yarn 52 of the second weft yarn group of the second layer, then over the central weft yarns 71 and 76, and finally under the second weft edge yarn 95.

(27) The two central warp yarns 26 and 27 of the warp yarn group 25-28 in the second layer are woven under all of the four weft yarns 56, 67, 80, and 91 of the second layer and over all four weft yarns 49, 63, 73, and 87 in the first layer. Therefore, the second layer and the first layer are tied to each other.

(28) Therefore, as shown in FIGS. 5A 5H, warp yarn 11 and warp yarn 21 may come in contact with each other, but weft yarn 93 and weft yarn 49 are inhibited from contacting each other, In fact, all the weft yarns in the columns containing yarns 45 and 54 are inhibited from contacting each other. As a result channels are formed through the thickness of the fabric layers.

(29) In a similar manner, of the 4 weft yarns in groups of a particular layer, n, the two central weft yarns are woven with the warp yarns in the particular layer alternating between being woven under all of the four yarns in the warp yarn group in the same layer, n, and then woven over all of the four yarns in the warp yarn group in the upper layer n1, which is over this particular layer n in the through-thickness direction.

(30) For example, as shown in FIGS. 5A-5H, in a first group of four weft yarns 54, 69, 78, and 93, edge weft yarns 54, 93 are woven over first warp edge yarn 11, under all central warp yarns 12, 13 and then over second warp edge yarn 14 in the first warp group of the first layer, and then edge weft yarns 54, 93 are woven under first warp edge yarn 15, over all central warp yarns 16, 17 and then under second warp edge yarn 18 in the second warp group of the first layer.

(31) As shown in FIGS. 5A-5H, in the first group of four weft yarns 54, 69, 78, and 93, central weft yarns 69, 78 are woven under all the warp yarns 11-14 in the first warp yarn group, and then over all the warp yarns 15-18 in the second warp yarn group.

(32) In the second weft yarn group 49, 63, 73, and 87, weft edge yarns 49, 87 are woven under warp edge yarn 11, over all central warp yarns 12, 13 and then under second warp edge yarn 14, and then edge weft yarns 49, 87 are woven over first warp edge yarn 15, under central warp yarns 26, 27 of the second warp yarn group in the second layer and then under second warp edge yarn 18 of the second warp group of the first layer. Subsequent, weft edge yarns in each group alternate in a similar manner.

(33) Central weft yarns 63, 73 of the second weft yarn group 49, 63, 73, and 87 are woven under the first edge warp yarn 15 of the second warp yarn group in the first layer, and then under the warp yarn 26, 27 of the second warp group in the second layer, and then under the second edge warp yarn 18 of the second warp yarn group in the first layer. Therefore, the first layer and the second layer are tied to each other.

(34) Similarly, as shown in FIGS. 5A-5H, in a first group of four weft yarns 56, 67, 80, and 91 of the second layer, edge weft yarns 56, 91 are woven over first warp edge yarn 21, under all central warp yarns 22, 23 and then over second warp edge yarn 24 in the first warp group of the second layer, and then edge weft yarns 56, 91 are woven under first warp edge yarn 25, over all central warp yarns 26, 27 and then under second warp edge yarn 28 in the second warp group of the second layer.

(35) As shown in FIGS. 5A-5H, in the first group of four weft yarns 56, 67, 80, and 91, central weft yarns 67, 80 are woven under all the warp yarns 21-24 in the first warp yarn group, and then over all the warp yarns 25-28 in the second warp yarn group.

(36) In the second weft yarn group 52, 71, 76, and 95, weft edge yarns 52, 95 are woven under warp edge yarn 21, over all central warp yarns 22, 23 and then under second warp edge yarn 24, and then edge weft yarns 52, 95 are woven over first warp edge yarn 25, under central warp yarns 36, 37 of the second warp yarn group in the third layer and then under second warp edge yarn 28 of the second warp group of the second layer. Subsequent, weft edge yarns in each group alternate in a similar manner.

(37) Central weft yarns 71, 76 of the second weft yarn group 52, 71, 76, and 95 are woven under the first edge warp yarn 25 of the second warp yarn group in the second layer, and then under the warp yarn 36, 37 of the second warp group in the third layer, and then under the second edge warp yarn 28 of the second warp yarn group in the second layer. Therefore, the second layer and the third layer are tied to each other.

(38) FIG. 6 illustrates the plans used to generate the top of a 3D woven preform with channels. The pattern, as shown in FIG. 6, works by allowing some columns of yarns (warp and weft) to repel each other (4 and 5; 8 and 1) while others enable compact nesting (1 and 4; 5 and 8). Plans 2, 3, 6, & 7 are used to tie one layer to the next.

(39) The stiffness of the fiber yarns, combined with a specific over and under weave path, lead to a natural repulsion of some yarns and attraction of other yarns. This leads to the grouping of yarns in each direction that is beneficial for some applications. Stiffer yarns result in larger spacings between yarns, thus resulting in larger channels.

(40) Certain selections of warp yarn groupings in the reed can mute or accentuate the formed paths or channels. Similarly, certain patterns of take-up spacing can also mute or accentuate the formed paths or channels. The most accentuated results come from arranging the yarns as in Plans 1-4 in a dent, Plans 5-8 in a dent, and smaller take-ups between weft yarn columns 1-4 and again 5-8.

(41) Therefore, in the 3D woven preform of the instant invention, an open weave is accomplished by using only the up and down yarn movement pattern available on the weaving system and without using additional mechanical actuators.

(42) FIG. 7 illustrates other examples of 3D woven preforms. A variety of thicknesses (layers) and spacings may be used for a warp/weft column.

(43) The 3D mock leno weave pattern has the following characteristics and features: make 3D woven preforms with higher thickness at a lower fiber weight at the same thickness as a conventional 3D pattern or laminated structure. For example, a 3D preform with a traditional fiber volume (FV) has a certain thickness and a certain weight, and a preform with open channels disclosed in the instant invention, which has the same thickness, has a weight less than that of the 3D preform with the traditional fiber volume; create through thickness channels for fluid to flow either during processing of the preform into a composite; or as a cooling channel when the preform or composite is used as part of another assembly requiring heat dissipation; vary the channel spacing by varying the number of warp yarns grouped together; vary the dimensions of the channels in the Z (through thickness) direction; have less bruising, shoving or yarn displacement; have at least 3 warp and weft yarns in a group; stiffer warp and/or weft yarns will increase the repulsive force between yarn groups thus creating larger channels in the x or y planes (z being through thickness plane); vary take-up between yarn groupings to vary the channel size in the warp direction; groupings occur in both x-y plane directions, which results in rectangular, other polygonal shaped channels; warp and/or weft yarns bind from one layer to the next layer below, or bind multiple layers with one yarn.

(44) After the desired 3D woven preform structure has been formed, the structure may be impregnated in a matrix material to form a composite. The structure becomes encased in the matrix material and matrix material fills some or all of the interstitial areas between the constituent elements of the structure. The matrix material may be any of a wide variety of materials, such as epoxy, polyester, vinyl-ester, ceramic, carbon and/or other materials, which also exhibit desired physical, thermal, chemical, and/or other properties. The materials chosen for use as the matrix may or may not be the same as that of the structure and may or may not have comparable physical, chemical, thermal or other properties. Typically, however, they will not be of the same materials or have comparable physical, chemical, thermal or other properties, because a common objective sought in using composites is to achieve a combination of characteristics in the finished product that is not attainable through the use of one constituent material alone. So combined, the structure and the matrix material may then be cured and stabilized in the same operation by thermosetting or other known methods, and then subjected to other operations toward producing the desired component. After being so cured, the then solidified masses of the matrix material are adhered to the structure. As a result, stress on the finished component, particularly via its matrix material acting as an adhesive between fibers, may be effectively transferred to and borne by the constituent material of structure. Further, if Chemical Vapor Infiltration (CVI) is utilized to add the matrix material to form the composite, some or all of the channels formed in the substrate might remain open and free of the resin material.

(45) It should be appreciated that the yarns in the warp and weft directions may be of same or different materials and/or sizes. For example, the warp yarns and weft yarns can be made of carbon, nylon, rayon, fiberglass, cotton, ceramic, aramid, polyester, metal, polyethylene, and/or other materials that exhibit desired physical, thermal, chemical or other properties.

(46) It should be appreciated that other 3D mock leno weaves can be used to create the polygonal shaped channels, and that the number of layers of warp yarns is at least two or more. It should also be appreciated that in some embodiments, all the channels extend through the entire preform thickness. In other embodiments, a plurality of channels extend through the entire thickness. That is, in a desired pattern, not all of the channels necessarily extend through the entire thickness of the preform.

(47) It should also be appreciated that on one or both outer surfaces of the 3D woven preform, or one or both outer surfaces of the composite, other structures may be attached as a separate skin by methods such as stitch bonding, pinning, T-Forming (see U.S. Pat. No. 6,103,337), mechanically bolting, use of appropriate adhesives, or other methods known to those skilled in the art.