Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: An integrally woven three-dimensional preform with stiffeners in two directions constructed from a woven base fabric having first, second and third woven fabrics. A plurality of yarns are interwoven over a region between the first and second fabrics such that the first fabric is foldable relative to the second fabric. An additional plurality of yarns are interwoven over a region between the second and third fabrics such that the third fabric is foldable relative to the second fabric. Upon folding of the woven base fabric, the integrally woven three-dimensional preform with stiffeners in two directions is formed.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: A corner fitting and a method of forming a corner fitting including steps of providing a flat woven fabric including a first woven portion having first and second direction woven fibers, a second woven portion adjacent the first woven portion having first direction fibers and sacrificial second direction fibers and a third semi-woven portion having first direction fibers selectively engaged by the sacrificial second direction yarns. The method further comprising steps of folding the flat woven fabric in at least one direction, and removing the sacrificial second direction fibers, wherein during removal, the sacrificial second direction fibers are replaced in the second woven portion by the first direction fibers of the third semi-woven portion and form a corner fitting having continuous fibers connecting all sides.