Abstract: Fabric and methods of forming thick 3-D woven preforms wherein substantially orthogonal yarn systems are manipulated in each direction to provide predetermined thickness and cross-sectional shapes.

Abstract: A wind blade spar cap for strengthening a wind blade including an integral, unitary three-dimensional woven material having a first end and a second end, corresponding to a root end of the blade and a tip end of the blade, wherein the material tapers in width from the first to the second end while maintaining a constant thickness and decreasing weight therebetween, the cap being capable of being affixed to the blade for providing increased strength with controlled variation in weight from the root end to the tip end based upon the tapered width of the material thereof. The present inventions also include the method of making the wind blade spar cap and a wind blade including the wind blade spar cap.

Abstract: A base material for a printed circuit board, and a printed circuit board constructed therefrom. The base material is formed from a three-dimensional orthogonally woven fabric having a crimp-free fiber architecture in the x-y plane and an integrated multi-layer structure. The base material comprises a first system of straight first fibers extending along a first direction in a first plane, a second system of straight second fibers extending along a second direction in a second plane parallel to the first plane, and a third system of third fibers extending along a third direction through the first and second systems and binding the first and second fibers thereof. A filler material coats a portion of the first, second and third systems. The printed circuit board comprises the base material and one or more conductive layers attached to surfaces of the base material.

Abstract: A machine for producing complex-shaped, three-dimensional engineered fiber preforms having unitary, integral and seamless structures and, a method for making the preforms on the machine, and preforms produced thereby. The integral design and structure of the preform is formed by a combination of interlacing and non-interlacing fiber systems that permits variable cross-sectional area and dimensions from a first end to a second end along an axis via selective activation and control of at least one module, preferably a plurality of moduli connected to each other in any desirable configuration.

Abstract: A three-dimensional engineered fiber preform having a unitary, integral and seamless structure and rigid composite structure made therefrom for use as a mechanical component, particularly for use as a valve, and method for making the preform. The integral design and structure of the preform is formed by a combination of interlacing and non-interlacing fiber systems that permits variable cross-sectional area and dimensions from a first end to a second end along an axis, or from a stem end to a head end of a valve.

Abstract: A method and machine for high speed formation of a three-dimensional woven fiber structure having at least two warp yarn systems having approximately zero crimp and at least three filling yarns having approximately zero crimp, wherein the warp and filling yarns are non-interlacing with each other, and are secured as an integral fabric via at least one vertical or Z yarn system and the warp yarn systems provided to be positioned via harness frames. The 3-D woven fabric of the present invention is fabricated on a 3-D weaving machine having rapier filling insertion that provides filling yarn insertions in unique shed openings in series to produce a complete filling insertion cycle for every movement of Z-direction yarn harnesses.

Abstract: A shaped three-dimensional engineered fiber preform construction having at least one insertion hole therein and rigid composite structure formed therefrom having a singular, unitary component construction, thereby providing improved and uniform finished product characteristics and performance for structural applications, particularly for use as a connector, coupling, and the like. The shaped 3-D engineered fiber preform construction of the present invention is fabricated on a 3-D weaving machine designed and configured to produce a variety of cross-sectional shapes and sizes as well as to produce a plurality of structures in series for subsequent separation and processing.

Abstract: A multilayer laminated woven structure for ballistic protective wear that is moldable to substantially conform to a female torso and capable of retaining that molded shape for providing increased comfort and ease of movement when the protective wear is in use. A three-dimensional woven material is used for the base functional layer of the ballistic protective wear. Also, a thermoplastic material is employed to fuse the fibers of the three-dimensional woven material to each other to provide improved handling during lamination of the material and improved ballistic resistance during use.

Abstract: A three-dimensional multiaxial circular woven fabric of a generally cylindrical shape having a core defined therein about a central axis. A plurality of concentric axial yarn layers extend radially outwardly in spaced-apart relationship from the central axis, and each of the layers comprises a plurality of axial yarns extending parallel to the central axis of the fabric. A plurality of radially spaced-apart circumferential yarns extend outwardly from the central axis of the fabric and define a plane substantially perpendicular thereto, and each of a selected number of the plurality of circumferential yarns is woven between a corresponding plurality of next adjacent and successive concentric axial yarn layers. A plurality of radial yarns is provided in the fabric wherein each of a selected number of the radial yarns is woven between a corresponding plurality of next adjacent and successive axial yarns and each axial yarn layer of a plurality of concentric yarn layers.