Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

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: 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: 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 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.

Abstract: A method of forming a wear-resistant reinforcing coating on a substrate, such as concrete, wood, metal or particulate. A reinforcing fiber mat is placed on the substrate and a liquid matrix material is mixed with small colored stones. The mixture of matrix material and stones is poured onto the mat, and the liquid wets the mat and contacts the substrate. After curing, a composite coating is formed with stones as the wearing surface. A membrane can be interposed between the substrate and the reinforcing coating to prevent adhesion and “starving” of the mat.

Abstract: A method of forming a wear-resistant reinforcing coating on a substrate, such as concrete, wood, metal or particulate. A reinforcing fiber mat is placed on the substrate and a liquid matrix material is mixed with small colored stones. The mixture of matrix material and stones is poured onto the mat, and the liquid wets the mat and contacts the substrate. After curing, a composite coating is formed with stones as the wearing surface. A membrane can be interposed between the substrate and the reinforcing coating to prevent adhesion and “starving” of the mat.

Abstract: A wall reinforcing method including reinforcing members adhered to the wall. The reinforcing members are either pre-cured composite plates or composite members formed in situ, that is, a fabric of reinforcing fibers that is saturated with an adhesive to form the matrix of the composite and to adhere the reinforcement to the wall. The in situ members are either strips of fabric or wide sheets that cover most of the wall. The spacing of the reinforcing members is determined, in one embodiment, by an array of spacing distances. The array, which is preferably in table form, is consulted by the installer who first measures some of the wall parameters and environmental characteristics.

Abstract: A wall reinforcing system is provided for strengthening of walls formed of masonry or from wood, metal or other structural materials. A basic system comprises utilization of rigid, fiber reinforced polymer plates of a length to extend substantially the full vertical heigth of the wall. These plates incorporate a plurality of filamentary fibers of length to extend the full length of a plate with these fibers formed from carbon, glass or other material exhibiting high tensile strength and are affixed in a cured polymer matrix. A number of these plates are securely fixed to a wall in spaced parallel relationship by a resin bonding agent or by mechanical fastening devices, or by a combination of both. A plate may include a plurality of plates secured in stacked, superposed relationship and ridgidly secured together by a resin bonding agent into a unitary structure.

Abstract: A method of forming a thermoactive binder composite product is performed by injecting a hot dry gas to activate the thermoactive binder. In the preferred embodiment, the hot dry gas is air. The method is particularly beneficial as applied to forming thermoplastic composite products and particularly thermoplastic/cellulose composites. Also part of the present invention is a two stage pressing process in which hot gas is injected during the first stage and the press charge is precompressed. The press charge is then placed in a second consolidation press where the hot gas is no longer injected and it is consolidated and cooled. Machinery for practicing the method includes a platen with a platen press which includes upper and lower platens with a plurality of hot air injection jets disposed on the surface of each platen. The platens are spaced apart and surrounded on the sides by an air-permeable containment shell structure to form a compression chamber to hold the base material to be pressed.