Abstract: Various embodiments provide an apparatus, method, and/or system by which fiber, e.g., in the form of tow or tow, is used to create a shaped ply by facilitating drawing fiber from a supply along a fiber axis between two sets of pins; moving the pins across the fiber axis to form a fiber web in the desired ply shape; fixing the fiber web to form the shaped ply; and releasing the shaped ply. By enabling formation of shaped plies (including plies with doubly curved surfaces and simultaneous sequences of strategically shaped plies) directly from a single piece of fiber tow, various embodiments discussed herein enable substantial reductions in labor and materials costs that are conventionally associated with construction of composite preforms and accompanying composite products.

Abstract: Implementations include a system including a preform fabrication apparatus and method for creating composite preforms through a process of determining a preform shape and number of layers required to assemble the preform and using a preform layer assembly apparatus to provide a number of functions such as receiving and holding a composite layer, shaping the composite layer, pressing composite layer onto a preform support structure, forming the composite layer into a preform shape, etc. Multiple composite layers may be picked up, held, shaped, and applied to a preform by the assembly apparatus. The assembly apparatus includes a flexible membrane settable to a deformable shape and a rigid state such that flexible membrane may be configured to be deformed into an assembly shape, which is then held in a rigid state. The flexible membrane may be used to apply pressure to an article to conform the article to the assembly shape.

Abstract: A slip ring segment, used as a part of a downhole tool placeable within a well casing, includes a stack of fabric layers, the fabric layers comprising fibers, such as carbon fiber and glass fiber, the stack having first and second surfaces, which can be axially tapering surfaces, and stitching passing through the stack. The stitching can conform to ASTM D6193, 205 hand stitching. The stitching includes first stitching portions passing through the stack, and second stitching portions connecting selected first stitching portions and extending along the first and second surfaces without knots, crimps or loops, with the first and second surfaces and the fabric layers substantially un-deformed by the stitching. The slip ring segment also includes a matrix binding the stack of fabric layers and the stitching, and well casing-engaging elements extending from the interior of the stack out past first surface.

Abstract: A process to create composite preforms and parts by stacking layers of two-dimensional fiber material (e.g., fiber cloth, fiber reinforced fabric, etc.) having pin-receiving holes and/or gaps disposed between the fibers of the fiber material is described. The stack is pinned together using a subset of pins, such as fiber reinforcing pins, inserted into a subset of the pin receiving holes and/or gaps, leaving at least some of the pin receiving holes and/or gaps available for pinning other layers, as layers of fiber material are added to the stack. As additional layers are added to the stack, different subsets of pins connect the additional layers to the stack, thereby building up the stack. Each layer of fiber material may have a different shape than the other layers and any arbitrary topology, potentially including non-convex and/or disjoint shapes. Furthermore, implementations may produce composite preforms having an arbitrary number of interconnected layers.

Abstract: A system fabricating composite preforms includes a layer assembly stage with a first stage for receiving new layers, such as layer N; and a second stage for holding up to K layers, such as layers N?1 to N?K. An interlayer reinforcement insertion mechanism inserts interlayer reinforcements Q through layer N and the layers N?1 to N?K, using a first layer spacing between layer N?K and layer N-K?1 in a completed layer stage. Following the interlayer reinforcements Q insertion, the layer assembly stage transfers the layer N?K to the completed layer stage; closes the first layer spacing, bringing layers N?K and N?K?1 into contact; and transfers the layer N to the second stage. The system repeats this cycle of receiving new layers, inserting interlayer reinforcements using layer spacings between the second and completed layer stages, closing these layer spacings, and transferring layers to construct composite preforms with arbitrary numbers of layers.

Abstract: Various embodiments provide an apparatus, method, and/or system by which fiber, e.g., in the form of tow or tow, is used to create a shaped ply by facilitating drawing fiber from a supply along a fiber axis between two sets of pins; moving the pins across the fiber axis to form a fiber web in the desired ply shape; fixing the fiber web to form the shaped ply; and releasing the shaped ply. By enabling formation of shaped plies (including plies with doubly curved surfaces and simultaneous sequences of strategically shaped plies) directly from a single piece of fiber tow, various embodiments discussed herein enable substantial reductions in labor and materials costs that are conventionally associated with construction of composite preforms and accompanying composite products.

Abstract: A method and system for automated fabrication of composite preforms. In one implementation, a fabrication apparatus includes a stitching assembly, needle apparatus, motion stage, preform cartridge, CAD/CAM Software, and embedded machine software. The stitching assembly includes an upper portion that supports a stitching mechanism. The stitching mechanism includes at least one needle assembly. The needle assembly may be configured with at least one needle apparatus configured to pass filaments through composite preforms. In one implementation, the stitching assembly is used to stitch layers of the composite preforms using a variety of stitching patterns. The fabrication apparatus may be configured to fold fabric layers of the composite preform before or after stitching two or more layers of the composite preform.

Abstract: A process to create composite preforms and parts by stacking layers of two-dimensional fiber material (e.g., fiber cloth, fiber reinforced fabric, etc.) having pin-receiving holes and/or gaps disposed between the fibers of the fiber material is described. The stack is pinned together using a subset of pins, such as fiber reinforcing pins, inserted into a subset of the pin receiving holes and/or gaps, leaving at least some of the pin receiving holes and/or gaps available for pinning other layers, as layers of fiber material are added to the stack. As additional layers are added to the stack, different subsets of pins connect the additional layers to the stack, thereby building up the stack. Each layer of fiber material may have a different shape than the other layers and any arbitrary topology, potentially including non-convex and/or disjoint shapes. Furthermore, implementations may produce composite preforms having an arbitrary number of interconnected layers.

Abstract: A system fabricating composite preforms includes a layer assembly stage with a first stage for receiving new layers, such as layer N; and a second stage for holding up to K layers, such as layers N?1 to N?K. An interlayer reinforcement insertion mechanism inserts interlayer reinforcements Q through layer N and the layers N?1 to N?K, using a first layer spacing between layer N?K and layer N?K?1 in a completed layer stage. Following the interlayer reinforcements Q insertion, the layer assembly stage transfers the layer N?K to the completed layer stage; closes the first layer spacing, bringing layers N?K and N?K?1 into contact; and transfers the layer N to the second stage. The system repeats this cycle of receiving new layers, inserting interlayer reinforcements using layer spacings between the second and completed layer stages, closing these layer spacings, and transferring layers to construct composite preforms with arbitrary numbers of layers.

Abstract: A system fabricating composite preforms includes a layer assembly stage with a first stage for receiving new layers, such as layer N; and a second stage for holding up to K layers, such as layers N?1 to N?K. An interlayer reinforcement insertion mechanism inserts interlayer reinforcements Q through layer N and the layers N?1 to N?K, using a first layer spacing between layer N?K and layer N?K?1 in a completed layer stage. Following the interlayer reinforcements Q insertion, the layer assembly stage transfers the layer N?K to the completed layer stage; closes the first layer spacing, bringing layers N?K and N?K?1 into contact; and transfers the layer N to the second stage. The system repeats this cycle of receiving new layers, inserting interlayer reinforcements using layer spacings between the second and completed layer stages, closing these layer spacings, and transferring layers to construct composite preforms with arbitrary numbers of layers.

Abstract: Methods creating composite preforms with a three-dimensional weaving pattern include stacking material layers and then connecting them with interlayer reinforcements. First and second layers are aligned and separated by a first layer spacing. First interlayer reinforcements are then inserted through at least the first and the second layers. At least a third layer is aligned with at least the first and second layers. Second interlayer reinforcements are inserted through at least the second and third layers, using the first layer spacing between the first and second layers to manipulated the second interlayer reinforcements during insertion. Following the insertion of at least the second interlayer reinforcement, this layer spacing is closed to bring the first and second layers into contact. Further layers and interlayer reinforcements may be added, using additional layer spacings to manipulate additional interlayer reinforcements to form complex three-dimensionally woven composite preforms.

Abstract: Systems and methods fabricate composite preforms in a flat or unfolded format. Following fabrication, the preform is folded and placed in or around a mold for curing. To facilitate folding and produce strong parts, the preform is fabricated with integrated, 3D woven joints at preform edges. These joints connect the folded preform portions to other parts of the preform, such as other unfolded or folded preform portions or internal features. Integrated joints may be flexible to facilitate assembly prior to curing. The unfolded preform design may be generated from a preform model by splitting the preform model at an initial joint location, unfolding the preform model into an unfolded preform, creating joint connectors in the unfolded preform at the initial joint location, determining a fiber layup of the unfolded preform, and generating fabrication data.