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 method of fabricating a turbomachine blade out of a composite material including fiber reinforcement densified by a matrix, the method including making a one-piece fiber blank by three-dimensional weaving; shaping the fiber blank to obtain a one-piece fiber preform having a first portion forming a blade airfoil and root preform and at least one second portion forming a preform for an inner or outer blade platform; and densifying the preform with a matrix to obtain a composite material blade having fiber reinforcement constituted by the preform and densified by the matrix, fowling a single part with incorporated inner and/or outer platform.

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 reinforcement for a darted three-dimensional Pi or T-shaped preform, a method of making thereof and a composite structure including the reinforcement is disclosed. The reinforcement is a steered fabric having a width, a length, a first face surface and a second face surface separated by a thickness. The first face surface of the steered fabric is affixed to a darted component of the preform. The steered fabric reinforcement can be a single layer or multilayer fabric, which can be woven using a programmable take up system.

Abstract: A woven fiber preform, a fiber reinforced composite incorporating the preform, and methods of making thereof are disclosed. The woven preform includes a plurality of warp and weft yarns or fibers interwoven to form a continuous spiral fabric. The spiral fabric may take the shape of an Archimedes spiral. The weft yarns in the preform may have a uniform or variable pick spacing, or a uniform or variable angular separation. The spiral fabric of the Archimedes spiral may be assembled or wrapped to form a conical shell structure, which could be a portion of a spinner or an exit cone. The spiral fabric may be woven on a loom equipped with a differential take-up mechanism.

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 three dimensional woven preform, a fiber reinforced composite incorporating the preform, and methods of making thereof are disclosed. The woven preform includes one or more layers of a warp steered fabric. A portion of the warp steered fabric is compressed into a mold to form an upstanding leg. The preform includes the upstanding leg and a joggle in a body portion. The body portion and upstanding leg are integrally woven so there is continuous fiber across the preform. A portion of the warp steered fabric includes stretch broken carbon fibers in the warp direction, and another portion includes conventional carbon fibers. The warp steered fabric can be woven on a loom equipped with a differential take-up mechanism. The warp steered fabric can be a single or multilayer fabric. The preform or the composite can be a portion of an aircraft window frame.

Abstract: A quasi-isotropic three-dimensional preform and a method of making thereof are disclosed. The preform includes a plurality of woven elements that are braided with each other. The woven elements have one or more integrally woven stiffeners or walls in a direction perpendicular to the plane of the woven element. The preform may be used in forming a fiber reinforced composite.

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

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 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: 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 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.