• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    STRUCTURE OF FIBER WOVEN AS A SINGLE PIECE FOR WEAVING IN 3D, AND AN APPLICATION OF THE SAME TO MANUFACTURE A PART OF COMPOSITE MATERIAL. In a fiber structure woven as a single piece by three-dimensional weaving, first weft threads interconnect layers of warp yarns in a first portion (12) of the fiber structure (10) adjacent to an unconnected zone (16) and also yarns warp of a second portion (14) of the fiber structure beyond the unconnected zone, and second weft threads interconnect layers of warp yarns of the second portion (14) of the fiber structure adjacent to the unconnected zone and also layers of yarn warp of the first portion (12) of the fiber structure beyond the unconnected zone, so that the paths of the first and second weft threads intersect in at least one transition zone (18) extending within the fiber structure a from the end of the unconnected zone, the transition zone extending in the weft direction over a distance greater than step (p) between adjacent warp columns.
    公开号:BR112014014244B1
    申请号:R112014014244-0
    申请日:2012-12-10
    公开日:2021-01-05
    发明作者:Yann Marchal；Dominique Coupe；Monica Fruscello；Jonathan Goering
    申请人:Snecma；
    IPC主号:
    专利说明:

    Fundamentals of the invention
    [0001] The invention relates to the production of a woven fiber structure as a single piece by three-dimensional (3D) weaving, in particular to manufacture a part of composite material. A particular, but not exclusive, field of application of the invention is situated in the production of fiber structures for preforms of parts of composite material for aircraft or aeromotors, in particular for aircraft turbine engines.
    [0002] In a well known manner, a part of composite material can be obtained by producing a fiber preform and by densifying the preform with a matrix. Depending on the intended application, the preform can be made of glass, carbon, or ceramic fibers, and the matrix can be made of an organic material (a polymer), carbon, or ceramic.
    [0003] For parts that are relatively complex in shape, it is known to produce a structure or fiber blank as a single piece by multi-layer weaving or in 3D, and to shape the blank in order to obtain a preform of fiber that has a shape that is close to the shape of the part that must be manufactured.
    [0004] In order to facilitate such forming, and in order to avoid making incisions, which result in threads being cut and leading to a reduction in mechanical strength, it is known to leave one or more unconnected zones within the fiber structure while it is being woven. Such unconnected zones can be obtained by locally omitting any interconnection of the adjacent wire layers, thus making it possible to fold portions of the fiber structure adjacent to the unconnected zones.
    [0005] The production of composite material parts that are complex in shape from woven structures with unconnected zones is described in particular in WO 2010/061139 and WO 2010/103213.
    [0006] However, the conformation of a fiber structure by folding portions that are separated by an unconnected zone can give rise to weakness at the end of the unconnected zone and excessive levels of tension on the strands that are subject to tension , while such conformation is carried out. Purpose and summary of the invention
    [0007] An objective of the invention is to eliminate such disadvantages.
    [0008] In a first aspect of the invention, this objective is achieved with a fiber structure woven as a single piece by three-dimensional weaving, the fiber structure having opposite surfaces and presenting: - a first portion having a plurality of layers of yarn warp and forming a first portion of the thickness of the fiber structure between its opposite surfaces; - a second portion having a plurality of layers of warp threads and forming a second thick portion of the fiber structure, the warps being arranged in columns, each of which includes warp threads of the first portion and the second portion; and - a set of weft threads interconnecting the warp threads layers of the first portion and the second portion while leaving at least one unconnected zone separating the first and second portions over a portion of the dimension of the fiber structure in the weft direction. an edge of the fiber structure to an end of the unconnected zone; wherein the fiber structure, in each plane: - one or more of the same first weft threads interconnect layers of warp threads from the first portion of the fiber structure adjacent to the unconnected zone and layers of warp threads from the second portion of the structure fiber beyond the unconnected zone; and - one or more of the same second warp yarns interconnect layers of weft yarns from the second portion of the fiber structure adjacent to the non-interconnected zone and layers of warp yarns from the first portion of the fiber structure in addition to the non-interconnected zone; - so that the paths of the first weft yarn (s) and the second weft yarn (s) overlap in at least one transition zone extending into the fiber structure from the end of the unconnected zone; and - the transition zone extends in the weft direction over a distance that is greater than the pitch between adjacent warp columns.
    [0009] The overlapping of weft threads in the transition zone adjacent to the end of the non-interconnected zone reinforces said end and can give rise to reduced tension on the threads during the folding of the fraction of the fiber structure, adjacent to the non-interconnected zone.
    [0010] In one embodiment, a plurality of first weft threads, as well as a plurality of second weft threads, follow similar paths between the ends in the weft direction of the transition zone.
    [0011] In another embodiment, a plurality of first weft threads, as well as a plurality of second weft threads, follow similar paths that are mutually displaced in the weft direction in the transition zone (s).
    [0012] Advantageously, the outer layers of warp threads adjacent to the opposite surfaces of the fiber structure are woven with the same weft threads extending continuously over the entire dimension of the fiber structure in the weft direction, thus making it possible to preserve continuity surface wires.
    [0013] Also advantageously, in at least one of the first and second portions of the fiber structure, the warp threads of the outer layers of warp threads adjacent to the surface of the fiber structure are woven with the same weft threads having paths that they cross over at a location substantially corresponding to that of the transition zone, thus making it possible, during the folding of the fraction of the fiber structure, adjacent to the unconnected zone, to limit the curvature that is imposed on the weft threads adjacent to the surface.
    [0014] In one embodiment, the fiber structure has at least two unconnected zones separating the first and second portions over a portion of the fiber structure dimension in the weft direction from opposite edges of the fiber structure by as much as the respective ends of the unconnected zones, thus making it possible, after shaping, to obtain a fiber preform having a section that is shaped in π or shaped in I.
    [0015] In another aspect of the invention, the intended objective is achieved with a fiber structure as defined above, in which the terms "weft" and "warp" are exchanged.
    [0016] In yet another aspect of the invention, the invention provides a method of manufacturing a part of composite material comprising producing a fiber preform by shaping a fiber structure as defined above, the shaping including at least folding a fraction of the first or second portion of the fiber structure adjacent to an unconnected zone, and densification of the preform with a matrix.
    [0017] In accordance with yet another aspect of the invention, the invention provides a method of manufacturing a part of composite material having a substantially π-shaped section, the method comprising producing a fiber preform by forming a fiber structure as defined above with two unconnected zones, the conformation including folding fractions of the first or second portion of the fiber structure adjacent to the two unconnected zones, and densification of the preform with a matrix.
    [0018] As an example, such a part that has a section that is substantially shaped in π can be a fan blade platform for a turbine engine.
    [0019] According to another aspect of the invention, the invention provides a method of fabricating a portion of composite material of substantially I shaped section, the method comprising producing a fiber preform by forming a fiber structure as defined above with two unconnected zones, the conformation including folding fractions of the first and the second portion of the fiber structure adjacent to the two unconnected zones, and densification of the preform with a matrix.
    [0020] By way of example, such a section part that is shaped in I can be an output guide vane of a turbine engine.
    [0021] In accordance with yet other aspects, the invention provides a hollow propeller blade for an aeromotor, obtained by a method as defined above. Brief description of the drawings
    [0022] The invention can be better understood by reading the following description given as a non-limiting indication and with reference to the attached drawings, in which:
    [0023] Figure 1 is a highly schematic sectional view of a 3D woven fiber structure, in an embodiment of the invention;
    [0024] Figure 2 is a highly schematic section view of a preform obtained by shaping the fiber structure of figure 1;
    [0025] Figure 3 is a schematic plan view of a 3D woven fiber structure, in an embodiment of the invention;
    [0026] Figure 4 is a schematic plan view of a π-shaped preform, obtained by shaping the fiber structure of Figure 3;
    [0027] Figure 5 is a highly schematic section view of a 3D woven fiber structure, in an embodiment of the invention;
    [0028] Figure 6 is a highly schematic sectional view of a preform obtained by shaping the fiber structure of Figure 5;
    [0029] Figure 7 is a schematic plan view of a preform shaped in π section, in one embodiment of the invention;
    [0030] Figure 8 is a highly schematic sectional view of a 3D woven fiber structure in one embodiment of the invention;
    [0031] Figure 9 is a highly schematic section view of a preform obtained by shaping the fiber structure of Figure 8;
    [0032] Figure 10 is a schematic plan view of a π section preform in one embodiment of the invention;
    [0033] Figure 11 is a highly schematic sectional view of a 3D woven fiber structure in one embodiment of the invention;
    [0034] Figure 12 is a highly schematic section view of a preform obtained by shaping the fiber structure of Figure 11;
    [0035] Figure 13 is a schematic perspective view of a fan blade platform, obtained by densification of a section preform substantially shaped in π;
    [0036] Figure 14 is a highly schematic sectional view of a structure woven in 3D, in an embodiment of the invention;
    [0037] Figure 15 is a highly schematic section view of an I-shaped profile preform, obtained by shaping the fiber structure of Figure 14;
    [0038] Figure 16 is a schematic perspective view of an exit guide vane obtained by densification of a preform of I-shaped profile;
    [0039] Figure 17 is a schematic sectional view of a structure woven in 3D, in an embodiment of the invention;
    [0040] Figure 18 is a highly schematic section view of a V shaped profile preform, obtained by shaping the fiber structure of Figure 17; and
    [0041] Figure 19 is a schematic view of a propellant obtained by densification of a V-shaped profile preform. Detailed description of the modalities
    [0042] In order to avoid congestion of the drawings, in Figures 1, 2, 3, 4, 5, 7, 8, 10 and 11, the paths of the weft threads are drawn as straight lines, while the warp threads, shown in section, are represented by dots. Once the 3D weaving is involved, it will be understood that the weft threads follow sinuous paths in order to interconnect the warp threads that belong to different layers of warp threads, with the exception of non-interconnected areas, being observed that the weaving in 3D, and in particular using interweaving, can include 2D weaving on the surface. As an example, several 3D weavings can be used, such as interwoven, multiple satin, or multiple flat weavings, as described in particular in WO 2006/136755.
    [0043] Figure 1 shows in a highly schematic way a weft plane in a 3D 10 woven fiber structure constituting a single piece having opposite faces 10a and 10b. The term "weft plane" is used here to mean a section plane perpendicular to the warp direction and showing a column of weft threads. The fiber structure 10 comprises two portions 12 and 14, respectively, forming first and second portions of the thickness of the fiber structure 10. Each portion 12, 14 comprises a plurality of superimposed layers of warp yarns, four of them, in the example shown; the number of layers of warp yarn potentially any desired number not less than two, depending on the desired thickness. In addition, the number of layers of warp yarns in portions 12 and 14 could be different from each other. It is also possible to have a number of layers of warp threads that are not constant along the entire weft direction. The warp yarns are arranged in columns, each comprising both warp yarns from portion 12 and warp yarns from portion 14 of the fiber structure 10.
    [0044] On the dimension portion of the fiber structure 10 in the weft direction (t), the two portions 12 and 14 of the fiber structure are totally separated from each other by an unconnected zone 16 that extends from an edge 10c of the fiber structure 10 to an end 16a of the unconnected zone. The term unconnected zone is used here to mean a zone that is not crossed by weft threads interconnecting the warp threads in the layers that respectively belong to portions 12 and 14 of the fiber structure 10.
    [0045] Except in the unconnected area, the layers of warp threads are interconnected by weft threads belonging to a plurality of layers of weft threads.
    [0046] In the example shown, in each plane of the fiber structure 10, first weft threads t11 to t14 interconnect the warps of the layers of warps in the fraction 12a of the portion 12 adjacent to the unconnected zone 16, and also wires warp of the warp yarn layers of portion 16 beyond the unconnected zone 16. Conversely, second weft threads t15 to t18 interconnect the warp yarns of the warp layers in fraction 14a of the portion 14 adjacent to the non-woven zone interconnected 16 and also warp yarns of the layers of warp yarns in the portion 12 beyond the unconnected zone 16. Naturally, the portions 12 and 14 of the fiber structure 10 beyond the unconnected zone 16 are properly interconnected.
    [0047] As an example, it is possible to adopt a satin stitch on the surface for the weft threads t14 and t15 in fractions 12a and 12b that are separated by the unconnected zone 16, with the weaving continuing with an interconnecting weaving beyond of the unconnected area 16.
    [0048] Thus, the paths of the wires t11 to t14 and the paths of the wires t15 to t18 intersect in the transition zone 18 which extends from the end 16a of the unconnected zone 16. In the weft direction, this transition zone 18 extends over a distance greater than a step p between adjacent columns of warp yarns, and preferably not less than 2p. In the example shown, this distance is equal to 4p. In the transition zone 18, the wires t11 to t14, like the wires t15 to t18, follow similar parallel paths between the ends of the transition zone 18 in the weft direction.
    [0049] A fiber preform 19 of a substantially T-shaped profile (Figure 2) is obtained by folding fractions 12a and 14a on either side of the unconnected zone 16. Because the weft threads pass through the layers of warp in the transition zone 18 in a progressive manner, the weft threads are less exposed to any damage disc compared to crossing more suddenly through an interstice between two warp columns. In addition, the fact that the transition zone has to extend in the weft direction over a length that is relatively long provides better deformation capacity.
    [0050] Figure 3 is a plan view of a fiber structure 20 having a base portion with an outer face 20a and an inner face 20b. In its thickness, the fiber structure includes two fractions 22 and 24 which are mutually separated over a portion of the dimension of the fiber structure in the weft direction by unconnected zones 26 and 26 '. The unconnected zones 26 and 26 'extend from opposite edges 20c and 20d of the fiber structure 20 to respective ends 26a and 26'a of the unconnected zones, with the central fraction of the fiber structure 20 not including any non-interconnected zones. interconnected.
    [0051] Each portion 22 and 24 of the fiber structure has a plurality of layers of warp, the number of layers of warp in portions 22 and 24 being different in this example.
    [0052] In each plane of the fiber structure 20, the same first weft threads t21, t22, t23, t24 interconnect the warp threads in the portion 24 in addition to the unconnected zone 26 'and also interconnect the warps in the fraction 22a portion 22 next to the unconnected zone. Conversely, the same second weft threads t25, t26, t27, t28 interconnect the warp yarns in the fraction 22'a of the portion 22 next to the unconnected zone 26 'and also interconnect the warps in the portion 24 before the non-interconnected area.
    [0053] Thus, the paths of the wires t21, t22, t23, t24 cross the paths of the wires t25, t26, t27, t28 in the transition zone 28 located in the central portion of the fiber structure 20 between the ends 26a and 26'a of the unconnected zones 26 and 26 '. As in the embodiment of Figure 1, the paths of the weft threads t21, t22, t23, t24 and also the paths of the weft threads t25, t26, t27, t28 between the ends of the transition zone 28 are similar, with the transition 28 extending over a distance in the weft direction that is greater than p, here equal to 4p.
    [0054] It should be noted that, from one weft plane to the other, that, from one weft plane to the other, the transition zone can be shifted in the weft direction in order to avoid having any portion with a greater number of upper wire crossings than any other portion between the unconnected zones 26 and 26 '.
    [0055] The conformation of the fiber structure 20 in order to obtain a fiber preform 29 of structure substantially shaped in π comprises the folding of the fractions of the portion 24 of the fiber structure beside the unconnected zones 26 and 26 ', as shown in Figure 4, in order to form the legs 24a and 24'a of the π shape in the section, legs extending from the inner face 20b. In the portion of the fiber structure 20 and the fiber preform 29 adjacent to the outer face 20a, it should be noted that the weaving is carried out with a satin stitch (t29 thread) on the surface, in order to provide surface continuity without passing through the layers of warp yarns and without crossing any other weft yarns.
    [0056] In the example shown, it should also be noted that the fractions of the portion 24 of the fiber structure 20 that should form the legs 24a and 24'a extend beyond the edges of the portion 22 by adding warp yarn columns, in order to provide a desired length for legs 24a and 24'a.
    [0057] Figure 5 shows, in a highly schematic way, a fiber structure woven in 3D 40, of one piece, in a second embodiment of the invention. For the elements that are common between the fiber structure 40 of Figure 4 and the fiber structure 10 of Figure 1 the same references are given and they will not be described again.
    [0058] The fiber structure 40 differs from the fiber structure 10 in the paths followed through the layers of warp threads by the weft threads that cross in the transition zone 18.
    [0059] Thus, each weft yarn t11, t12, t13, t14 passes through it over a distance in the weft direction that is equal to the step p between the warp yarn columns, however the paths of the weft threads t11 a t14 are mutually displaced in the frame direction, with the displacement in the example shown being equal to step p. The same applies to weft threads t15, t16, t17, and t18. There is thus a transition zone 18 which, as in the mode described above, extends in the weft direction over a distance that is greater than step p, specifically over a distance of 4p. In comparison with the modality of Figure 1, greater tension is exerted on the weft threads when they pass through the transition zone, but their dimension provides good capacity for deformation.
    [0060] Figure 6 shows a fiber preform 49 of substantially T-shaped section, obtained after folding fractions 12a and 14a on either side of the unconnected zone 16 of portions 12 and 14 of fiber structure 40.
    [0061] Figure 7 is a plan view of a fiber structure 50, suitable for obtaining a substantially π-shaped section preform. For the common elements between the fiber structure 50 of Figure 7 and the fiber structure 20 of Figure 3 the same references are given and they are not described again.
    [0062] The fiber structure 50 differs from the fiber structure 20 in the paths followed through the layers of warp threads through the weft threads.
    [0063] Thus, each of the weft threads t21, t22, t23, t24 passes through the layers over a distance in the weft direction that is equal to the step p between the warp columns, with the same application for the paths followed by each of the weft threads t25, t26, t27, t28. However, the places where the threads t21 to t24 and also the places where the threads t25 to t28 cross each other in the passage through are displaced in relation to each other in the weft direction. In the example of Figure 7, the transition zone 28 extends over a relatively long distance between the ends 26a and 26'a of the unconnected zones 26 and 26 ', being formed over a plurality of individual transition zones 281, 282, 283 , and 284, with the upper crossings thus being distributed in the weft direction over the fraction of the fiber structure that extends between the unconnected zones 26 and 26 '.
    [0064] A section fiber preform that is substantially π-shaped is obtained by folding the fractions of the portion 24 of the fiber structure, which are adjacent to the unconnected zones 26 and 26 ', as in Figure 4.
    [0065] Figure 8 is a highly schematic view of a one-piece 3D 60 woven fiber structure in a third embodiment of the invention. For the elements that are common to the fiber structure 60 of Figure 8 and structures 10 and 40 of Figures 1 and 5 the same references are given and they are not described again.
    [0066] The fiber structure 60 differs from the fiber structure 10 in that, in each plane, only some of the weft threads are responsible for the process of passing through and overlapping, those weft threads being those that interconnect the threads of warp of the layers of warp yarns in the fractions of the fiber structure 60 adjacent to the unconnected zone 16, while the warps located in the fractions of the fiber structure adjacent to their faces 10a and 10b extend continuously along these surfaces without passing through of warp layers or cross other weft threads. In this way, it is possible to reinforce the fiber structure at the end of the unconnected zone, while preserving the surface continuity that encourages a good surface condition for a part of composite material as finally obtained.
    [0067] In the example shown, the weft threads t11, t12, t17, and t18 extend continuously between the edges 10c and 10d of the fiber structure 60 without crossing other weft threads. In contrast, the weft yarns t13 and t14 in the fraction 12a of the portion 12 of the fiber structure 60 adjacent to the unconnected zone 16 pass through layers of warp threads just beyond the end 16a of the unconnected zone 16 in order to enter the portion 14 of fiber structure 60. Conversely, weft threads t15 and t16 in fraction 14a of portion 14 of fiber structure 60 adjacent to the unconnected zone 16 pass through layers of warp threads immediately beyond the end 16a of unconnected zone 16, crossing the weft threads t13 and t14 in order to enter the portion 12 of the fiber structure 10. The paths through the warp threads and the upper crossings with the weft threads take place in the transition zone 18, which presents a dimension in the weft direction that is greater than the step p between warp yarn columns, this dimension being equal to 2p, in the present example. The configuration with weft threads extending continuously close to faces 10a and 10b, and weft threads involved in the process of passing through and cross-crossing within the fiber structure 60 must be found in each plane of the fiber structure.
    [0068] Naturally, the number of weft threads located in fractions 12a and 14a adjacent to the non-interconnected zone and responsible for the crossing and overlapping process can be different from two, and should not be less than one. Similarly, the number of weft threads adjacent to faces 10a and 10b and extending continuously without upper intersections between edges s10c and 10b can be different from two, being at least equal to one.
    [0069] Figure 9 shows a fiber preform 69 of substantially T-shaped section, obtained after folding fractions 12a and 14a on either side of the unconnected zone 16 of portions 12 and 14 of fiber structure 60. The weft yarns t11, t12, t17, t18 that are not responsible for the crossing and overlapping process follow a smooth path through the curved areas.
    [0070] Figure 10 shows a plan of a fiber structure 70, suitable for obtaining a substantially π section fiber preform. For the common elements between the fiber structure 70 of Figure 11 and the fiber structures 20 and 50 of Figures 3 and 7 the same references are given and they will not be described again.
    [0071] The fiber structure 70 differs from the fiber structures 20 and 50 in particular in the presence of a weft yarn t'29 that extends continuously along the inner face 20b and along the faces of the fractions of the portion 24 on the side of the unconnected zones 26 and 26 ', thus providing continuity for the surface of the preform on the inner side.
    [0072] In addition, the upper crossings between the weft threads take place in two transition zones 28 'and 28 ", which are located in the immediate vicinity of the ends 26a and 26'a of the unconnected zones 26 and 26'. transition zone extends in the weft direction over a distance that is greater than the step p between warp yarn columns, specifically over a distance equal to 2p.
    [0073] Figure 11 is a diagram of a fiber structure woven in 3D 80, of one piece, in a fourth embodiment of the invention. For the elements that are common between the fiber structure 80 of Figure 11 and structures 10, 40, and 60 of Figures 1, 5, and 8 the same references are given and they will not be described again.
    [0074] Fiber structure 80 differs from fiber structure 60 in that, in each plane, the weft threads that weave the warp threads of the layers of warp threads closest to faces 10a and 10b, specifically the threads weft threads t11 and t12 and also weft threads t17 and t18, overlap in their paths between the opposite edges 10c and 10d without crossing any other weft threads. These upper intersections are located substantially at the end of the unconnected zone 16, that is, at connections 12'a and 14'a between fractions 12a and 14a and the rest of the fiber structure 80, when it is shaped, as shown in Figure 12.
    [0075] The effect of this overcrossing configuration in connection zones 12'a and 14'a is for wires t11, t12, t17, and t18 to have lesser amounts of curvature, that is, to follow greater radii of curvature, compared to The embodiment of Figures 8 and 9. The wires t11, t12, t17, and t18 are thus less tensioned during forming, in particular when the angle at which the fraction 12a or 14a is folded is relatively large.
    [0076] In the various modalities described, the fiber structure is formed by weaving in 3D with threads of a nature that is selected as a function of the intended application, for example, threads made of glass, carbon, or ceramic.
    [0077] After the fiber structure has been shaped, the fiber preform is densified by forming a matrix that is also of a nature that is selected as a function of the intended application, for example, an organic matrix obtained in particular of a resin that is a precursor to a polymer matrix, such as an epoxy, bismaleimide, or polyimide resin, or a carbon matrix, or a ceramic matrix. For a carbon matrix or a ceramic matrix, densification can be carried out by infiltration of chemical vapor (CVI) or by impregnation with a liquid composition containing a precursor carbon or ceramic resin and by applying heat treatment to pyrolyze or ceramize the precursor, methods that are properly well known.
    [0078] Figure 13 is a highly schematic view of a fan platform 30 for an aviation turbine engine, the platform being made of composite material of the type that can be obtained by densification of a fiber preform having a section substantially π-shaped, as shown in Figure 4 or as obtained from the fiber structures of Figures 7 and 10. The fibers are preferably carbon fibers and the matrix is preferably a polymer matrix.
    [0079] The platform 30 comprises a base 32 having an upper face 32a and a lower face 32b, and two legs 34 and 36 which in particular serves to form continuous reinforcing sections and extending from the lower face 32b of the platform 30 , which thus has a section conformed to π, as shown in dashed lines.
    [0080] The platform 30 is designed to be mounted in the intersection between two fan blades, in the vicinity of their roots, in order to define the interior of an annular air inlet passage through the fan, which is defined outside by a fan housing. Platform 30 is machined to its final dimensions after the fiber preform has been densified.
    [0081] Fiber preforms obtained from fiber structures having one or more non-interconnected zones and according to the invention can be used to manufacture other parts of composite material from aeromotors.
    [0082] Thus, Figure 14 is a highly schematic view of a weft plane of a 3D 90 woven fiber structure, which differs from the fiber structure 10 of Figure 1 in particular in that portions 14 and 16 are separated from each other along two unconnected zones 16 and 16 ', which extend from opposite edges 10c and 10d of the fiber structure 90 to the respective unconnected zone ends 16 and 16'a.
    [0083] The paths of the weft threads overlap the transition zones 18 and 18 'extending from the ends 16a and 16'a of the unconnected zones 16 and 16'. The transition zones 18 and 18 'can be similar to the transition zone 18 of the fiber structure 10 in Figure 1. In a variant, it is possible to adopt transition zones that are analogous to the transition zones of the fiber structures 40 and 60 of the Figures 5 and 8.
    [0084] A fiber preform 99 of substantially I-shaped section (or H-shaped section) is obtained (Figure 15) by folding fractions 12a and 14a of portions 12 and 14 next to the unconnected zone 16 and the fractions 12'a and 14'a of portions 12 and 14 next to the unconnected zone 16 '.
    [0085] Figure 16 is a highly schematic view of an exhaust guide vane (OGV) 100, made of composite material, of an aviation turbine engine, as can be obtained by densification of a section fiber preform which is substantially I-shaped or which is substantially H-shaped. The fibers are preferably carbon fibers and the matrix is preferably a polymer matrix.
    [0086] The exit guide vane 100 comprises an aerodynamic profile 102 attached at its ends to an external preform 104 and to an internal platform 106, the vane 100 being for mounting in a secondary flow passage of an engine bypass aviation turbine, downstream from the fan. The outlet guide vane 100 has a section that is substantially shaped in I (or H), as shown in dashed lines in Figure 16.
    [0087] In order to manufacture such an exit guide reed 100, it is possible to use a fiber preform similar to that shown in Figure 15 with cuts formed in order to reproduce the dimensions of the aerodynamic profile and of the platforms when developed flat.
    [0088] Figure 17 is a highly schematic view of a weft plane of a smoothed fiber structure in 3D 110, which differs from the fiber structure 10 of Figure 1 in that portions 12 and 14 are separated from each other by an unconnected zone 16, which extends over most of the dimension of the fiber structure 110 in the weft direction, from an edge 10c and extending to an end of unconnected zone 16a.
    [0089] The paths of the weft threads cross the transition zone 18 which extends from the end 16a of the non-interconnected zone 16. The transition zone 18 of the fiber structure 110 may be similar to the transition zone of the fiber structure 10 in Figure 1. In a variant, it is possible to adopt a transition zone similar to that of fiber structure 40 in Figure 5 or fiber structure 60 in Figure 8.
    [0090] A fiber preform 119 of substantially V shaped section is obtained (Figure 18) by widening the fractions 12a and 14a of the portions 12 and 14 that are adjacent to the unconnected zone 16.
    [0091] Figure 19 is a highly schematic view of an aeromotor hollow propeller blade 120, of the type that can be obtained by densifying a section fiber preform that is substantially V-shaped. The fibers are preferably carbon fibers and the matrix is preferably a polymer matrix.
    [0092] The propeller blade 120 has a solid portion along its front edge 122 and at its tip 124, this solid portion being extended by a hollow portion providing a substantially V shaped section profile, as shown in Figure 19.
    [0093] Propeller blade 120 can be obtained by densifying a preform derived from a fiber structure with non-interconnection similar to that of Figure 17. During the weaving of the fiber structure, the locations of the transition zones in successive planes are selected to match the propeller blade profile.
    [0094] In the various modalities described above, weft threads located on one side of an unconnected zone and weft threads located on the other side of the unconnected zone overlap the portion of the fiber structure beyond the end of the unconnected zone through a through passage layers of warp yarns, with the upper intersections being spread in the weft direction over the transition zone that extends over a distance that is greater than the pitch between the warp columns, typically over a distance of several steps, the transition zone covering all of these upper intersections possibly being itself made up of a plurality of individual transition zones. The weft threads that cross over the transition zone preferably belong to the fractions of the fiber structure that are adjacent to an unconnected zone, the weft threads located in the fraction of the fiber structure adjacent to an external surface possibly not being involved by the process of passing through the layers of warp threads and crossing other weft threads.
    [0095] Finally, it should be noted that, in the modalities described, the terms "weft" and "warp" could be changed.
    权利要求:
    Claims (6)
    [0001]
    1. Fiber structure woven as a single piece by three-dimensional weaving, the fiber structure characterized by the fact that it has first and second opposing surfaces and comprises: a first portion including a plurality of layers of warp yarns and forming a first portion of the thickness the fiber structure between the first and second opposing surfaces; a second portion including a plurality of layers of warp threads and forming a second portion of the thickness of the fiber structure, the warps being arranged in columns, each of which includes warp threads of the first portion and the second portion; and in each plane of the fiber structure, a set of weft threads interconnecting the warp layers of the first portion and the layers of warp of the second portion while leaving at least one unconnected zone separating the first and second portions on a portion of the fiber structure dimension in the weft direction from a first edge of the fiber structure to an end of the unconnected zone, wherein: at least two first weft threads interconnect layers of warp threads from the first portion of the fiber structure fiber adjacent to the unconnected zone and layers of warp threads from the second portion of the fiber structure in addition to the unconnected zone; and at least two second warp yarns interconnect layers of weft yarns from the second portion of the fiber structure adjacent to the unconnected zone and layers of warp yarns from the first portion of the fiber structure in addition to the unconnected zone; paths of the first weft yarn (s) and paths of the second weft yarn (s) intersect in a transition zone in a single pass extending through the fiber structure in the direction frame from the end of the unconnected zone; and the transition zone extends in the weft direction over a distance that is greater than one step between adjacent warp columns, at least one warp yarn in the transition zone is free to interconnect with the first weft threads and is free to interconnect with the second weft threads; the first weft threads interconnect the warp layers of the second portion immediately after crossing the transition zone in the weft direction, each weft thread of the first weft threads interconnecting with a respective single layer of the second warp threads portion between a section of the second portion adjacent to an end of the transition zone through which the first weft threads intersect and a second edge of the fiber structure in the direction of the weft, so that the first weft threads extend only in the weft direction between the first and second opposing surfaces, and the second weft threads interconnect the warp layers of the first portion immediately after crossing the transition zone in the weft direction, each weft thread of the second weft threads interconnecting them with a respective single layer of the first portion warp threads between a section of the first portion adjacent to an end of the transition zone through which the second weft threads and the second edge of the fiber structure in the weft direction intersect, so that the second weft threads extend only in the weft direction between the first and second opposing surfaces.
    [0002]
    Fiber structure according to claim 1, characterized in that a plurality of first weft threads and a plurality of second weft threads follow similar paths between the ends in the weft direction of the transition zone (18; 28 ).
    [0003]
    Fiber structure according to claim 1, characterized in that a plurality of first weft threads and a plurality of second weft threads follow similar paths that are mutually displaced in the weft direction in the transition zone (18; 28).
    [0004]
    Fiber structure according to claim 1, characterized by the fact that outer layers of warp threads adjacent to the first and second opposite surfaces of the fiber structure are woven with the same weft threads extending continuously over an entire dimension of fiber structure in the weft direction.
    [0005]
    Fiber structure according to claim 1, characterized in that, in at least one of the first and second portions of the fiber structure, the warp threads of the outer layers of warp threads adjacent to the surface of the fiber structure they are woven with the same weft threads having paths that cross at a location substantially corresponding to that of the transition zone.
    [0006]
    Fiber structure according to claim 1, characterized in that it comprises at least two unconnected zones (16, 16 '; 26, 26') separating the first and second portions over a portion of the dimension of the fiber structure (20; 50; 70; 90) in the weft direction from opposite edges of the fiber structure as well as to the respective ends of the unconnected zones.
    类似技术:
    公开号 | 公开日 | 专利标题
    BR112014014244B1|2021-01-05|fiber structure woven as a single piece by three-dimensional weaving
    BR112014026522B1|2021-05-18|fiber blank, method for manufacturing a preform for a closed box frame platform, and closed box frame platform
    BR112014016859B1|2021-02-09|process of making a fibrous preform for the manufacture of a turbomachine blade, fibrous preform of a turbomachine blade, turbomachine fan blade and turbomachine fan
    BR112014014383B1|2021-05-25|fiber structure by three-dimensional weaving, fiber preform and composite material part
    JP4058033B2|2008-03-05|Turbo engine blade, in particular fan blade, and method of manufacturing the same
    BR112015010844B1|2021-04-06|FIBER PREFORM FOR A TURBOMACHINE SHOVEL, TURBOMACHINE SHOVEL, INTERMEDIATE TURBOMACHINE HOUSING, TURBOMACHINE FAN, AND, TURBOMACHINE
    ES2671375T3|2018-06-06|Pi preform with variable width fork and related training method
    ES2603206T3|2017-02-24|Method for weaving closed structures with intersecting walls
    ES2837723T3|2021-07-01|Preform and method of reinforcing nodes with woven fiber
    BR112014020115B1|2021-05-04|woven preform for use in reinforced composite structures, method for forming woven preform and pi preform
    BR112013014578B1|2020-12-01|piece made of composite material comprising a fibrous reinforcement densified by a matrix
    BRPI0923147B1|2019-12-03|process of making a shovel by weaving 3d a preform
    JP6165774B2|2017-07-19|Composite material reinforced part with π-type cross section, specifically, platform for turbine engine fan, and manufacturing method thereof
    BR112013006453B1|2018-10-16|one-piece manufacturing process, composite solid part obtained by this process and turbocharger fan blade
    BR112012009798B1|2020-03-10|FIBER PREFORM, REINFORCED FIBER COMPOSITE AND RESPECTIVE TRAINING METHODS
    BR112012007154B1|2019-12-10|three-dimensional woven, fiber-reinforced composite preform and methods of forming three-dimensional woven and fiber-reinforced composite preform
    CN107636255A|2018-01-26|Include the blade of the platform with insert
    ES2826723T3|2021-05-19|Preform, frame part and manufacturing process of said preform
    BR112020003874A2|2020-09-24|fibrous structure, fibrous preform, gas turbine engine housing, and aircraft gas turbine engine.
    US9551094B2|2017-01-24|Fiber preform of π-shaped section, in particular for a fan platform made of composite material
    BR112017023163B1|2021-11-16|PREFORM, TURBINE ENGINE BLADE, BLADE WHEEL, E, TURBINE ENGINE
    同族专利:
    公开号 | 公开日
    CA2858320C|2019-04-16|
    JP6254533B2|2017-12-27|
    CA2858320A1|2013-06-20|
    US20170260661A1|2017-09-14|
    RU2612927C2|2017-03-13|
    BR112014014244A2|2017-06-13|
    WO2013088040A2|2013-06-20|
    EP2791473A2|2014-10-22|
    CN103998721A|2014-08-20|
    US20140349538A1|2014-11-27|
    CN103998721B|2016-01-20|
    RU2014128571A|2016-02-10|
    US10280537B2|2019-05-07|
    EP2791473B1|2019-02-06|
    US10519576B2|2019-12-31|
    WO2013088040A3|2014-01-23|
    JP2015505916A|2015-02-26|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    DE3812909A1|1987-09-26|1989-04-13|Vorwerk Co Interholding|MULTI-LAYER PRE-FORMING|
    CN1066220C|1996-10-28|2001-05-23|王光华|Three dimension stereo fabric for composite material and weaving method|
    US6446675B1|2001-07-05|2002-09-10|Albany International Techniweave, Inc.|Minimum distortion 3D woven preforms|
    US6874543B2|2001-09-12|2005-04-05|Lockheed Martin Corporation|Woven preform for structural joints|
    FR2861143B1|2003-10-20|2006-01-20|Snecma Moteurs|TURBOMACHINE BLADE, IN PARTICULAR BLADE OF BLOWER AND METHOD OF MANUFACTURING THE SAME|
    US7713893B2|2004-12-08|2010-05-11|Albany Engineered Composites, Inc.|Three-dimensional woven integrally stiffened panel|
    FR2887601B1|2005-06-24|2007-10-05|Snecma Moteurs Sa|MECHANICAL PIECE AND METHOD FOR MANUFACTURING SUCH A PART|
    US7943535B2|2005-11-17|2011-05-17|Albany Engineered Composites, Inc.|Hybrid three-dimensional woven/laminated struts for composite structural applications|
    FR2902802B1|2006-06-21|2008-12-12|Snecma Propulsion Solide Sa|FIBROUS REINFORCING STRUCTURE FOR A PIECE OF COMPOSITE MATERIAL AND PART COMPRISING THE SAME|
    US20100119777A1|2006-11-16|2010-05-13|Siemens Power Generation, Inc.|Ceramic matrix composite surfaces with open features for improved bonding to coatings|
    US8058191B2|2008-09-04|2011-11-15|Siemens Energy, Inc.|Multilayered ceramic matrix composite structure having increased structural strength|
    US8079387B2|2008-10-29|2011-12-20|Albany Engineered Composites, Inc.|Pi-shaped preform|
    FR2939130B1|2008-11-28|2011-09-16|Snecma Propulsion Solide|PROCESS FOR MANUFACTURING COMPOUND FORM SHAPE PIECE OF COMPOSITE MATERIAL|
    FR2939153B1|2008-11-28|2011-12-09|Snecma Propulsion Solide|REALIZING A FIBROUS STRUCTURE WITH AN EVOLVING THICKNESS THROUGH 3D WEAVING|
    ES2398727T3|2009-03-09|2013-03-21|Snecma|Turbine ring set|
    CN201801711U|2010-09-26|2011-04-20|吴伯明|Integral multi-layer top fabric with yarn preserved on peripheral edge|US9771810B2|2012-01-09|2017-09-26|Snecma|Fiber preform for a turbine engine blade made of composite material and having an integrated platform, and a method of making it|
    FR2989977B1|2012-04-26|2014-05-23|Snecma|FIBROUS BENDING IN ONE PIECE BY THREE-DIMENSIONAL WEAVING FOR THE PRODUCTION OF A CLOSED BOARD PLATFORM FOR A TURBOMACHINE BLOWER OF COMPOSITE MATERIAL|
    FR3003668B1|2013-03-25|2020-10-30|Snecma|PROCESS FOR DESIGNING A COMMON PREFORM FOR THE REALIZATION OF PREFORMS OF TURBOMACHINE OUTLET GUIDELINES IN COMPOSITE MATERIAL WITH DIFFERENT GEOMETRIC PROFILES|
    FR3025529B1|2014-09-10|2017-07-14|Aircelle Sa|PREFORM FOR CURVED COMPOSITE STIFFENER FOR AXISYMETRIC PIECE SUCH AS A VIROLE|
    JP5874802B1|2014-11-25|2016-03-02|株式会社豊田自動織機|Fiber structure and fiber reinforced composite|
    FR3032726B1|2015-02-16|2017-06-02|Herakles|FIBROUS STRUCTURE FOR REINFORCING PIECES OF COMPOSITE MATERIAL WITH HIGH THICKNESS VARIATION|
    FR3037097B1|2015-06-03|2017-06-23|Snecma|COMPOSITE AUBE COMPRISING A PLATFORM WITH A STIFFENER|
    JP6524880B2|2015-10-15|2019-06-05|株式会社豊田自動織機|Multilayer fabric|
    CN105442154B|2015-12-15|2017-05-10|机械科学研究总院先进制造技术研究中心|Knitting method of three-dimension precast body of gradient structure|
    US9725832B1|2016-02-09|2017-08-08|Albany Engineered Composites, Inc.|Weaving multilayer products using multiple warp columns and heddle columns|
    US10207471B2|2016-05-04|2019-02-19|General Electric Company|Perforated ceramic matrix composite ply, ceramic matrix composite article, and method for forming ceramic matrix composite article|
    US10436036B2|2016-07-05|2019-10-08|Safran Aircraft Engines|Fitted platform for a turbine engine fan, and a method of fabricating it|
    US10443409B2|2016-10-28|2019-10-15|Rolls-Royce North American Technologies Inc.|Turbine blade with ceramic matrix composite material construction|
    US10577939B2|2016-11-01|2020-03-03|Rolls-Royce Corporation|Turbine blade with three-dimensional CMC construction elements|
    US10352273B2|2016-11-08|2019-07-16|Rohr, Inc.|Track beam with composite lug|
    US10392946B2|2016-12-21|2019-08-27|Rolls-Royce North American Technologies Inc.|Turbine blade with reinforced platform for composite material construction|
    US10557350B2|2017-03-30|2020-02-11|General Electric Company|I beam blade platform|
    FR3070402B1|2017-08-30|2020-08-28|Safran Aircraft Engines|WOVEN FIBROUS TEXTURE FOR THE FORMATION OF A CRANKCASE PREFORM|
    FR3079445B1|2018-03-28|2020-04-24|Safran|PROCESS FOR MANUFACTURING A BLADE OF COMPOSITE MATERIAL ON BOARD OF AN ADDED METAL ATTACK FOR GAS TURBINE|
    US11035239B2|2018-10-25|2021-06-15|General Electric Company|Ceramic matrix composite turbine nozzle shell and method of assembly|
    FR3090449B1|2018-12-21|2022-01-14|Safran|preformed with fiber reinforcement woven in one piece for inter-blade platform|
    FR3091724B1|2019-01-15|2021-01-22|Safran Aircraft Engines|Blade or blade of composite propeller for aircraft incorporating a conformation foam|
    FR3097314B1|2019-06-14|2021-12-10|Safran Aircraft Engines|Determination of a thickness by colorimetry.|
    FR3097904B1|2019-06-26|2021-06-11|Safran Aircraft Engines|Inter-vane platform with sacrificial box|
    法律状态:
    2018-12-04| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2020-01-28| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-10-27| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-01-05| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 10/12/2012, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US201161570432P| true| 2011-12-14|2011-12-14|
    US61/570,432|2011-12-14|
    PCT/FR2012/052853|WO2013088040A2|2011-12-14|2012-12-10|Fiber structure woven into a single part by means of 3d weaving, and use in the manufacture of a composite material part|
    [返回顶部]