Fiber structure woven as a single piece by 3D weaving and application to the manufacturing of composite material part

{
  "publication_number": "US10280537B2",
  "country": "US",
  "kind": "B2",
  "title": "Fiber structure woven as a single piece by 3D weaving and application to the manufacturing of composite material part",
  "abstract": "In a fiber structure woven as a single piece by three-dimensional weaving, first weft yarns interlink layers of warp yarns in a first portion of the fiber structure adjacent to a non-interlinked zone and also warp yarns of a second portion of the fiber structure beyond the non-interlinked zone, and second weft yarns interlink layers of warp yarns of the second portion of the fiber structure adjacent to the non-interlinked zone and also layers of warp yarns of the first portion of the fiber structure beyond the non-interlinked zone, such that the paths of the first and second weft yarns cross in at least one transition zone extending within the fiber structure from the end of the non-interlinked zone, the transition zone extending in the weft direction over a distance greater than the pitch between adjacent warp columns.",
  "claims": [
    "1. A fiber structure woven as a single piece by three-dimensional weaving, the fiber structure having first and second opposite surfaces and comprising: a first portion including a plurality of layers of warp yarns and forming a first portion of a thickness of the fiber structure between the first and second opposite surfaces; a second portion including a plurality of layers of warp yarns and forming a second portion of the thickness of the fiber structure, the warp yarns being arranged in columns each of which includes warp yarns of the first portion and of the second portion; and in each plane of the fiber structure, a set of weft yarns interlinking the layers of warp yarns of the first portion and the layers of warp yarns of the second portion while leaving at least one non-interlinked zone separating the first and second portions over a portion of a dimension of the fiber structure in the weft direction from a first edge of the fiber structure to an end of non-interlinked zone, wherein: at least two first weft yarns interlink layers of warp yarns of the first portion of the fiber structure adjacent to the non-interlinked zone and layers of warp yarns of the second portion of the fiber structure beyond the non-interlinked zone; at least two second weft yarns interlink layers of warp yarns of the second portion of the fiber structure adjacent to the non-interlinked zone and layers of warp yarns of the first portion of the fiber structure beyond the non-interlinked zone; paths of the first weft yarns and paths of the second weft yarns cross over in a transition zone in a single pass extending in the fiber structure in the weft direction from the end of the non-interlinked zone; the transition zone extends in the weft direction over a distance that is greater than a pitch between adjacent warp columns; at least one warp yarn in the transition zone is free of interlinking with the first weft yarns and is free of interlinking with the second weft yarns; the first weft yarns interlink the layers of warp yarns of the second portion immediately after crossing through the transition zone in the weft direction, each weft yarn of the first weft yarns interlinking with a respective single layer of the warp yarns of the second portion between a section of the second portion adjacent to an end of the transition zone through which the first weft yarns cross and a second edge of the fiber structure in the weft direction such that the first weft yarns only extend in the weft direction between the first and second opposite surfaces, and the second weft yarns interlink the layers of warp yarns of the first portion immediately after crossing through the transition zone in the weft direction, each weft yarn of the second weft yarns interlinking with a respective single layer of the warp yarns of the first portion between a section of the first portion adjacent to an end of the transition zone through which the second weft yarns cross and the second edge of the fiber structure in the weft direction such that the second weft yarns only extend in the weft direction between the first and second opposite surfaces.",
    "2. The fiber structure according to claim 1, wherein a plurality of first weft yarns and a plurality of second weft yarns follow similar paths between ends in the weft direction of the transition zone.",
    "3. The fiber structure according to claim 1, wherein a plurality of first weft yarns and a plurality of second weft yarns follow similar paths that are mutually offset in the weft direction in the transition zone.",
    "4. The fiber structure according to claim 1, wherein outer layers of warp yarns adjacent to the first and second opposite surfaces of the fiber structure are woven with same weft yarns extending continuously over an entire dimension of the fiber structure in the weft direction.",
    "5. The fiber structure according to claim 1, wherein, in at least one of the first and second portions of the fiber structure, the warp yarns of outer layers of warp yarns adjacent to a surface of the fiber structure are woven with same weft yarns having paths that cross over at a location corresponding substantially to that of the transition zone.",
    "6. The fiber structure according to claim 1, comprising at least two non-interlinked zones separating the first and second portions over a portion of the dimension of the fiber structure in the weft direction from opposite edges of the fiber structure as far as respective ends of non-interlinked zones.",
    "7. A method of fabricating a composite material part comprising making a fiber preform by shaping a fiber structure according to claim 1, the shaping including at least folding out a fraction of the first or the second portion of the fiber structure adjacent to a non-interlinked zone, and densifying the preform with a matrix.",
    "8. A method of fabricating a composite material part having a substantially π-shaped section, the method comprising making a fiber preform by shaping a fiber structure according to claim 6, the shaping including folding out fractions of the first or the second portion of the fiber structure adjacent to the two non-interlinked zones, and densifying the preform with a matrix.",
    "9. A turbine engine fan blade platform made of composite material, the turbine engine fan blade platform being obtained by the method of claim 8.",
    "10. A method of fabricating a composite material part of substantially I-shaped section, the method comprising making a fiber preform by shaping a fiber structure according to claim 6, the shaping including folding out fractions of the first and second portions of the fiber structure adjacent to the two non-interlinked zones, and densifying the preform with a matrix.",
    "11. A turbine engine outlet guide vane made of composite material, the turbine engine outlet guide vane being obtained by the method of claim 10.",
    "12. A hollow propeller blade for an aeroengine and made of composite material, the hollow propeller blade being obtained by the method of claim 7.",
    "13. The fiber structure according to claim 1, wherein the thickness of the fiber structure is constant.",
    "14. The fiber structure according to claim 1, wherein the first and second opposite surfaces of the fiber structure each has a satin weave beyond the transition zone in the weft direction."
  ],
  "description_excerpt": "The invention relates to making a fiber structure woven as a single piece by three-dimensional (3D) weaving, in particular for fabricating a composite material part. One particular, but non-exclusive, field of application of the invention lies in making fiber structures for preforms of composite material parts for aircraft or aeroengines, in particular for airplane turbine engines.\n\nIn well-known manner, a composite material part may be obtained by making a fiber preform and by densifying the preform with a matrix. Depending on the intended application, the preform may be made of glass, carbon, or ceramic fibers, and the matrix may be made of an organic material (a polymer), of carbon, or of ceramic.\n\nFor parts that are relatively complex in shape, it is known to make a fiber structure or blank as a single piece by 3D or multiple-layer weaving, and to shape the blank in order to obtain a fiber preform that presents a shape that is close to the shape of the part that is to be fabricated.\n\nIn order to facilitate such shaping, and in order to avoid making incisions that result in yarns being cut and that lead to a reduction in mechanical strength, it is known to leave one or more non-interlinked zones within the fiber structure while it is being woven. Such non-interlinked zones may be obtained by locally omitting any interlinking of the layers of adjacent yarns, thereby making it possible to fold out portions of the fiber structure adjacent to the non-interlinked zones.",
  "cpc": [
    "D03D 25/005",
    "B29B 11/16",
    "B29C 70/24",
    "D03D 1/00",
    "D03D 13/00",
    "D10B 2505/00",
    "F01D 5/147",
    "F05D 2220/36",
    "F05D 2300/6012",
    "F05D 2300/6034",
    "Y10T 156/1051",
    "Y10T 442/3203"
  ],
  "ipc": [
    "D03D 1/00",
    "D03D 13/00",
    "D03D 25/00",
    "F01D 5/14",
    "B29B 11/16",
    "B29C 70/24"
  ],
  "assignees": [
    "Sanfran Aircraft Engines"
  ],
  "inventors": [
    "Yann Marchal",
    "Dominique Coupe",
    "Monica Fruscello",
    "Jonathan Goering"
  ],
  "filing_date": "2012-12-10",
  "publication_date": "2019-05-07",
  "grant_date": "2019-05-07",
  "priority_date": "2011-12-14",
  "application_number": "US-201214365369-A",
  "family_id": "47666413",
  "cited_by_count": 7,
  "citations": [
    "US4922968A",
    "US20030056847A1",
    "US7101154B2",
    "US20100144227A1",
    "US20100105269A1",
    "US20110277869A1"
  ]
}