Integral 3-D foam core fabrics, composites made therefrom and methods of making

• US 20060057920A1
• Filed: 11/07/2005
• Published: 03/16/2006
• Est. Priority Date: 11/19/2003
• Status: Active Grant

• Current Assignee: Donald E. Wigent III
• Original Assignee: Donald E. Wigent III
• Inventors: Wigent, Donald E. III
• Granted Patent: US 7,611,997 B2
• Time in Patent Office: Days
• US Class Current: 442/221
• CPC Class Codes: B29C 70/24 oriented in at least three directions forming a three dimensional structure
• CPC Class Codes: B29C 70/88 characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
• CPC Class Codes: C08L 2201/12 Shape memory
• CPC Class Codes: D03D 1/0088 Fabrics having an electronic function
• CPC Class Codes: D03D 25/005 Three-dimensional woven fabrics
• CPC Class Codes: D10B 2101/12 Carbon; Pitch
• CPC Class Codes: D10B 2401/046 Shape recovering or form memory
• CPC Class Codes: D10B 2401/20 optical
• CPC Class Codes: Y10T 428/24058 including grain, strips, or filamentary elements in respective layers or components in angular relation
• CPC Class Codes: Y10T 442/3195 Three-dimensional weave [e.g., x-y-z planes, multi-planar warps and/or wefts, etc.]
• CPC Class Codes: Y10T 442/322 Warp differs from weft
• CPC Class Codes: Y10T 442/3325 Including a foamed layer or component
• CPC Class Codes: Y10T 442/3366 Woven fabric is coated, impregnated, or autogenously bonded

Abstract

A 3-D woven fabric having substantially elongated foam elements integrally formed therein during fabric formation for providing open corridors within the fabric. The fabric is preferably used for structural, stiffener, or component applications.

Claims

1. A three-dimensional (3-D) woven fabric comprising:

a 3-D woven fabric formed from three independent, orthogonal yarn systems and corresponding components thereof, including a warp, x-direction components;

a weft, y-direction components; and

a vertical, thickness, z-direction components; and

selvage edges formed by the weft yarns and selvage yarns;

wherein at least one of the yarn components includes substantially elongate foam elements for providing lightweight foam core components within the fabric.

2. The fabric of claim 1, wherein the substantially elongate foam elements are inserted in the weft or y-direction.

3. The fabric of claim 1, wherein the substantially elongate foam elements are introduced to replace yarns in the weft or y-direction.

4. The fabric of claim 1, wherein the body of the fabric forms a substantially rectangular cross-sectional shape.

5. The fabric of claim 1, wherein the substantially elongate foam elements are at least partially flexible.

6. The fabric of claim 1, wherein the substantially elongate foam elements are removed or eliminated after fabric formation to leave open channels within the fabric.

7. The fabric of claim 4, wherein the open channels are filled with a resin to form a composite structure.

8. The fabric of claim 1, wherein the fabric is treated with a resin to form a composite structure.

9. A composite material comprising:

a 3-D woven fabric formed from three independent, orthogonal yarn systems and corresponding components thereof, including a warp, x-direction components;

a weft, y-direction components; and

a vertical, thickness, z-direction components; and

selvage edges formed by the weft yarns and selvage yarns;

wherein at least one of the yarn components includes substantially elongate foam elements for providing lightweight foam core components within the fabric;

and wherein the fabric is infused with a resin and cured to form a rigid composite structure.

10. The composite material of claim 9, wherein the substantially elongate foam elements are inserted in the weft or y-direction.

11. The composite material of claim 9, wherein the substantially elongate foam elements are introduced to replace yarns in the weft or y-direction.

12. The composite material of claim 11, wherein the fabric has a substantially rectangular cross-sectional shape.

13. The fabric of claim 9, wherein the substantially elongate foam elements are at least partially flexible.

14. The fabric of claim 9, wherein the substantially elongate foam elements are removed or eliminated after fabric formation to leave open channels within the fabric.

15. The fabric of claim 14, wherein the open channels are filled with resin during formation of the composite structure.

16. A method for weaving a three-dimensional fabric having a predetermined substantially rectangular cross-sectional shape according to the present invention comprising the steps of:

a. providing a plurality of layers of warp yarns which are in horizontal and vertical alignment and maintained under tension, the layers of warp yarns defining a variable predetermined cross-sectional shape;

b. selectively inserting a plurality of weft yarns which are secured in place by selvage yarn components at the respective fore ends thereof into spaces between the layers of warp yarn, the weft yarns being alternately or simultaneously inserted a predetermined distance from opposing sides of the warp yarn cross-sectional shape in accordance with the rectangular shape of the fabric being formed, the weft yarns from each side of the warp yarn cross-sectional rectangular shape being inserted at substantially uniform horizontal distances;

c. bringing a reed into contact with the fell of the fabric being formed;

d. inserting vertical yarns into spaces between vertical rows of the warp yarns in a direction substantially perpendicular to both the warp and weft yarns, the vertical yarns being selectively threaded through a plurality of harnesses so as to be separated into a predetermined plurality of vertically movable yarn systems by the harnesses in accordance with the shape of the fabric being formed, and the yarn systems being selectively vertically moved by the harnesses to insert the vertical yarns into the fabric; and

f. repeating the steps (a)-(d) after insertion of the vertical yarns;

wherein at least one of the yarn components includes substantially elongated foam elements to provide lightweight, open channels within the fabric.

17. The method of claim 16, wherein the foam elements are provided in the weft direction.

18. The method of claim 16, wherein the weft yarns are simultaneously inserted from both sides of the warp yarn cross-sectional shape.

19. The method of claim 16, wherein the weft yarns from one side of the warp yarn cross-sectional shape are inserted at substantially similar horizontal distances as the weft yarns from the other side of the warp yarn cross-sectional shape.

20. The method of claim 16, wherein the weft yarns from each side of the warp yarn cross-sectional shape are inserted at uniform horizontal distances.