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

• US 7,611,997 B2
• Filed: 11/07/2005
• Issued: 11/03/2009
• 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
• Primary Examiner(s): Salvatore; Lynda
• Application Number:
  US11/268,126
• Publication Number:
  US 20060057920A1
• Time in Patent Office: 1,457 Days
• Field of Search: 442/181, 442/205, 442/208, 442/221, 428/105
• 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 with the elongate foam elements being removed or eliminated after fabric formation to leave open channels 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 4, wherein the open channels are filled with a resin to form a composite structure.

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

8. 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 with the elongate foam elements being removed or eliminated after fabric formation to leave open channels within the fabric; and

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

9. The composite material of claim 8, wherein the substantially elongate foam elements are inserted in the weft or y-direction.

10. The composite material of claim 8, wherein the substantially elongate foam elements are introduced to replace yarns in the weft or y-direction.

11. The composite material of claim 10, wherein the fabric has a substantially rectangular cross-sectional shape.

12. The fabric of claim 8, wherein the substantially elongate foam elements are at least partially flexible.

13. The fabric of claim 8, wherein the open channels are filled with resin during formation of the composite structure.