KR20240135276A - Manufacturing seamless integral 3D textile preform using 3D weaving technology and using it as a thermal protection system - Google Patents

Abstract

One embodiment of the present invention provides a seamless, integral three-dimensional fabric preform using a three-dimensional weaving technology, a method for manufacturing the same, and a heat protection system utilizing the same. The three-dimensional fabric preform can be manufactured by dividing warp yarns into fixed warp yarns and weaving warp yarns, inserting weft yarns, and weaving. The weaving is performed by weaving a combination of fixed warp yarns and weft yarns made in the thickness direction into a weaving warp yarn, and the thickness is controlled through the number of layers in the thickness direction, and the layers are connected with the weaving warp yarns, and the pattern of the weaving warp yarns connecting the layers is not fixed. Through this, continuous and rapid weaving is possible for various structures. In addition, a seamless, integral three-dimensional fabric heat protection system can be manufactured using the three-dimensional weaving technology.

Description

{Manufacturing seamless integral 3D textile preform using 3D weaving technology and using it as a thermal protection system}

The present invention relates to a three-dimensional fabric preform, and more particularly, to a method for manufacturing a seamless, integral three-dimensional fabric preform using a three-dimensional weaving technique and its use as a heat protection system.

Recently, as technology advances and industries become more advanced, many energy resources are being depleted. Accordingly, the need for energy conservation and environmental protection is continuously increasing. This trend is also showing itself in the mobility industry, and is drawing much attention to the development of lightweight materials. Among them, carbon fiber reinforced composite materials have high strength and stiffness relative to their weight, and are attracting attention as a substitute for materials such as metals.

Composite materials used in aircraft and automobile parts have excellent in-plane properties, but do not have fiber reinforcement in the thickness direction. For this reason, there is a problem that the thickness direction properties are reduced. Various 3D technologies are being developed to solve this problem. Among them, 3D weaving technology is being considered important because it is easy to expand from the diversity and usability of 2D weaving technology to 3D technology.

Carbon fiber reinforced composites must have a specific structural shape depending on their intended use. In existing technologies, two-dimensional carbon fiber reinforced materials in the form of fabrics are laminated and then placed in a mold of a specific structural shape to create a composite material, or these reinforced materials are artificially made to have the shape of a structure and then joints are added to give them the shape. The limitation of these technologies is that when using a mold, problems such as wrinkling occur as the shape becomes more complex, and when using joints, even if the complexity problem is solved, there are the fragility of the joints, a considerably long manufacturing time, and difficulties in resin injection.

Throughout the academic world, great efforts have been made to use continuous carbon fiber composites as component materials. Research has been conducted mainly in the composite manufacturing stage or the post-processing/processing stage. Although there have been reports on seamless 3D carrier-type composite material manufacturing technology, they have been limited to the production of fragmentary specimens, and due to the complexity of the manufacturing technology, there has been no report on mass production technology. In addition, although research has been conducted to utilize composites as components, the complexity of the manufacturing process remains an unresolved problem.

KR 10-2020-0100229 A

The technical problem to be achieved by the present invention is to secure a technology for manufacturing a composite material in a seamless three-dimensional carrier shape, thereby resolving the vulnerability of the joint portion, long manufacturing time, and difficulty in resin injection, and to provide a technology for rapidly and continuously manufacturing a composite material that can be used for large aircraft or ships beyond the category of small parts for mobility through three-dimensional weaving technology.

The technical problems to be achieved by the present invention are not limited to the technical problems mentioned above, and other technical problems not mentioned can be clearly understood by a person having ordinary skill in the technical field to which the present invention belongs from the description below.

In order to achieve the above technical task, one embodiment of the present invention provides an integrated three-dimensional fabric preform including a fixed warp yarn, a weft yarn arranged to intersect the fixed warp yarn, and a weaving warp yarn that interweaves the fixed warp yarn and the weft yarn to be woven, wherein the fixed warp yarn and the weft yarn form layers in the thickness direction, but the pattern of the weaving warp yarn connecting the layer layers is not fixed.

In an embodiment of the present invention, the woven fabric may be characterized by seamlessly connecting the layers.

In an embodiment of the present invention, the weaving angle may be a multiple of 2.

In order to achieve the above technical task, another embodiment of the present invention provides a method for manufacturing an integral three-dimensional fabric preform, comprising the steps of preparing a fixed warp, inserting a weft yarn between the fixed warp yarns so as to intersect each other, and weaving the fixed warp yarn and the weft yarn using a weaving warp yarn, wherein the weaving step is characterized in that the weft yarn is selected and woven.

In an embodiment of the present invention, the weaving step may further include a step of removing the weft yarns that are not woven and thus lack the weaving warp yarns and the fixed warp yarns that are not adjacent to the weaving warp yarns through a post-processing process.

In order to achieve the above technical task, another embodiment of the present invention provides an integrated three-dimensional fabric thermal protection system including an upper plate, a lower plate positioned parallel to the upper plate, first weft yarns positioned on the upper plate and the lower plate, second weft yarns continuously connecting the upper plate and the lower plate, first weft yarns wrapping the first weft yarns, and second weft yarns wrapping a portion of the first weft yarns and the second weft yarns.

According to an embodiment of the present invention, a seamless, integral three-dimensional fabric preform can be manufactured using one loom and one process. The three-dimensional fabric preform can be manufactured by dividing warp yarns into fixed warp yarns and weaving warp yarns, inserting weft yarns, and weaving. The weaving is performed by weaving a combination of fixed warp yarns and weft yarns made in the thickness direction into a weaving warp yarn, and the thickness is controlled through the number of layers in the thickness direction, and the layers are connected with the weaving warp yarns, and the pattern of the weaving warp yarns connecting the layers is not fixed. Through this, continuous and rapid weaving is possible for various structures. In addition, a seamless, integral three-dimensional fabric thermal protection system can be manufactured using a three-dimensional weaving technology.

The effects of the present invention are not limited to the effects described above, and should be understood to include all effects that can be inferred from the detailed description of the present invention or the composition of the invention described in the claims.

Figure 1 is an image showing (a) the overall structure, (b) a cross-sectional view, and (c) a three-dimensional structure of an integral three-dimensional fabric preform.
Figure 2 is an image showing (a) the case where the warp yarns cover all the weft yarns, (b) the case where some of the weft yarns are selected and a deficiency of the warp yarns occurs, and (c) the case where the weft yarns and fixed warp yarns are removed through individual post-processing processes.
Figure 3 is an image that confirms the continuity of the integral three-dimensional fabric preform in (a) the plane direction and (b) the thickness direction.
Figure 4 is an image showing (a) a plan view and (b) a three-dimensional structure of an integrated three-dimensional fabric thermal protection system, respectively.

Hereinafter, the present invention will be described with reference to the attached drawings. However, the present invention can be implemented in various different forms, and therefore, it is not limited to the embodiments described herein. In addition, in order to clearly describe the present invention in the drawings, parts that are not related to the description are omitted, and similar parts are assigned similar drawing reference numerals throughout the specification.

Throughout the specification, when a part is said to be "connected (connected, contacted, joined)" to another part, this includes not only cases where it is "directly connected" but also cases where it is "indirectly connected" with another member in between. Also, when a part is said to "include" a certain component, this does not mean that other components are excluded, unless otherwise specifically stated, but that other components can be included.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present invention. The singular expression includes the plural expression unless the context clearly indicates otherwise. As used herein, the terms "comprises" or "has" and the like are intended to specify the presence of a feature, number, step, operation, component, part or combination thereof described in the specification, but should be understood to not exclude in advance the possibility of the presence or addition of one or more other features, numbers, steps, operations, components, parts or combinations thereof.

Hereinafter, an embodiment of the present invention will be described in detail with reference to the attached drawings.

Figure 1 is an image showing (a) the overall structure, (b) a cross-sectional view, and (c) a three-dimensional structure of an integral three-dimensional fabric preform.

An integral three-dimensional fabric preform according to an embodiment of the present invention is described with reference to FIG. 1.

An integral three-dimensional fabric preform according to one embodiment of the present invention comprises a fixed warp yarn (100), a weft yarn (200) arranged to intersect the fixed warp yarn (100), and a weaving warp yarn (300) that interweaves the fixed warp yarn (100) and the weft yarn (200) to form a weave, and the fixed warp yarn (100) and the weft yarn (200) may be characterized in that the pattern of the weaving warp yarn (300) connecting the layer layers is not fixed.

A seamless, integral three-dimensional fabric preform can be made with one loom and one process. The three-dimensional fabric preform can be made by dividing warp yarns into fixed warp yarns (100) and weaving warp yarns (300), inserting weft yarns (200), and weaving. The weaving can be performed by weaving a combination of fixed warp yarns (100) and weft yarns (200) made in the thickness direction into a weaving warp yarn (300). The thickness can be controlled by changing the number of layers in the thickness direction, and the layers can be connected with the weaving warp yarns (300).

The above-mentioned weaving warp (300) can seamlessly connect the above-mentioned layers. By controlling the above-mentioned weaving warp (300), a seamless box-shaped woven fabric can be produced without a post-process such as joining or cutting. A woven fabric composed of up to eight layers can be produced.

The above-mentioned warp yarns (300) may be a multiple of 2. A set including two of the above-mentioned warp yarns (300) may be configured to wrap the above-mentioned weft yarns (200).

Hereinafter, a method for manufacturing an integral three-dimensional fabric preform according to another embodiment of the present invention will be described. The structure of the three-dimensional fabric preform can be continuously referenced with reference to FIG. 1.

A method for manufacturing an integral three-dimensional fabric preform according to one embodiment of the present invention includes a step of preparing a fixed warp yarn (100), a step of inserting a weft yarn (200) so as to intersect each other between the fixed warp yarns (100), and a step of interweaving the fixed warp yarn (100) and the weft yarn (200) using a weaving warp yarn (300), and the weaving step may be characterized by selecting and weaving the weft yarn (200).

The first step is to prepare a fixed slope (100). The slope can be divided into a fixed slope (100) and a woven slope (300) to prepare the fixed slope (100).

The next step is to insert the weft (200) by intersecting it between the fixed warp yarns (100). After dividing the warp yarns into the fixed warp yarns (100) and the woven warp yarns (300), the weft yarns (200) can be inserted.

The final step is a step of weaving by interweaving the fixed warp yarn (100) and the weft yarn (200) using the weaving warp yarn (300). This can be performed by interweaving the combination of the fixed warp yarn (100) and the weft yarn (200) made in the thickness direction with the weaving warp yarn (300). The thickness is controlled by the number of layers in the thickness direction, and the layers can be connected with the weaving warp yarn (300).

The pattern of the woven warp yarn (300) connecting the above-mentioned layer layers may not be fixed. Accordingly, various woven fabric shapes can be created depending on the pattern combination of the fixed warp yarn (100), weft yarn (200), and woven warp yarn (300), and since each type of fiber can be woven differently, various derivative technologies can be formed depending on the business field.

Figure 2 is an image showing (a) the case where the woven warp yarns cover all the weft yarns, (b) the case where some weft yarns are selected to cause a deficiency of the woven warp yarns, and (c) the case where the weft and fixed warp yarns are removed through individual post-processing processes. Figure 3 is an image showing the continuity of the integral three-dimensional fabric preform in (a) the plane direction and (b) the thickness direction, respectively.

Referring to FIG. 2, a technology for manufacturing a seamless three-dimensional carrier-type composite material according to an embodiment of the present invention is described.

The step of weaving the fixed warp yarn (100) and the weft yarn (200) by interweaving them using the above-mentioned weaving warp yarn (300) may further include a step of removing the weft yarn (200) that is deficient in the weaving warp yarn (300) due to the weaving warp yarn (300) not being interwoven and the fixed warp yarn (100) that is not adjacent to the weaving warp yarn (300) through a post-processing process.

The lack of the weaving warp (300) can be woven by controlling the process mechanism during weaving so that the weft (200) is selectively twisted by the weft (300), and there can be weft (200) that is not twisted by the weft (300). Through a post-processing process, the weft (200) portion that is not twisted by the weft (300) and the fixed warp (100) that is not adjacent to the weft (300) can be manually removed, and this can be done by cutting.

Figure 4 is an image showing (a) a plan view and (b) a three-dimensional structure of an integrated three-dimensional fabric thermal protection system, respectively.

Referring to FIG. 4, an integrated three-dimensional fabric thermal protection system according to another embodiment of the present invention is described.

An integrated three-dimensional fabric thermal protection system according to one embodiment of the present invention may include an upper plate (400), a lower plate (500) positioned parallel to the upper plate (400), a first weft yarn (600) positioned on the upper plate (400) and the lower plate (500), a second weft yarn (700) continuously connecting the upper plate (400) and the lower plate (500), a first weft yarn (800) wrapping around the first weft yarn (600), and a second weft yarn (900) wrapping around a portion of the first weft yarn (600) and the second weft yarn (700).

In order to manufacture a seamless, integral three-dimensional fabric thermal protection system, the fixed warp yarns can be excluded from the process, and the weft yarns can also be optionally left in the same shape as the existing thermal protection system. Through the selective weaving method of the weaving warp yarns, some of the weaving warp yarns, such as the first weaving warp yarn (800), are woven by wrapping around the first weft yarn (600) of the upper plate (400) and the lower plate (500), and the remaining weaving warp yarns, such as the second weaving warp yarn (900), are woven by wrapping around some of the first weft yarns (600) of the upper plate (400) and the lower plate (500) and the second weft yarns (700) that continuously connect the upper plate (400) and the lower plate (500), thereby manufacturing the corrugated structure of the thermal protection system.

Hereinafter, embodiments of the present invention will be described in detail.

In order to manufacture an integral three-dimensional fabric preform, fixed warp yarns were prepared, weft yarns were inserted between the fixed warp yarns by crossing each other, and then the fixed warp yarns and the weft yarns were woven using a weaving warp yarn. At this time, the weft yarns were selected and woven.

The thickness is controlled by the number of layers in the thickness direction, and the layers are connected with woven warp yarns. The pattern of the woven warp yarns connecting the layers is not fixed, and various woven fabric shapes can be created depending on the combination of the patterns of the fixed warp yarns, weft yarns, and woven warp yarns.

At this time, the weft was selected and woven.

Referring to FIGS. 2 and 3, by controlling the process mechanism during weaving, weft yarns are selectively woven so that there are weft yarns that are not twisted in the weaving warp yarns, and when such a deficiency of weaving warp yarns occurs, the weft yarn portions that are not twisted in the weaving warp yarns and the fixed warp yarns that are not adjacent to the weaving warp yarns can be manually removed through individual post-processing processes, and this can be achieved through cutting. Accordingly, a seamless, integral three-dimensional fabric preform with continuity can be manufactured.

By utilizing such an integral three-dimensional fabric preform, a seamless integral three-dimensional fabric thermal protection system can be manufactured. By excluding the fixed warp yarn from the process and through a selective weaving method of the weaving warp yarn, some of the weaving warp yarns, such as the first weaving warp yarn, are woven by wrapping around the first weft yarns, which are the weft yarns of the upper and lower plates, and the remaining weaving warp yarns, such as the second weaving warp yarns, are woven by wrapping around some of the first weft yarns and the second weft yarns, which are the weft yarns that continuously connect the upper and lower plates, so that a corrugated structure of the thermal protection system can be manufactured.

The shape, spacing, and angle of these corrugated structures can be controlled through the weaving process.

The above description of the present invention is for illustrative purposes, and those skilled in the art will understand that the present invention can be easily modified into other specific forms without changing the technical idea or essential characteristics of the present invention. Therefore, it should be understood that the embodiments described above are exemplary in all respects and not restrictive. For example, each component described as a single component may be implemented in a distributed manner, and likewise, components described as distributed may be implemented in a combined form.

The scope of the present invention is indicated by the claims described below, and all changes or modifications derived from the meaning and scope of the claims and their equivalent concepts should be interpreted as being included in the scope of the present invention.

100: Fixed slope
200: Victim
300: Weaving warp
400: Top plate
500: Lower plate
600: 1st place
700: 2nd Lieutenant
800: First straight line
900: Second straight line

Claims (6)

fixed slope;
The above fixed slope and the weft arranged to intersect each other; and
Including a weaving warp that is woven by interweaving the above fixed warp and the above weft,
The above fixed slope and the above weft form layers in the thickness direction,
An integral three-dimensional fabric preform, characterized in that the pattern of the woven warp connecting the above-mentioned layers is not fixed.
In the first paragraph,
An integral three-dimensional fabric preform characterized in that the above-mentioned woven slope seamlessly connects the above-mentioned layers.
In the first paragraph,
An integral three-dimensional fabric preform characterized in that the above-mentioned weaving angle is a multiple of 2.
Steps to prepare a fixed slope;
A step of inserting a weft yarn by intersecting each other between the fixed slopes; and
It includes a step of weaving by interweaving the fixed warp and the weft using a weaving warp,
A method for manufacturing an integral three-dimensional fabric preform, characterized in that the weaving step comprises selecting the weft yarn and weaving it.
In paragraph 4,
A method for manufacturing an integral three-dimensional fabric preform, characterized in that the weaving step further includes a step of removing, through a post-processing process, the weft yarns that are deficient in the weaving warp yarns and the fixed warp yarns that are not adjacent to the weaving warp yarns.
top plate;
A lower plate positioned parallel to the upper plate;
The first saddle located on the upper plate and the lower plate;
A second sash that continuously connects the upper plate and the lower plate;
A first weaving warp yarn wrapping the first weft yarn; and
An integral three-dimensional fabric thermal protection system comprising a first woven warp yarn and a second woven warp yarn wrapping the second woven warp yarn.