Turbo engine blade, particularly compressor blade and its fabrication method

p0001The invention relates to a composite turbine engine blade comprising a preform son or woven fiber (s) in three dimensions and a binder maintaining the relative arrangement between the son of the preform, said preform being formed chain and son of son frame, the direction of the warp son forming the longitudinal direction of the preform.

p0002More particularly, the present invention relates to a fan blade for a turbojet.

p0003Also, the present invention relates to method of manufacturing such blades.

p0004Usually, the fan blades made of composite material, particularly carbon fibers, are made from a stack of unidirectional prepreg plies that are placed in a mold by directing successive folds differently, prior to compaction and polymerization in an autoclave. This technique requires very delicate to perform the stacking operations manually folds, which is long and costly.

p0005It has also been proposed to prepare woven preforms of dry fibers that are then sewn together before impregnation by injecting resin into a closed mold. An alternative was to perform a single woven preform which is mounted with one or more inserts full before injection. These solutions (<patcit id="pcit0001" dnum="US5672417A"><text>US 5672417</text></patcit> and <patcit id="pcit0002" dnum="US5013216A"><text>US 5013216</text></patcit>) Have the disadvantage of requiring the assembly of several parts and create in these assembly areas, preferred sites of weakness, such delamination, which is very detrimental in terms of mechanical strength, especially for holding impacts.

p0006The present invention aims to provide a preform son or woven fiber (s) in three dimensions to form alone, possibly after cutting and injection, the final part forming the turbomachine blade, without using the using inserts or other insert.

p0007The present invention also aims to achieve a blade comprising a preform son or woven fiber (s) in three dimensions that this inhomogeneous mechanical characteristics to reflect solicitation differences, including mechanical, which can be subjected two different parts intended to form respectively the foot and the body of the blade.

p0008To this end, according to the present invention, said preform comprises at least a first portion made in a first weave, forming the airfoil of the blade, and a second portion formed in a second weave, which forms the root of the blade, the first portion and the second portion being separated by a transition zone in which the first weave is gradually changed to reach the second weave, whereby a reduction is obtained of at least the thickness of the vane between the second portion and the first part.

p0009In this way, it is understood that by the presence of a first weave, corresponding to a first portion of the preform, and in the presence of a second weave, corresponding to a second portion of the preform, are performed successively, by weaving continuously in a longitudinal direction, two portions with different weave patterns, therefore with different mechanical strength properties.

p0010Thus, it is understood that, because of the two weaves carried out successively in such a preform, said first part and said second part have a different dimension in at least one direction perpendicular to said longitudinal direction. This allows the production of a preform with different dimensions in said direction, including forming the thickness of the blade between the first part (body of the blade) and the second part (root of the blade).

p0011Advantageously, it is provided that said first portion and said second portion does not have the same number of warp son. This arrangement reinforces the fact that said first part and said second part have a different dimension in at least one direction perpendicular to said longitudinal direction.

p0012Preferably, said son or fibers belong to the group consisting of carbon fibers, glass fibers, silica fibers, silicon carbide fibers, alumina fibers, aramid fibers and aromatic polyamide fibers.

p0013According to a very advantageous embodiment, the shrinkage angle of the warp son is between 2 and 10, both in the first part (body of the blade) or in part (root of the blade) . Thus, due to this low value, it maintains a strong cohesion between the warp son and son woven frame them in a three-dimensional configuration, so that one gets a blade having a good resistance to impact , the impact energy being absorbed easily, which results in possible damage that are highly localized.

p0014According to another advantageous feature, said first part and said second part have a volume ratio chain / different frame. This solution changes the fiber content also has the additional advantage of allowing to modify the angle of shrinkage (angle formed by a warp yarn or a weft yarn with respect to a horizontal plane) between the first weave (first part) and the second weave (second part), which directly affects the mechanical properties of the two relevant parties, including the modulus of elasticity and resistance to impacts, and the relative thickness of the first and second parts.

p0015Preferably, said first portion has a volume chain report / frame between 80/20% and 50/50% and in that said second part has a volume ratio warp / weft between 30/70% and 50/50%, preferably of the order of 40/60%.

p0016Also, preferential and advantageous way, the title chain son varies between the edge and the remainder of the blade, the son of chain edge is thinner, which allows users to modify the mechanical properties of dawn between its surface and its central part, either for the foot (part) or the body of the blade (part one).

p0017Preferably, the title chain son of the edge of the blade is about 900 tex (son of 24,000 filaments) and that the title of the remainder of the blade chain is about son 1800 tex (son of 48000 filaments).

p0018According to a preferred exemplary embodiment, the first weave comprises a base pattern comprising at least thirty-six weft son staggered in alternating columns of at least four weft son in a vertical direction, separated in a longitudinal direction by one step, and at least five columns son bunk frame, separated by the same pitch, the weft son being distributed in at least eight columns extending in a vertical direction, the frame being thus disposed on son at least nine levels, and at least twenty-eight chain son arranged on at least eight vertical planes parallel to each other in the transverse direction, with alternating planes of a first type, having four son of superimposed parallel chain, plans for a second type containing three son of superimposed parallel chain, said plans for a first type having:<ul><li>a first warp yarn connecting a top end weft yarn of a column at least five weft son to the upper intermediate weft yarn of a column of at least five spaced weft son of the preceding column by at least two steps, and returning to an extreme weft yarn of a column of at least five weft son, spaced from the first column by at least four steps,</li><li>a second warp yarn connecting an upper intermediate weft yarn of a column of at least five weft son the median weft yarn of a column at least five spaced weft son of the preceding column by at least two not, and returning to an upper intermediate weft yarn of a column at least five weft son, spaced from the first column by at least four steps,</li><li>a third warp yarn connecting a middle weft yarn of a column at least five weft son to the lower intermediate weft yarn of a column at least five spaced weft son of the preceding column by at least two not, and returning to a middle weft yarn of a column at least five weft son, spaced from the first column by at least four steps,</li><li>a fourth warp yarn connecting a lower intermediate weft yarn of a column of at least five weft son the lowermost weft yarn of a column of at least five spaced weft son of the preceding column by at least not two, and returning to a lower intermediate weft yarn of a column of at least five weft son, spaced from the first column by at least four steps;</li></ul>said planes of a second type having:<ul><li>a first warp yarn connecting a top end weft yarn of a column of at least four weft son to the upper intermediate weft yarn of a column at least four spaced frame son of the preceding column by at least two steps, and returning to an extreme weft yarn of a column of at least four weft son, spaced from the first column by at least four steps,</li><li>a second warp yarn connecting an upper intermediate weft yarn of a column of at least four weft son to the lower intermediate weft yarn of a column of at least four spaced frame son of the preceding column by at least two steps, and returning to an intermediate weft yarn of a column of at least four weft son, spaced from the first column by at least four steps,</li><li>a third warp yarn connecting a lower intermediate weft yarn of a column of at least four weft son the lowermost weft yarn of a column of at least four spaced frame son of the preceding column by at least not two, and returning to a lower intermediate weft yarn of a column of at least four weft son, spaced from the first column by at least four steps.</li></ul>

p0019Also according to a preferred exemplary embodiment, the second weave has a basic pattern comprising at least forty-five weft son staggered in alternating columns of at least four weft son in a vertical direction, in a separate longitudinal direction by a step, and at least five columns son bunk frame, separated by the same pitch, the son frame being divided into at least ten columns extending in a vertical direction, the frame thus being son disposed on at least nine levels, and at least forty chain son arranged on at least ten vertical planes parallel to each other in the transverse direction, each plane containing four son of superimposed parallel chain with alternating planes of a first type and plans for a second type, said plans for a first type having:<ul><li>a first warp yarn connecting a top end weft yarn of a column at least five weft son the uppermost weft yarn of a column at least four spaced frame son of the preceding column by at least two and a half steps, and returning to an extreme weft yarn of a column of at least five weft son, spaced from the first column by at least five steps,</li><li>a second warp yarn connecting an upper intermediate weft yarn of a column at least five weft son to the upper intermediate weft yarn of a column at least four spaced frame son of the preceding column by at least not two and a half, and returning to an upper intermediate weft yarn of a column of at least five weft son, spaced from the first column by at least five steps</li><li>a third warp yarn connecting a middle weft yarn of a column at least five weft son to the lower intermediate weft yarn of a column at least four spaced frame son of the preceding column by at least two and not half, and returning to a middle weft yarn of a column at least five weft son, spaced from the first column by at least five steps,</li><li>a fourth warp yarn connecting a lower intermediate weft yarn of a column of at least five weft son the lowermost weft yarn of a column of at least four spaced frame son of the preceding column by at least not two and a half, and returning to a lower intermediate weft yarn of a column of at least five weft son, spaced from the first column by at least five steps;</li></ul>said planes of a second type having:<ul><li>a first warp yarn connecting a top end weft yarn of a column of at least four weft son to the upper intermediate weft yarn of a column of at least five spaced weft son of the preceding column by at least two and a half steps, and returning to an extreme weft yarn of a column of at least four weft son, spaced from the first column by at least five steps,</li><li>a second warp yarn connecting an upper intermediate weft yarn of a column of at least four weft son the median weft yarn of a column of at least five spaced weft son of the preceding column by at least two and not half, and returning to an upper intermediate weft yarn of a column of at least four weft son, spaced from the first column by at least five steps,</li><li>a third warp thread connecting a lower intermediate weft yarn of a column of at least four weft son to the lower intermediate weft yarn of a column of at least five spaced frame son of the preceding column by at least not two and a half, and returning to a lower intermediate weft yarn of a column of at least four weft son, spaced from the first column by at least five steps</li><li>a fourth warp yarn connecting a lower end weft wire of a column of at least four weft son over extreme lower frame of a column of at least five spaced weft son of the preceding column by at least two and a half steps, and returning to a lower extreme weft yarn of a column of at least four weft son, spaced from the first column by at least five steps,</li></ul>parallel groups of four chain son being shifted longitudinally of no plan in neighboring plan.

p0020According to another advantageous arrangement, the second part of the blade has a core zone with larger frame with a different son as the son of frame surrounding said core area.

p0021In this case, we preferentially provides that the title frame son of the core zone of the second portion of the blade is about 3600 tex (son of 96000 filaments) and that the title of son frame surrounding said core area is about 1800 tex (son of 48000 filaments).

p0022Preferably said binder is up to the group consisting of organic resins, especially epoxy resins, refractory and metals.

p0023Also, it is advantageously provided that the said blade of the invention is a fan blade for a turbojet.

p0024Finally, the present invention also relates to a method of manufacturing a fan blade for a turbojet, characterized in that it comprises the following steps:<ul><li>is woven warp son and weft son to form a preform son or woven fiber in three dimensions, formed of chain son and weft son, the direction of the warp son forming the longitudinal direction of the preform, said preform having at least a first portion made in a first weave (a) and a second portion formed in a second weave (B), said first portion and said second portion being separated by a transition zone in which the first weave is progressively modified to achieve the second weave, whereby obtaining a reduction of at least the thickness of the blade between the second part and the first part,</li><li>are cut said preform to the shape and dimensions of the constituent parts of the blade; </li><li>providing a mold wherein said preform is placed;</li><li>injecting into said mold a binder comprising a thermosetting resin to impregnate the entire preform;</li><li>said mold is heated; and</li><li>it emerges from the mold a molded part.</li></ul>

p0025Other advantages and characteristics of the invention appear on reading the following description given by way of example and with reference to the accompanying drawings in which:<ul><li>the <figref idrefs="f0001">figure 1</figref> schematically shows a Jacquard loom type that can perform three-dimensional weaving of a preform according to the invention,</li><li>the <figref idrefs="f0002">2</figref> schematically shows, in section along the longitudinal and vertical directions, the son of frame and chain contained in a first plane of the first armor</li><li>the <figref idrefs="f0003 f0004 f0005">Figures 3-9</figref> are views similar to that of <figref idrefs="f0002">2</figref> for the weft and warp son respectively, in a second plane, a third plane, a fourth plane, a fifth level, sixth level, seventh level and an eighth plane of the first armor, these planes being parallel to the fore of the <figref idrefs="f0002">2</figref>,</li><li>the <figref idrefs="f0006 f0007 f0008 f0009">Figures 10-19</figref> are views similar to that of <figref idrefs="f0002">2</figref> for the weft son and chain contained in a first plane, a second plane, a third plane, a fourth plane, a fifth level, sixth level, seventh level, an eighth plan, the Ninth Plan and a tenth plan the second armor, and</li><li>the <figref idrefs="f0010">Figure 20</figref> shows, in section according to the longitudinal and vertical directions, the transition zone from the second weave B to the left towards the first weave A to the right,</li><li>the <figref idrefs="f0011">Figure 21</figref> shows the transition area from the top of the preform, since the second weave B down toward the first weave A above,</li><li>the <figref idrefs="f0012">Figure 22</figref> schematically in section along the longitudinal and vertical directions, mounted on the loom of Jacquard type, a portion of a blade: left foot (Part B) and right blade (Part A)</li><li>the <figref idrefs="f0013">Figure 23</figref> shows an enlarged part of a view similar to that of the <figref idrefs="f0012">Figure 22</figref> for an alternative embodiment of the blade, </li><li>the <figref idrefs="f0014">Figures 24 and 25</figref> show schematically in section along the longitudinal and vertical directions, and the weft son chain contained in a first plane respectively a first and a second embodiments of the first weave, and</li><li>the <figref idrefs="f0015">Figure 26</figref> schematically, in section and in the longitudinal and vertical directions, the son of frame and chain contained in a first plane and in a second plane of a third variant of the first armor.</li></ul>

p0026In the following description, the longitudinal direction, the transverse direction and the vertical direction correspond to directions of arrows x, y and z in the figures.

p0027On the <figref idrefs="f0001">figure 1</figref>Is schematically illustrated a loom of Jacquard type on which are mounted warp son, which are oriented in the longitudinal direction (arrow x) and extending over several layers in the vertical direction (arrow z) and son of frame oriented in the transverse direction (arrow y).

p0028The <figref idrefs="f0002 f0003 f0004 f0005">2 to 9</figref> show the basic pattern of the first weave a preform according to the present invention. This first armor includes thirty-six son frame 1 to 36 (it is their section which is visible), staggered over nine superposed levels N1 to N9, and in eight columns C1 to C8 as:<ul><li>a first column C1 of five superposed weft son 1-5 situated at levels N1, N3 N5, N7 and N9;</li><li>a second column C2 of four weft son 6-9 situated at levels N2, N4, N6 and N8;</li><li>a third column C3 five frame bunk son from 10 to 14 situated respectively at levels N1, N3, N5, N7 and N9;</li><li>a fourth column C4 of four weft son 15-18 located at levels N2, N4, N6 and N8;</li><li>a fifth column C5 of five frame bunk son 19-23 located respectively at levels N1, N3, N5, N7 and N9;</li><li>a sixth column C6 of four weft son 24-27 located at levels N2, N4, N6 and N8;</li><li>a seventh column C7 five frame bunk son 28-32 located respectively at levels N1, N3, N5, N7 and N9; and</li><li>an eighth column C8 of four weft son from 33 to 36 situated respectively at levels N2, N4, N6 and N8.</li></ul>

p0029The odd columns C1, C3, C5, C7 formed of five superposed weft son are separated from each other by a constant interval in the longitudinal direction, corresponding to a predetermined pitch P. Even the pitch P between the pairs columns C2, C4, C6, C8 formed of four son bunk frame, which are inserted between the previous columns, these four weft son being staggered with five weft son of the two columns neighboring odd.

p0030This basic pattern of the first weave is repeated in the longitudinal direction (warp son) in the transverse direction (weft son), and in the vertical direction (thickness direction), forming tablecloths.

p0031field 1 of the son to 36 are linked together by twenty-eight chain son 51-78 which are arranged in eight parallel planes P1 to P8 respectively visible on the <figref idrefs="f0002 f0003 f0004 f0005">2 to 9</figref> and which are oriented in the longitudinal direction (arrow x) and vertical (arrow z).

p0032P1 to P8 planes follow one another in the transverse direction and are uniformly offset from each other a not always identical and which is between 1.5 and 3 mm, being preferably equal to 2.1mm.

p0033Each of these planes P1 to P8 contains three or four parallel warp son, bunk, the arrangement of each plan being:

p0034In the plane P1 (<figref idrefs="f0002">2</figref>), A first warp yarn 51 connects the extreme weft yarn 1 of column C1 to the intermediate weft yarn 20 of the column C5 (downhill), and it returns (in amount) on the uppermost weft corresponding to the wire 1 in the following base pattern. A second warp yarn 52 connects the intermediate weft yarn 2 of the column C1 to the median weft yarn 21 of the column C5 (downhill), and it returns (upwards) on the upper intermediate weft yarn, corresponding to wire 2, in the following base pattern. A third channel 53 of wire connects the middle weft yarn 3 of the column C1 to the lower intermediate weft yarn 22 of the column C5 (downhill), and it returns (upwards) on the middle weft yarn, corresponding to the yarn 3, in the following base pattern. A fourth warp yarn 54 connects the intermediate weft yarn bottom 4 of the column C1 to the thread lowermost frame 23 of the column C5 (downhill), and it returns (upwards) onto the lower intermediate weft yarn, corresponding over 4, in the following base pattern.

p0035In the plane P2 (<figref idrefs="f0003">3</figref>), A first warp yarn 55 connects the extreme weft yarn 15 of the yarn C4 column upper intermediate weft 34 C8 column (downhill), and it returns (in amount) on the uppermost weft , corresponding to the yarn 15 in the following base pattern. A second warp yarn 56 connects the intermediate weft yarn 16 of the yarn column C4 lower intermediate frame 35 to the C8 column (downhill), and it returns (upwards) on the upper intermediate weft yarn, corresponding over 16 in the following base pattern. A third warp yarn 57 connects the lower intermediate weft yarn 17 of the column C4 throughout lowermost frame 36 of the C8 column (downhill), and it returns (upwards) onto the lower intermediate weft yarn, corresponding over 17, the following base pattern.

p0036In the plane P3 (<figref idrefs="f0003">4</figref> ), A first channel 58 wire connects the extreme weft yarn 19 of the column C5 to the intermediate weft yarn 2 of the column C1 (downwards) in the following base pattern, and it returns (upwards) the uppermost wire frame, corresponding to the yarn 19 in the following base pattern. A second warp yarn 59 connects the middle weft yarn 20 of the column C5 to the middle weft yarn 3 of the column C1 (downwards) in the following base pattern, and it returns (upwards) onto the wire upper middle frame, corresponding to the yarn 20 in the following base pattern. A third warp yarn 60 connects the middle weft yarn 21 of the yarn C5 column lower middle frame 4 of the column C3 (downhill), in the following base pattern, and it returns (upwards) on the wire median frame, corresponding to the yarn 21 in the following base pattern. A fourth warp yarn 61 connects the lower intermediate weft yarn 22 of the column C1 over extreme lower frame 5 of the column C1 (downwards) in the following base pattern, and it returns (upwards) onto the wire lower middle frame, corresponding to the yarn 22 in the following base pattern.

p0037In the plane P4 (<figref idrefs="f0003">5</figref>), A first chain 62 of wire connects the extreme weft yarn 33 of the C8 column to the intermediate weft yarn 16 from the C4 column (downhill), in the following base pattern, and it returns (uphill) the uppermost wire frame, corresponding to the yarn 33 in the following base pattern. A second channel 63 of wire connects the upper intermediate weft yarn 34 from the C8 column at lower intermediate weft yarn 17 from the C4 column (downhill), in the following base pattern, and it returns (upwards) on the intermediate weft yarn, corresponding to the yarn 34 in the following base pattern. A third channel 64 of wire connects the lower intermediate weft yarn 35 from the C8 column at extreme weft bottom 18 of column C4 (downhill), in the following base pattern, and it returns (upwards) on the wire lower middle frame, corresponding to the yarn 35 in the following base pattern.

p0038In the plane P5 (<figref idrefs="f0004">6</figref>), A first warp yarn 65 connects the weft yarn upper end 10 of the column C3 to the intermediate weft yarn 29 of the column C7 (downhill), and it returns (in amount) on the uppermost weft , corresponding to the yarn 10 in the following base pattern. A second warp yarn 66 connects the intermediate weft yarn 11 of the yarn column C3 median frame 30 of the column C7 (downhill), and it returns (upwards) on the upper intermediate weft yarn, corresponding to over 11 in the following base pattern. A third warp yarn 67 connects the middle weft yarn 12 of the column C3 over lower intermediate frame 31 of the column C7 (downhill), and it returns (upwards) on the middle weft yarn, corresponding to the yarn 12 in the following base pattern. A fourth warp yarn 68 connects the lower intermediate weft yarn 13 of the column C3 the lowermost weft yarn 32 of the column C7 (downhill), and it returns (upwards) onto the lower intermediate weft yarn, corresponding over 13 in the following base pattern.

p0039P6 in the plane (<figref idrefs="f0004">7</figref>), A first warp yarn 69 connects the extreme weft yarn 6 of column C2 to the intermediate weft yarn 25 of the column C6 (downhill), and it returns (in amount) on the uppermost weft , corresponding to the yarn 6 in the following base pattern. A second warp yarn 70 connects the intermediate weft yarn 7 of the wire of column C2 lower middle frame 26 of the column C6 (downhill), and it returns (upwards) on the upper intermediate weft yarn, corresponding over 7 in the following base pattern. A third channel 71 of wire connects the lower intermediate weft yarn 8 of the wire of column C2 lowermost frame 27 of the column C6 (downhill), and it returns (upwards) onto the lower intermediate weft yarn, corresponding over 8 in the following base pattern.

p0040In the plane P7 (<figref idrefs="f0004">8</figref>), A first warp yarn 72 connects the extreme weft yarn 28 of the yarn column C7 of upper intermediate weft 11 of the column C3 (downhill), in the following base pattern, and it returns (uphill) the uppermost wire frame, corresponding to the yarn 28 in the following base pattern. A second warp yarn 73 connects the intermediate weft yarn 29 of the column C7 to the middle weft yarn 12 of the column C3 (downhill), in the following base pattern, and it returns (upwards) on the wire upper middle frame, corresponding to the yarn 29 in the following base pattern. A third channel 74 of wire connects the middle weft yarn 30 of the column C7 to the lower intermediate weft yarn 13 of the column C3 (downhill), in the following base pattern, and it returns (upwards) on the wire median frame, corresponding to the yarn 30, in the following base pattern. A fourth warp yarn 75 connects the lower intermediate weft yarn 31 of the column C7 to the lower end weft yarn 14 of the column C3 (downhill), in the following base pattern, and it returns (upwards) on the wire lower middle frame, corresponding to the yarn 31 in the following base pattern.

p0041Finally, in the plane P8 (<figref idrefs="f0005">9</figref>), A first warp yarn 76 connects the extreme weft yarn 24 of the column C6 the upper intermediate weft yarn 7 of the column C2 (downhill), in the following base pattern, and it returns (uphill) on the extreme weft yarn, corresponding to the yarn 24, in the following base pattern. A second warp yarn 77 connects the middle weft yarn 25 of the column C6 to the lower intermediate weft yarn 8 of column C2 (downwards) in the following base pattern, and it returns (upwards) onto the intermediate weft yarn, corresponding to the yarn 25 in the following base pattern. A third warp yarn 78 connects the lower intermediate weft yarn 26 of the column C6 the lowermost weft yarn 9 of column C2 (downhill), in the following base pattern, and it returns (upwards) on the wire lower middle frame, corresponding to the yarn 26 in the following base pattern.

p0042Note in passing from one plane to another plane, neighbor, we alternate the use of a configuration with three parallel warp son (plans of a first type (P1, P3, P5, P7)) and a configuration of four parallel warp son (plans of a second type (P2, P4, P6, P8)), these configurations being offset in the longitudinal direction (arrow x on <figref idrefs="f0002">2</figref>) Irregularly: 1.5P between P1 and P2; 0.5 P between P2 and P3; 1.5 P between P3 and P4, 1.5 P between P4 and P5; -0.5 P between P5 and P6, P -1.5 and between P6 and P7 - 0.5 P between P7 and P8.

p0043Thus, a first weave is obtained (A) having a base pattern comprising exactly thirty-six weft son (1 to 36) staggered in alternating columns (C2, C4, C6, C8) of exactly four son bunk frame in a vertical direction, separated in the longitudinal direction by a pitch (P), and columns (C1, C3, C5, C7) of exactly five superposed weft son, separated from each other in the longitudinal direction by the even (P). The weft son (1 to 36) are divided into exactly eight columns (C1 to C8) extending in a vertical direction, the weft son (1 to 36) thus being arranged on exactly nine levels (N1-N9). The basic pattern of the first armor also includes exactly twenty-eight son string (51 to 78) arranged on exactly eight parallel vertical planes (P1 to P8) between them in the transverse direction, with alternating planes of a first type (P1, P3, P5, P7), containing exactly four superposed parallel son of chain, and plans a second type (P2, P4, P6, P8) containing exactly three son of superimposed parallel chain.

p0044Said planes of one type (P1, P3, P5, P7) are:<ul><li>a first warp yarn (51, 58, 65, 72) connecting a top end weft yarn (1, 19, 10, 28) of a column (C1, C5, C3, C7) exactly five weft son over upper middle frame (20, 2, 29, 11) of a column (C5, C1, C7, C3) spaced exactly five weft son of the previous column by exactly two steps (P), and returning on an extreme weft yarn (1, 19, 10, 28)) of a column (C1, C5, C3, C7) exactly five weft son, spaced from the first column by exactly four pitch (P) ,</li><li>a second warp yarn (52, 59, 66, 73) connecting an upper intermediate weft yarn (2, 20, 11, 29) of a column (C1, C5, C3, C7) exactly five weft son the median weft (21, 3, 30, 12) of a column (C5, C1, C7, C3) spaced exactly five weft son of the previous column by exactly two steps (P), and returning to an upper intermediate weft yarn (2, 20, 11, 29) of a column (C1, C5, C3, C7) exactly five weft son, spaced from the first column by exactly four pitch (P),</li><li>a third warp yarn (53, 60, 67, 74) connecting a middle weft yarn (3, 21, 12, 30) of a column (C1, C5, C3, C7) exactly five weft son to wire lower middle frame (22, 4, 31, 13) of a column (C5, C1, C7, C3) spaced exactly five weft son of the previous column by exactly two steps (P), and returning to a middle weft yarn (3, 21, 12, 30) of a column (C1, C5, C3, C7) exactly five weft son, spaced from the first column by exactly four pitch (P),</li><li>a fourth warp yarn (54, 61, 68, 75) connecting a lower intermediate weft yarn (4, 22, 13, 31) of a column (C1, C5, C3, C7) exactly five weft son over lower end weft (23, 5, 32, 14) of a column (C5, C1, C7, C3) spaced exactly five weft son of the previous column by exactly two steps (P), and returning to a lower intermediate weft yarn (4, 22, 13, 31) of a column (C1, C5, C3, C7) exactly five weft son, spaced from the first column by exactly four pitch (P).</li></ul>

p0045Said planes of a second type (P2, P4, P6, P8) are:<ul><li>a first warp yarn (55, 62, 69, 76) connecting a top end weft yarn (15, 33, 6, 24) of a column (C4, C8, C2, C6) of exactly four weft son over upper middle frame (34, 16, 25, 7) of a column (C8, C4, C6, C2) of exactly four spaced frame son of the previous column by exactly two steps (P), and returning on an extreme weft yarn (15, 33, 6, 24) of a column (C4, C8, C2, C6) of exactly four weft son, spaced from the first column by exactly four pitch (P),</li><li>a second warp yarn (56, 63, 70, 77) connecting an intermediate weft yarn (16, 34, 7, 25) of a column (C4, C8, C2, C6) of exactly four weft son over lower intermediate frame (35, 17, 26, 8) of a column (C8, C4, C6, C2) of exactly four spaced frame son of the previous column by exactly two steps (P), and returning on an intermediate weft yarn (16, 34, 7, 25) of a column (C4, C8, C2, C6) of exactly four weft son, spaced from the first column by exactly four pitch (P),</li><li>a third warp yarn (57, 64, 71, 78) connecting a lower intermediate weft yarn (17, 35, 8, 24) of a column (C4, C8, C2, C6) of exactly four weft son over lower end weft (36, 18, 27, 9) of a column (C4, C8, C2, C6) of exactly four spaced frame son of the previous column by exactly two steps (P), and returning to a lower intermediate weft yarn (17, 35, 8, 24) of a column (C4, C8, C2, C6) of exactly four weft son, spaced from the first column by exactly four pitch (P).</li></ul>

p0046The <figref idrefs="f0006 f0007 f0008 f0009">Figures 10-19</figref> show the basic pattern of the second weave a preform according to the present invention. This second weave comprises forty five weft son 1 'to 45' (that is, their section is visible) arranged in staggered rows on nine superposed levels N1 'N9', and divided into ten columns C1 'to C10' by:<ul><li>a first column C1 'of five superposed weft son 1' to 5 'located at levels N1', N3 'N5', N7 'and N9';</li><li>a second column C2 'of four weft son 6' to 9 'located at levels N2', N4 ', N6' and N8 ';</li><li>a third column C3 'of five superposed weft son 10' to 14 'located respectively at levels N1', N3 ', N5', N7 'and N9';</li><li>a fourth column C4 'of four weft son 15' to 18 'located at levels respectively N2', N4 ', N6' and N8 ';</li><li>a fifth column C5 'of five superposed weft son 19' to 23 'situated respectively at levels N1', N3 ', N5' N7 ', and N9';</li><li>a sixth column C6 'of four weft son 24' to 27 'situated respectively at levels N2', N4 ', N6' and N8 ';</li><li>a seventh column C7 'of five superposed weft son 28' to 32 'located N1 levels respectively', N3 ', N5' N7 ', and N9';</li><li>an eighth column C8 'of four weft son 33' to 36 'situated respectively at levels N2', N4 ', N6' and N8 ';</li><li>a ninth column C9 'of five superposed weft son 37' 'N1 located levels respectively to 41, N3', N5 'N7', and N9 '; and</li><li>a tenth column C10 'of four weft son 42' to 45 'located respectively at levels N2', N4 ', N6' and N8 '.</li></ul>

p0047The odd columns C1 ', C3', C'5, C7 'and C9', formed of five son of bunk frame are separated from each other by a constant interval in the longitudinal direction, corresponding to the pitch P 'always identical in the same plane Pi Pi but different from a plane to another plane close along the planes P1 'to P10' (we can consider that not P 'is scalable in weaving).

p0048The same pitch P 'separates the even columns C2', C4 ', C6', C8 'and C10' formed of four son bunk frame, which are inserted between the previous columns, these four weft son being staggered with five weft son of the two adjacent odd columns.

p0049Note that not P 'is in fact equal to the pitch P of the first armor if the first and second armor reports showed volumetric frame / same chain.

p0050This basic pattern of the second weave is repeated in the longitudinal direction (warp son) in the transverse direction (weft son), and in the vertical direction (thickness direction), forming tablecloths.

p0051Son weft 1 'to 45' are interconnected by forty warp son 51 'to 90' which are arranged in ten parallel planes P1 'to P10', respectively, on the visible <figref idrefs="f0006 f0007 f0008 f0009">Figures 10-19</figref>.

p0052The planes P1 'to P10' follow one another in the transverse direction and are uniformly offset from each other a pitch between 1.5 and 3 mm, being preferably equal to 2.1mm.

p0053Each of these planes P1 'to P10' son has four parallel warp bunk, available to each plane being as follows:

p0054In the plane P1 '(<figref idrefs="f0006">Figure 10</figref>), A first warp yarn 51 'connects the extreme weft yarn 1' of the column C1 at wire uppermost frame 24 'of the column C6' (downhill), and it returns (upwards) on the wire uppermost frame, corresponding to the yarn 1 ', in the following base pattern. A second warp yarn 52 'connects the middle weft yarn 2' of the column C1 at intermediate weft yarn 25 'of the column C6' (downwards), and it returns (upwards) onto the wire intermediate upper frame, corresponding to the yarn 2 'in the following base pattern. A third warp yarn 53 'connects the middle weft yarn 3' of the column C1 at lower intermediate weft yarn 26 'of the column C6' (downhill), and it returns (upwards) on the weft yarn median, corresponding to over 3 'in the following base pattern. A fourth warp yarn 54 'connects the intermediate weft yarn bottom 4' of the column C1 at lower end weft yarn 27 'of the column C6' (downhill), and it returns (upwards) on the wire lower middle frame, corresponding to the yarn 4 'in the following base pattern.

p0055In the plane P2 '(<figref idrefs="f0007">11</figref>), A first warp yarn 55 'connects the extreme weft yarn 15' of the column C4 'to the intermediate weft yarn 38' C9 'column (downhill), and it returns (upwards) on the wire uppermost frame, corresponding to the yarn 15 ', in the following base pattern. A second warp yarn 56 'connects the intermediate weft yarn 16' of the column C4 'to the median weft thread 39' of the column C9 '(downhill), and it returns (upwards) on the weft yarn upper intermediate, corresponding to the yarn 16 'in the following base pattern. A third warp yarn 57 'connects the lower intermediate weft yarn 17' of the column C4 'to the lower intermediate weft yarn 40' of the column C9 '(downwards), and it returns (upwards) onto the wire lower middle frame, corresponding to the yarn 17 'in the following base pattern. A fourth warp yarn 58 'connects the end weft wire bottom 18' of the column C4 'to the extreme weft lower 41' C9 'column (downhill), and it returns (upwards) on the wire lowermost frame, corresponding to the yarn 18 'in the following base pattern.

p0056In the plane P3 '(<figref idrefs="f0007">Figure 12</figref>), A first warp yarn 59 'connects the extreme weft yarn 28' of the column C7 at extreme weft yarn 6 'of the column C2' (downhill), in the following base pattern, and back (upwards) on the uppermost weft yarn, corresponding to the yarn 28 ', in the following base pattern. A second warp yarn 60 'connects the intermediate weft yarn 29' of the column C7 'to the intermediate weft yarn 7' of the column C2 '(downhill), in the following base pattern, and it returns ( amount) on the upper intermediate weft yarn, corresponding to the yarn 29 'in the following base pattern. A third warp yarn 61 'connects the middle weft yarn 30' of the column C7 at lower intermediate weft thread 8 'of the column C2' (downhill), in the following base pattern, and it returns (in amount) on the middle weft yarn, corresponding to the yarn 30 ', in the following base pattern. A fourth warp yarn 62 'connects the intermediate weft yarn bottom 31' of the column C7 'to the lower end weft yarn 9' of the column C2 '(downhill), in the following base pattern, and it returns ( in amount) to the lower intermediate weft yarn, corresponding to the yarn 31 ', in the following base pattern.

p0057In the plane P4 '(<figref idrefs="f0007">13</figref>), A first warp yarn 63 'connects the extreme weft yarn 42' of the C10 column at intermediate weft yarn 20 'of the column C5' (downhill), in the following base pattern, and back (upwards) on the uppermost weft yarn, corresponding to the yarn 42 ', in the following base pattern. A second warp yarn 64 'connects the intermediate weft yarn 43' of the column C10 'to the median weft thread 21' of the column C5 '(downhill), in the following base pattern, and it returns (in amount) on the upper intermediate weft yarn, corresponding to the yarn 43 ', in the following base pattern. A third warp yarn 65 'connects the intermediate weft yarn bottom 44' of the column C10 at lower intermediate weft yarn 22 'of the column C5' (downhill), in the following base pattern, and it returns ( in amount) to the lower intermediate weft yarn, corresponding to the yarn 44 ', in the following base pattern. A fourth warp yarn 66 'connects the lower end weft yarn 45' of the column C10 'to the lowermost weft thread 23' of the column C5 '(downhill), in the following base pattern, and it returns ( in amount) to the lower intermediate weft yarn, corresponding to the yarn 45 ', in the following base pattern.

p0058In the plane P5 '(<figref idrefs="f0008">Figure 14</figref>), A first warp yarn 67 'connects the extreme weft yarn 10' of the column C3 'throughout uppermost frame 33' of the column C8 '(downhill), and it returns (upwards) on the wire uppermost frame, corresponding to the yarn 10 ', in the following base pattern. A second warp yarn 68 'connects the middle weft yarn 11' of the column C3 'to the upper intermediate weft yarn 34' of the column C8 '(downwards), and it returns (upwards) onto the wire upper intermediate weft, corresponding to the yarn 11 ', in the following base pattern. A third warp yarn 69 'connects the middle weft yarn 12' of the column C3 'to the intermediate weft bottom 35' of the column C8 '(downhill), and it returns (upwards) on the weft yarn median, corresponding to the yarn 12 'in the following base pattern. A fourth warp yarn 70 'connects the lower intermediate weft yarn 13' of the column C3 'to the lowermost weft thread 36' of the column C8 '(downhill), and it returns (upwards) on the wire lower middle frame, corresponding to the yarn 13 'in the following base pattern.

p0059In the plane P6 '(<figref idrefs="f0008">Figure 15</figref>), A first warp yarn 71 'connects the extreme weft yarn 24' of the column C6 at intermediate weft yarn 2 'of the column C1' (downhill), in the following base pattern, and back (upwards) on the uppermost weft yarn, corresponding to the yarn 24 ', in the following base pattern. A second warp yarn 72 'connects the intermediate weft yarn 25' of the column C6 at median weft yarn 3 'of the column C1' (downhill), and it returns (upwards) on the weft yarn upper intermediate, corresponding to the yarn 25 'in the following base pattern. A third warp yarn 73 'connects the lower intermediate weft yarn 26' of the column C6 at intermediate weft yarn bottom 4 'of the column C1' (downhill), in the following base pattern, and it returns ( in amount) to the lower intermediate weft yarn, corresponding to the yarn 26 ', in the following base pattern. A fourth warp yarn 74 'connects the end weft wire bottom 27' of the column C6 'over extreme lower frame 5' of the column C1 '(downhill), in the following base pattern, and it returns ( in amount) to the lower extreme weft yarn, corresponding to the yarn 27 ', in the following base pattern.

p0060In the plane P7 '(<figref idrefs="f0008">Figure 16</figref>), A first warp yarn 75 'connects the extreme weft yarn 37' of the column C9 at uppermost weft thread 15 'of the column C4' (downhill), in the following base pattern, and back (upwards) on the uppermost weft yarn, corresponding to the yarn 37 ', in the following base pattern. A second warp yarn 76 'connects the upper intermediate weft yarn 38' of the column C9 'to the middle weft yarn 16' of the column C4 '(downwards) in the following base pattern, and it returns ( amount) on the upper intermediate weft yarn, corresponding to the yarn 38 'in the following base pattern. A third warp yarn 77 'connects the middle weft yarn 39' of the column C9 at lower intermediate weft yarn 17 'of the column C4' (downhill), in the following base pattern, and it returns (in amount) on the middle weft yarn, corresponding to the yarn 39 ', in the following base pattern. A fourth warp yarn 78 'connects the lower intermediate weft yarn 40' of the column C9 at lowermost weft yarn 18 'of the column C4' (downhill), in the following base pattern, and it returns ( in amount) to the lower intermediate weft yarn, corresponding to the yarn 40 ', in the following base pattern.

p0061In the P8 Plan '(<figref idrefs="f0009">Figure 17</figref>), A first warp yarn 79 'connects the extreme weft yarn 6' of the column C2 at intermediate weft yarn 29 'of the column C7' (downhill), and it returns (upwards) on the wire uppermost frame, corresponding to the wire 6 'in the following base pattern. A second warp yarn 80 'connects the intermediate weft yarn 7' of the column C2 at wire median frame 30 'of the column C7' (downhill), and it returns (upwards) on the weft yarn upper intermediate, corresponding to over 7 'in the following base pattern. A third warp yarn 81 'connects the lower intermediate weft thread 8' of the column C2 'over lower intermediate frame 31' of the column C7 '(downhill), and it returns (upwards) on the wire lower middle frame, corresponding to the yarn 8 'in the following base pattern. A fourth warp yarn 82 'connects the lowermost weft yarn 9' of the column C2 at lowermost weft thread 32 'of the column C7' (downhill), and it returns (upwards) on the wire lowermost frame, corresponding to the yarn 9 ', in the following base pattern.

p0062P9 in the plane '(<figref idrefs="f0009">Figure 18</figref>), A first warp yarn 83 'connects the extreme weft yarn 19' of the column C5 'at the extreme weft yarn 42' of the column C10 '(downhill), and it returns (upwards) on the wire uppermost frame, corresponding to the yarn 19 ', in the following base pattern. A second warp yarn 84 'connects the middle weft yarn 20' of the column C5 'at the intermediate weft yarn 43' of the column C10 '(downwards), and it returns (upwards) onto the wire upper intermediate weft, corresponding to the yarn 20 ', in the following base pattern. A third warp yarn 85 'connects the middle weft yarn 21' of the column C5 'to the intermediate weft bottom 44' of the column C10 '(downhill), and it returns (upwards) on the weft yarn median, corresponding to the yarn 21 'in the following base pattern. A fourth warp yarn 86 'connects the lower intermediate weft yarn 22' of the column C5 'at the bottom end weft yarn 45' of the column C10 '(downwards), and it returns (upwards) onto the wire lower middle frame, corresponding to the yarn 22 'in the following base pattern.

p0063Finally, in the P10 level '(<figref idrefs="f0009">Figure 19</figref>), A first warp yarn 87 'connects the extreme weft yarn 33' of the C8 column at intermediate weft yarn 11 'of the column C3' (downhill), in the following base pattern, and back (upwards) on the uppermost weft yarn, corresponding to the yarn 33 ', in the following base pattern. A second warp yarn 88 'connects the upper intermediate weft yarn 34' of the C8 column at median weft thread 12 'of the column C3' (downhill), and it returns (upwards) on the weft yarn upper intermediate, corresponding to the yarn 34 'in the following base pattern. A third warp yarn 89 'connects the lower intermediate weft yarn 35' of the column C8 'to the lower intermediate weft yarn 13' of the column C3 '(downwards) in the following base pattern, and it returns ( in amount) to the lower intermediate weft yarn, corresponding to the yarn 35 ', in the following base pattern. A fourth warp yarn 90 'connects the bottom end weft yarn 36' of the C8 column at lowermost weft thread 14 'of the column C3' (downhill), in the following base pattern, and it returns ( in amount) to the lower extreme weft yarn, corresponding to the yarn 36 ', in the following base pattern.

p0064It is apparent from these <figref idrefs="f0006 f0007 f0008 f0009">Figures 10-19</figref>That the bond angle α '(or angle of shrinkage) son of chain is lower in the second weave the bond angle α of the first armor (<figref idrefs="f0002 f0003 f0004 f0005">2 to 9</figref>). In this regard, it should be noted that the figures are not, for reasons of clarity, to scale, the angles α and α 'visible on<figref idrefs="f0002 f0003 f0004 f0005 f0006 f0007 f0008 f0009">Figures 2 to 19</figref> do not correspond to actual values.

p0065Note that for the second weave, passing from one plane to another plane, neighbor, we find the same configuration son four parallel warp shifted smoothly in the transverse direction of 1.5 times the value of not P '. Of course, again, the basic pattern of the second weave defined on ten planes can be repeated indefinitely, in the longitudinal direction in the transverse direction and in the vertical direction (weft son 1 'to 45' forming sheets ).

p0066Thus, a second weave is obtained (B) having a base pattern comprising exactly forty five weft son (1 'to 45') staggered in alternating columns (C2 ', C4', C6 ', C8' C10 ') of exactly four weft son in a vertical direction, separated in the longitudinal direction by a pitch (P), and columns (C1', C3 ', C5' C7 'C9') of 'exactly five superposed weft son, separated from each other in the longitudinal direction by the same pitch (P'). Son the weft (1 'to 45') are divided into exactly ten columns (C1 'to C10') extending in a vertical direction, the weft son (1 'to 45') being so disposed on exactly nine levels (N1 'N9'). The basic pattern of the second weave also has exactly forty warp son (51 'to 90') arranged on exactly ten parallel vertical planes (P1 'to P10') between them in the transverse direction, each plane containing exactly four string of son superimposed parallel, alternating planes of a first type (P1 ', P3', P5 ', P7', P9 ') and plans a second type (P2', P4 ', P6', P8 ' P10 ').

p0067Said planes of one type (P1 ', P3', P5 ', P7', P9 ') have:<ul><li>a first warp yarn (51 ', 59', 67 ', 75', 83 ') connecting a top end weft yarn (1', 28 ', 10', 37 ', 19') of a column (C1 ', C7', C3 ', C9', C5 ') exactly five over weft son extreme upper frame (24', 6 ', 33', 15 ', 42') of a column (C6 ' , C2 ', C8', C4 ', C10') of spaced exactly four weft son of the previous column by exactly two and a half steps (P), and returning to a top end weft yarn (1 ', 28 ', 10', 37 ', 19') of a column (C1 ', C7', C3 ', C9', C5 ') exactly five weft son, spaced from the first column by exactly five pitch (P '),</li><li>a second warp yarn (52 ', 60', 68 ', 76', 84 ') connecting an upper intermediate weft yarn (2', 29 ', 11', 38 ', 20') of a column (C1 , C7 ', C3', C9 ', C5') exactly five over weft son of upper intermediate weft (25 ', 7', 34 ', 16', 43 ') of a column (C6' C2 ', C8', C4 ', C10') of exactly four spaced frame son of the previous column by exactly two and a half steps (P), and returning to an upper intermediate weft (2 ', 29' , 11 ', 38', 20 ') of a column (C1', C7 ', C3', C9 ', C5') exactly five weft son, spaced from the first column by exactly five pitch (P ' )</li><li>a third warp yarn (53 ', 61', 69 ', 77', 85 ') connecting a middle weft yarn (3', 30 ', 12', 39 ', 21') of a column (C1 ' , C7 ', C3', C9 ', C5') exactly five weft son of the lower intermediate weft yarn (26 ', 8', 35 ', 17', 44 ') of a column (C6' C2 ', C8', C4 ', C10') of spaced exactly four weft son of the previous column by exactly two and a half steps (P), and returning to a middle weft (3 ', 30' 12 ', 39', 21 ') of a column (C1', C7 ', C3', C9 ', C5') exactly five weft son, spaced from the first column by exactly five pitch (P ') ,</li><li>a fourth warp thread (54 ', 62', 70 ', 78', 86 ') connecting a lower intermediate weft yarn (4', 31 ', 13', 40 ', 22') of a column (C1 ', C7', C3 ', C9', C5 ') exactly five weft son over lower end weft (27', 9 ', 36', 18 ', 45') of a column (C6 ' , C2 ', C8', C4 ', C10') of spaced exactly four weft son of the previous column by exactly two and a half steps (P), and returning to a lower intermediate weft yarn (4 ', 31 ', 13', 40 ', 22') of a column (C1 ', C7', C3 ', C9', C5 ') of exactly five weft son, spaced from the first column by exactly five pitch (P ').</li></ul>

p0068Said planes of a second type (P2 ', P4', P6 ', P8' P10 ') have:<ul><li>a first warp yarn (55 ', 63', 71 ', 79', 87 ') connecting a top end weft yarn (15', 42 ', 24', 6 ', 33') of a column (C4 ', C10', C6 ', C2', C8 ') of exactly four over weft son of upper intermediate weft (38', 20 ', 2', 29 ', 11') of a column (C9 ' , C5 ', C1', C7, C3 ') exactly five spaced frame son of the previous column by exactly two and a half steps (P), and returning to a top end weft yarn (15', 42 ' , 24 ', 6', 33 ') of a column (C4', C10 ', C6', C2 ', C8') of exactly four weft son, spaced from the first column by exactly five pitch (P ' )</li><li>a second warp yarn (56 ', 64', 72 ', 80', 88 ') connecting an upper intermediate weft yarn (16', 43 ', 25', 7 ', 34') of a column (C4 ', C10', C6 ', C2', C8 ') of exactly four weft son the median weft thread (39', 21 ', 3', 30 ', 12') of a column (C9 ' C5 ', C1', C7, C3 ') exactly five spaced frame son of the previous column by exactly two and a half steps (P), and returning to an upper intermediate weft yarn (16', 43 ' 25 ', 7', 34 ') of a column (C4', C10 ', C6', C2 ', C8') of exactly four weft son, spaced from the first column by exactly five pitch (P '),</li><li>a third warp yarn (57 ', 65', 73 ', 81', 89 ') connecting a lower intermediate weft yarn (17', 44 ', 26', 8 ', 35') of a column (C4 ', C10', C6 ', C2', C8 ') of exactly four weft son of the lower intermediate weft yarn (40', 22 ', 4', 31 ', 13') of a column (C9 ' , C5 ', C1, C7, C3') exactly five spaced frame son of the previous column by exactly two and a half steps (P), and returning to a lower intermediate weft yarn (17 ', 44' 26 ', 8', 35 ') of a column (C4', C10 ', C6', C2 ', C8') of exactly four weft son, spaced from the first column by exactly five pitch (P ') ,</li><li>a fourth warp thread (58 ', 66', 74 ', 82', 90 ') connecting a lower end weft wire (18', 45 ', 27', 9 ', 36') of a column (C4 ', C10', C6 ', C2', C8 ') of exactly four weft son the extreme lower weft yarn 41' (41 ', 23', 5 ', 32', 14 ') of a column ( C9 'C5', C1 ', C7, C3') exactly five spaced frame son of the previous column by exactly two and a half steps (P), and returning to a far lower weft thread (18 ' 45 ', 27', 9 ', 36') of a column (C4 ', C10', C6 ', C2', C8 ') of exactly four weft son, spaced from the first column by not exactly five ( P ').</li></ul>

p0069Thus, we understand that the basic pattern of this second armor, parallel groups of four chain son (51 ', 52', 53 ', 54', 55 ', 56', 57 ', 58'; 59 ' , 60 ', 61', 62 '; 63', 64 ', 65', 66 '; 67', 68 ', 69', 70 '; 71', 72 ', 73', 74 '; 75, 76, 77 ', 78'; 79 ', 80', 81 ', 82'; 83 ', 84', 85 ', 86'; 87 ', 88', 89 ', 90') are offset longitudinally 1.5P 'a plan to the neighboring plane, that is to say between a plane of the first type (P1', P3 ', P5', P7 ', P9') and the plane of the second type (P2 ', P4' , P6 ', P8' P10 ') which is its neighbor.

p0070Between the first weave and the second weave, is created a transition region which will now be described in connection with the <figref idrefs="f0010 f0011 f0012">20 to 22</figref>.

p0071On the <figref idrefs="f0010">Figure 20</figref>This transition zone is shown in section in the longitudinal and vertical directions, since the second weave B to the left towards the first weave A to the right about a vertical transverse plane transition T indicated in phantom, the part high of the figure showing the situation for the planes P1 '(left) and P1 (right) and the lower part of the figure showing the situation for the planes P7' (left) and P2 (right).

p0072On the <figref idrefs="f0011">Figure 21</figref>This transition region is shown symbolically from the top of the preform, since the second weave B down toward the first weave A at the top, on either side of the vertical plane T transition indicated by a line. The black parts are visible chain son and the white parts are the visible frame son.

p0073On this <figref idrefs="f0011">Figure 21</figref>We see exactly in the bottom four basic patterns of the second weave (40 channel son forming four aligned series of columns C1 'to C10'), and in the top five basic patterns of the first armor (40 chain son forming five sets of aligned columns C1 to C8).

p0074The preform obtained form a multilayer bonded assembly, which may extend along the longitudinal direction of infinitely in its plane, by repeating the same set of basic patterns (in this case a first series for the first armor and a second series for the second armor).

p0075More specifically, the length of the warp and weft son son will determine the maximum possible length for the preform. It is understood that if these lengths permit, multiple preforms can be woven end to end in the longitudinal direction, by successively forming a first portion formed in the first weave, a transition zone, a second part made in the second weave, then a reverse transition zone and again a series formed by a first portion, a transition zone and a second portion, etc .....

p0076Of course, the weaving order of first and second portions can be reversed: weaving several preforms in succession in the longitudinal direction, by successively forming a second portion formed in the second weave, a transition zone, a first portion formed in the first weave, and a reverse transition zone and again a series formed by a second portion, a transition zone and a first part, etc .....

p0077At this stage, it should be noted that all the warp and son son every frame are referenced during the production of continuously weaving, so that a defect, or even rupture of one of them is spotted (e) repaired and (e) in situ and in real time. This makes it possible to know the nature and position of the defect to be recorded, which allows the traceability of defects generated during the weaving in relation to the part obtained from the preform.

p0078In practice, the weaving is fully automatic, by programming of the loom of the <figref idrefs="f0001">figure 1</figref>.

p0079Thus, when manufacturing a preform for a fan blade, therefore it is expected that the first weave A is the body of the blade and the second weave B is the root of the blade, the stilt ending in the transition zone.

p0080Note that the smallest thickness of the body of the blade relative to the root of the blade is obtained during the weaving of the transition zone, mainly by the signature change between the second part (second weave B corresponding to root of the blade) and the first part (first weave A corresponding to the body of the blade). Indeed, the weave of change allows a change in volume ratio chain / frame between the second part (second weave B corresponding to the root of the blade) and the first part (first weave A corresponding to the blade body ) which passes from 40/60% 70/30%.

p0081Also, the As is removed from the weaving a portion of the warp son, when the transition zone is completely carried out, at the first weave A corresponding to the body of the blade.

p0082This is illustrated in <figref idrefs="f0012">Figure 22</figref> which shows schematically in section along the longitudinal and vertical directions, mounted on the loom of Jacquard type, a portion of a blade: left foot (Part B) and right blade (part A). weft son are shown in section, only their section being illustrated, while the warp son are visible along their length from left to right.

p0083Thus, some of the warp son located in the upper part and the lower part are removed from the weaving of the preform intended to form the blade, at the first weave A corresponding to the blade body, being separated respectively up and down on the side play of the loom.

p0084Referring now to <figref idrefs="f0013">Figure 23</figref> with an alternative embodiment. Here, as in the case of the preform illustrated in<figref idrefs="f0002 f0003 f0004 f0005 f0006 f0007 f0008 f0009 f0010 f0011 f0012">Figures 2 to 22</figref>, The warp son (which run from left to right) are carbon fibers having a title of 48,000 filaments (about 1800 tex), and that one qualifies by following normal-sized son.

p0085More specifically, (not shown accuracy), to further improve the resistance to impact of the blade surface, son of chain is expected to use thinner over the entire contour of the preform, c ' is to say on its surface: they are fine chain with a son as 24,000 filaments (900 tex). It also provides a sub-layer of transition between the surface and the internal portion of the preform which contains both normal sized chain son and fine chain son.

p0086More particularly, the variant of the preform on the visible <figref idrefs="f0013">Figure 23</figref> comprises a second part B, to form the base of the blade, which breaks down into:<ul><li>a core region of the foot of the vane (area B1 on the <figref idrefs="f0013">Figure 23</figref>) Formed with big frame to a son with under 72,000 filaments (about 2700 tex) or even as a 96,000 filaments (about 3600 tex)</li><li>B2 area radially surrounding the core zone B1 of the root of the blade and is formed with normal sized frame with a son as 48,000 filaments (about 1800 tex) and</li><li>a B3 zone that extends longitudinally heart B1 foot area from dawn toward the first weave A corresponding to the body of the blade, and the thickness (z direction) and width (y-direction) taper: B3 this transition zone is formed with both normal sized frame with a son as 48,000 filaments (about 1800 tex) and with big frame with a title son to 96000 filaments (approximately 3600 tex).</li></ul>

p0087This variant according to <figref idrefs="f0013">Figure 23</figref> stiffens even more the root of the blade from the second B armor, particularly in the core area B1.

p0088Referring now to <figref idrefs="f0014">Figure 24</figref> which is a diagrammatic section along the longitudinal and vertical directions, the son of frame content in a first plane of a first embodiment of the first armor. This armor includes first fifty son frame 1 to 50 (it is their section which is visible), staggered ten superposed levels N1₁ to N10₁And divided into ten columns C1₁ C10₁, By:<ul><li>a first column C1₁ five frame bunk son 1-5 situated respectively at levels N1₁, N3₁, N5₁, N7₁ and N9₁ ;</li><li>a second column C2₁ five frame bunk son 6-10 located respectively at levels N2₁, N4₁, N6₁, N8₁And N10₁ ;</li><li>a third column C3₁ five frame bunk son from 11 to 15 situated respectively at levels N1₁, N3₁, N5₁, N7₁ and N9₁ ;</li><li>a fourth column C4₁ five frame bunk son from 16 to 20 situated respectively at levels N2₁, N4₁, N6₁, N8₁And N10₁ ;</li><li>a fifth column C5₁ five frame bunk son 21-25 located respectively at levels N1₁, N3₁, N5₁, N7₁ and N9₁ ;</li><li>a sixth column C6₁ five frame bunk son from 26 to 30 situated respectively at levels N2₁, N4₁, N6₁, N8₁And N10₁ ;</li><li>a seventh column C7₁ five frame bunk son 31-35 located respectively at levels N1₁, N3₁, N5₁, N7₁ and N9₁ ;</li><li>an eighth column C8₁ five frame bunk son from 36 to 40 situated respectively at levels N2₁, N4₁, N6₁, N8₁And N10₁ ;</li><li>a ninth column C9₁ five frame bunk son 41-45 located respectively at levels N1₁, N3₁, N5₁, N7₁ and N9₁ ; and</li><li>a tenth C10 column₁ five frame bunk son 46-50 located respectively at levels N2₁, N4₁, N6₁, N8₁And N10₁.</li></ul>

p0089The son of weft 1 to 50 are interconnected by chain 35 son 10 which are disposed in parallel planes which follow one another in the transverse direction and are uniformly offset from each other of not always identical and which is between 1.5 and 3 mm, being preferably equal to 2.1mm.

p0090Each of these plans contains three or four parallel warp son, bunk, available to the foreground, illustrated <figref idrefs="f0014">Figure 24</figref>, Being as follows:

p0091A first warp yarn 51 connects the extreme weft yarn 1 of column C1₁ the intermediate weft yarn 27 of the column C6₁ (Downwards), and it returns (upwards) onto the top end weft yarn, corresponding to the wire 1 in the following base pattern. A second chain 52 wire connects the upper intermediate weft yarn 2 of the column C1₁ the median weft yarn 28 of the column C6₁ (Downwards), and it returns (upwards) onto the upper intermediate weft yarn, corresponding to the wire 2, in the following base pattern. A third warp yarn 53 connects the middle weft yarn 3 of the column C1₁ the lower intermediate weft yarn 29 of the column C6₁ (Downwards), and it returns (upwards) onto the middle weft yarn, corresponding to yarn 3 in the following base pattern. A fourth warp yarn 54 connects the lower intermediate weft yarn 4 of the column C1₁ over extreme lower frame 30 of the column C6₁ (Downwards), and it returns (upwards) onto the lower intermediate weft yarn, corresponding to yarn 4 in the following base pattern.

p0092The <figref idrefs="f0014">Figure 25</figref> diagrammatic section along the longitudinal and vertical directions, the son of frame content in a first plane of a second variant of the first armor.

p0093This armor includes first fifty son frame 1 to 50 (it is their section which is visible), staggered ten superposed levels N1₂ to N10₂And divided into ten columns C1₂ C10₂ in the same arrangement as in the case of the first variant of the <figref idrefs="f0014">Figure 24</figref>.

p0094The weft son 1 to 50 are interconnected by chain 40 son 10 which are disposed in parallel planes which follow one another in the transverse direction and are uniformly offset from each other of not always identical and which is between 1.5 and 3 mm, being preferably equal to 2.1mm.

p0095Each of these plans contains four parallel warp son, bunk, available to the foreground, illustrated <figref idrefs="f0014">Figure 25</figref>, Being as follows:

p0096A first warp yarn 51 connects the extreme weft yarn 1 of column C1₂ senior intermediate frame 22 and son 32 columns C5₂ and C7₂ (Downwards), and it returns (upwards) onto the top end weft yarn, corresponding to the wire 1 in the following base pattern. A second chain 52 wire connects the upper intermediate weft yarn 2 of the column C1₂ the median frame 23 and son 33 columns C5₂ and C7₂ (Downwards), and it returns (upwards) onto the upper intermediate weft yarn, corresponding to the wire 2, in the following base pattern. A third warp yarn 53 connects the middle weft yarn 3 of the column C1₂ the intermediate frame 24 and lower 34 son of C5 columns₂ and C7₂ (Downwards), and it returns (upwards) onto the middle weft yarn, corresponding to yarn 3 in the following base pattern. A fourth warp yarn 54 connects the lower intermediate weft yarn 4 of the column C1₂ extreme lower frame 25 and son 35 columns C5₂ and C7₂ (Downwards), and it returns (upwards) onto the lower intermediate weft yarn, corresponding to yarn 4 in the following base pattern.

p0097The <figref idrefs="f0015">Figure 26</figref> schematically shows, in section along the longitudinal and vertical directions, the son of frame content in a first plane and a second plane of a third variant of the first armor.

p0098This first four-armor came ten son frame 1 to 90 (it is their section which is visible), staggered ten superposed levels N1₃ to N10₃And distributed in eighteen columns C1₃ to C18₃ in the same arrangement as in the case of the first variant of the <figref idrefs="f0014">Figure 24</figref>.

p0099The weft son 1 to 90 are interconnected by chain 63 son 18 which are disposed in parallel planes which follow one another in the transverse direction and are uniformly offset from each other of not always identical and which is between 1.5 and 3 mm, being preferably equal to 2.1mm.

p0100Each of these plans contains three or four parallel warp son, bunk, the arrangement of the first and second planes visible on <figref idrefs="f0015">Figure 26</figref> being as follows:

p0101In the first plane (chain son in solid lines), a first warp yarn 151 connects the extreme weft yarn 1 of column C1₃ the intermediate weft yarn 27 of the column C6₃ (Downwards), it returns (upwards) onto the top end weft yarn 51 of the column C11₃It comes (down) on the top end weft yarn 72 of the column C15₃ , And it returns (upwards) onto the top end weft yarn corresponding to 1 in the following base pattern. A second channel 152 wire connects the upper intermediate weft yarn 2 of the column C1₃ the median weft yarn 28 of the column C6₃ (Downwards), it returns (upwards) onto the middle weft yarn 52 of the column C11₃It comes (down) on the middle weft yarn 73 of the column C15₃, And it returns (upwards) onto the upper intermediate weft yarn, corresponding to the wire 2, in the following base pattern. A third warp yarn 153 connects the middle weft yarn 3 of the column C1₃ the lower intermediate weft yarn 29 of the column C6₃ (Downwards), it returns (upwards) onto the middle weft yarn 53 of the column C11₃It comes (down) on the lower intermediate weft yarn 74 of the column C15₃ and it returns (upwards) on the middle weft yarn, corresponding to the yarn 3, in the following base pattern. A fourth warp yarn 154 connects the lower intermediate weft yarn 4 of the column C1₃ over extreme lower frame 30 of the column C6₃ (Downwards), it returns (upwards) onto the lower intermediate weft yarn 54 of the column C11₃, It returns (downhill) to the lower extreme weft yarn 75 of the column C15₃, And it returns (upwards) onto the lower intermediate weft yarn, corresponding to yarn 4 in the following base pattern.

p0102In the second plane (son in chain dotted lines <figref idrefs="f0015">Figure 26</figref>), A first warp yarn 155 connects the extreme weft yarn 1 of column C1₃ the intermediate weft yarn 22 of the column C5₃ (Downwards), it returns (upwards) onto the top end weft yarn 41 of the column C9₃It comes (down) on the intermediate weft yarn 67 of the column C14₃, And it returns (in amount) on the uppermost weft thread corresponding to thread 1, the following base pattern. A second channel 156 wire connects the upper intermediate weft yarn 2 of the column C1₃ the median weft yarn 23 of the column C5₃ (Downwards), it returns (upwards) onto the middle weft yarn 42 of the column C9₃It comes (down) on the middle weft yarn 68 of the column C14₃, And it returns (upwards) onto the upper intermediate weft yarn, corresponding to the wire 2, in the following base pattern. A third warp yarn 157 connects the middle weft yarn 3 of the column C1₃ the lower intermediate weft yarn 24 of the column C5₃ (Downwards), it returns (upwards) onto the middle weft yarn 43 of the column C9₃It comes (down) on the lower intermediate weft yarn 69 of the column C14₃, And it returns (upwards) on the middle weft yarn, corresponding to the yarn 3, in the following base pattern. A fourth warp yarn 158 connects the lower intermediate weft yarn 4 of the column C1₃ the lower end weft yarn 25 of the column C5 (downwards), it returns (upwards) onto the lower intermediate weft yarn 44 of the column C9₃, It returns (downhill) to the lower extreme weft yarn 70 of the column C14₃, And it returns (upwards) onto the lower intermediate weft yarn, corresponding to yarn 4 in the following base pattern.

p0103In general, one can choose the son, especially carbon son, having a count of between 6000 filaments (225 tex) and 96000 filaments (3600 tex).

p0104Also, the present invention is not limited to the weaves described above, the crimp angle of the warp son being maintained at a low value, preferably between 2 and 10 °, and not in the weft of 0.2 to 5 mm.

p0105Note also (by far not shown) it is possible to change the title of surface channel son, between the trailing edge and the leading edge, the son of channels then being finer side the leading edge in order to improve the cohesion, and therefore the mechanical strength at this location particularly subject to high stresses during operation.

p0106According to the invention, a fan blade is performed for turbo-reactor with at least one first portion and at least a second portion extending successively in the longitudinal direction with different sizes and / or different mechanical properties depending on the manufacturing process following.

p0107is first made by weaving a three-dimensional preform as previously described.

p0108Then cutting the preform, for example by laser cutting or water jet, the shape and dimensions of the first part and second part of the blade.

p0109Due to the flexibility of the woven preform, the latter will adapt to the shape of the mold and it is therefore possible to perform only cutting of the contour of the preform along a vertical path.

p0110The next step is to place the cut preform in a mold which can be sealed with a housing having the shape and dimensions of the molded end piece. It is understood that during this step, the preform may be placed in torsion, depending on the final shape of the vane, and thus the mold.

p0111Then one closes the mold, the binder is injected comprising a thermosetting resin throughout the housing to impregnate the entire cut-out preform. Finally, the mold is heated to cure the resin and harden the part. After opening the mold, the molded part can be final output and form a finished article ready to be installed and / or used.

p0112According to an exemplary composite blade made according to the invention by using this type of preform according to the <figref idrefs="f0002 f0003 f0004 f0005 f0006 f0007 f0008 f0009 f0010 f0011 f0012">Figures 2 to 22</figref>Include a preform made from high-strength carbon fibers, density equal to 1.79 g / cm³, With the following parameters:<ul><li>A first armor (pale body in its thickest part, center): 18 channel son levels spaced in the transverse direction of a pitch of 2.1 mm, after densification after the injection process through liquid " RTM "(Resin Transfer Moulding) this first weave a has a thickness of 20 mm, a value of pitch P equal to 10 mm (that is to say a texture in frame 1 thread / cm), an average value of 4 ° for bond angles (to shrinkage) of the warp son, a volume ratio of 60% fibers, a chain son percentage reported to the weft son of 69/31%, a total fabric weight 21500 g / m², A basis weight in frame 6600 g / m² (Divided into 37 frame son levels or 180 g / m² level for each frame);</li><li>second weave B (foot of the pale in its thickest part, center): 32 channel son levels spaced in the transverse direction of a pitch of 2.1 mm, after densification after the injection liquid process "RTM" (Resin Transfer Moulding) the second weave B has a thickness of 79 mm, a value of not P 'longitudinally equal to 2.8 mm (that is to say in a texture frame 3.57 son / cm), an average value of 3 ° for bond angles (to shrinkage) of the warp son, a volume rate of 49% fiber, a chain son percentage reported to the weft son 40/60 % total fabric weight of 69000g / m², A basis weight in frame 41700g / m² (Divided into 65 levels weft son or 640g / m² level for each frame).</li></ul>

p0113The carbon fibers which are used have the following intrinsic mechanical characteristics:<ul><li>E (Young's modulus) = 280 GPa;</li><li>σ (breaking stress) = 5.5 GPa.</li></ul>

p0114As the binder, there was used a high performance epoxy resin sold under the reference PR 520 by the company Cytec.

p0115With such a composite material, the following mechanical properties are obtained:<ul><li>A first armor (light body):<ul><li>E string (traction) = or> 90 GPa</li><li>E frame (tension) = or> 40 GPa</li><li>σ chain (tension) = or> 700 MPa</li><li>σ frame (tension) = or> 210 MPa</li><li>σ chain (compression) = or> 450 MPa</li><li>σ frame (compression) = or> 200 MPa</li></ul></li><li>second weave B (and stilt walking):<ul><li>E string (traction) = or> 30 GPa</li><li>E frame (tension) = or> 80 GPa</li><li>σ chain (tension) = or> 300 MPa</li><li>σ frame (tension) = or> 500 MPa</li><li>σ chain (compression) = or> 200 MPa</li><li>σ frame (compression) = or> 500 MPa</li></ul></li></ul>

p0116For comparison, we also noted that the compressive strength of the armor "2.5D" or "interlock" (see the teaching of <patcit id="pcit0003" dnum="FR2610951"><text>FR2610951</text></patcit>) Is 300MPa, against a value of 450 MPa obtained with the armor of the first preform of the invention.

p0117The blade of the present invention comprising a preform son or woven fiber (s) in three dimensions is therefore preferably used for the realization of a fan blade, including wide-chord, a composite material, for a motor flight, especially for a turbo-reactor.

p0118It should be noted that to achieve this preform, the carbon fiber may be replaced by other types of fibers such as glass fibers, aramid fibers, silica or ceramics.

p0119In addition, the preform can not only be processed by injection proceeded by liquid "RTM" (Resin Transfer Moulding) for obtaining a structural composite material, but also by any other injection technique or by any other suitable technique such as vacuum infusion.