Office Action 1: Notice of Allowance (2024-11-06)

CLAIMS:
Claims

\[Claim 1\] A method for weaving a fibrous structure (400) intended to form the fibrous reinforcement of a turbomachine blade made of composite material comprising a fibrous reinforcement densified by a matrix, the fibrous structure being woven as a single piece on a loom by three- dimensional or multilayer weaving between a plurality of warp yarn layers (201) and a plurality of weft yarn layers (202), the fibrous structure comprising a blade root preform (410), characterised in that it comprises at least one first weaving step in which the warp yarns and the weft yarns are woven according to a first type of weave so as to form a first portion (411) of the blade root preform (410) of the fibrous structure, and a second weaving step in which the warp yarns and the weft yarns are woven according to a second type of weave so as to form a second portion (412) of the blade root preform (410) of the fibrous structure continuing on from the first portion (411) and located downstream of the first portion in the direction of advance of the fibrous structure at the outlet of the loom, the warp yarns and the weft yarns having a degree of interweaving in the first type of weave greater than the degree of interweaving of the warp yarns and the weft yarns present in the second type of weave, the degree of interweaving corresponding to the ratio of the number of layers of yarns crossed by the warp yarns or the weft yarns divided by the product of the weave ratio, the spacing between two weft columns and the spacing between two warp columns.

\[Claim 2\] The method according to claim 1, in which the warp yarns and the weft yarns present in the first type of weave have a degree of interweaving greater than or equal to 1.5 times the degree of interweaving of warp yarns and weft yarns present in the second type of weave.

\[Claim 3\] The method according to claim 1 or 2, in which the first and second weaves are of the same type.

\[Claim 4\] The method according to claim 1 or 2, in which the first and second weaves are of a different type.

\[Claim 5\] The method according to claims 3 or 4, in which the type of the first and second weaves is chosen from one of the following types:interlock, 3D orthogonal, multilayer plain or multilayer twill or multilayer satin.

\[Claim 6\] The method according to any one of claims 1 to 5, in which the first type of weave extends over at least 4 consecutive columns of weft yarns.

\[Claim 7\] A method for manufacturing a part made of composite material comprising the following steps:- producing a fibrous structure (400) in accordance with the method for weaving a fibrous structure according to any one of- producing a fibrous structure (400) in accordance with the method for weaving a fibrous structure according to any one of
\- removing the first portion of the fibrous structure,
\- shaping the fibrous structure in order to form a fibrous preform of the part to be manufactured,
\- densifying the fibrous preform.

\[Claim 8\] A fibrous structure (400) intended to form the fibrous reinforcement of a turbomachine blade made of composite material comprising a fibrous reinforcement densified by a matrix, the fibrous structure having a three-dimensional or multilayer weave between a plurality of warp yarn layers (201) and a plurality of weft yarn layers (202),the fibrous structure comprising a blade root preform (410), characterised in that the blade root preform (410) comprises at least one first portion (411) having a first type of weave and a second portion (412) continuing on from the first portion and having a second type of weave, the warp yarns and the weft yarns having a degree of interweaving in the first type of weave greater than the degree of interweaving of warp yarns and weft yarns present in the second type of weave, the degree of interweaving corresponding to the ratio of the number of layers of yarns crossed by the warp yarns or the weft yarns divided by the product of the weave ratio, the spacing between two weft columns and the spacing between two warp columns.

\[Claim 9\] The fibrous structure according to claim 8, in which the warp yarns and weft yarns present in the first type of weave have a degree of interweaving greater than or equal to 1.5 times the degree of interweaving of warp yarns and weft yarns present in the second type of weave.

\[Claim 10\] The fibrous structure according to claim 8 or 9, in which the first and second weaves are of the same type.

\[Claim 11\] The fibrous structure according to claim 8 or 9, in which the first and second weaves are of a different type

\[Claim 12\] The fibrous structure according to claims 10 or 11, in which the type of the first and second weaves is chosen from one of the following types: interlock, 3D orthogonal, multilayer plain or multilayer twill or multilayer satin.

\[Claim 13\] The fibrous structure according to any one of claims 8 to 12, in which the first type of weave extends over at least 4 consecutive columns of weft yarns.

OFFICE ACTION:
Notice of Pre-AIA  or AIA  Status
The present application, filed on or after March 16, 2013, is being examined under the first inventor to file provisions of the AIA .
Reasons for Allowance
The following is an examiner’s statement of reasons for allowance: independent claims 1, 8 and the respective depending claims are allowed.  Instant independent claim 1 requires a method for weaving a fibrous structure intended to form the fibrous reinforcement of a turbomachine blade made of composite material comprising a fibrous reinforcement densified by a matrix and claim 8 requires the corresponding fabric product requiring the same scope required in claim 1.  The instant method and woven fabric more specifically require weaving a multilayer woven fabric as a single piece on a three dimensional or multilayer loom having a first type of weave forming a first portion of a blade root preform and a second type of weave to form a second portion of the blade root preform located downstream of the first portion having a ‘degree of interweaving’ in the first type of weave greater than the ‘degree of interweaving’ in the second type of weave.  The ‘degree of interweaving’ is coined as a specially defined term in the instant specification as:
TE = Ncr/(RA x E-r x Ec)
where: - TE corresponds to the degree of interweaving between warp yarns and weft yarns in a three-dimensional fabric,
- Nc-r corresponds to the number of layers of the yarns crossed by the warp
yarns and/or the weft yarns,
- RA corresponds to the weave ratio, in other words the number of weft
columns over which the pattern of the weave type repeats,
- Er corresponds to the spacing between two weft columns which can also be
defined as the weft texture,
- Ec correspond to the spacing between warp columns which can also be
defined as the warp texture.
The claimed requirement of increasing the ‘degree of interweaving’ from a first portion to a second downstream portion creates a starting block or “back stop” which, due to its high degree of interweaving, prevents the slipping of the weft yarns then woven in the second portion. The spaces between the weft columns are thus controlled from the start of the weaving of the second portion, which makes it possible to immediately obtain a fibrous structure which respects the type of weave defined and consequently makes it possible to achieve much lower material loss than with the weaving technique of the prior art.
The closest prior art appears to be that of US 20050084377 (Dambrine et al.).  Dambrine et al. does teach a woven fabric and method for weaving woven fabric preforms used for producing turbomachine blade composite products having multiple sections and types of weaving patterns in subsequent sections.  Dambrine et al. does not disclose or teach as prima facie obvious the requirement in instant invention that the “degree of interweaving” of a first section is greater than the “degree of interweaving” of a subsequent second downstream section.  There is no disclosure in Dambrine et al., regarding the spacing between two weft columns and the spacing between two warp columns and no teaching/motivation regarding woven turboblade preform production/products to modify warp and weft column spacing to affect “degree of interweaving” as specially defined in instant specification to “back stop” slipping of weft yarns in subsequent lower degree of interweaving sections to enhance control of weft spacing in those sections resulting in much lower material loss than prior art woven turboblade preform processes/products.
Instant invention is in condition for allowance.
Any comments considered necessary by applicant must be submitted no later than the payment of the issue fee and, to avoid processing delays, should preferably accompany the issue fee.  Such submissions should be clearly labeled “Comments on Statement of Reasons for Allowance.”
Conclusion



CITED REFERENCE SUMMARIES: Ref US8505588B2: Claims:
A method of making a fiber structure by multilayer three-dimensional weaving, comprising increasing a thickness of the fiber structure in a direction perpendicular to warp and weft directions during a transition in the warp direction from a first portion of the fiber structure to a second portion of the fiber structure having a thickness that is greater than the thickness of the first portion, said thickness increasing including increasing a number of layers of warp yarns and decreasing a number of warp planes by constituting at least one warp plane in the second portion with warp yarns taken from at least two different warp planes in the first portion, said at least two different warp planes lying one behind the other in the weft direction, while conserving the same number of woven warp yarns along the warp direction.
during a transition in the warp direction from a first portion of the fiber structure to a second portion of the fiber structure having a thickness that is greater than the thickness of the first portion,
said thickness increasing including increasing a number of layers of warp yarns and decreasing a number of warp planes by constituting at least one warp plane in the second portion with warp yarns taken from at least two different warp planes in the first portion, said at least two different warp planes lying one behind the other in the weft direction, while conserving the same number of woven warp yarns along the warp direction.
A method of making a fiber structure by multilayer three-dimensional weaving, comprising decreasing a thickness of the fiber structure in a direction perpendicular to warp and weft directions during a transition in the warp direction from a second portion of the fiber structure to a first portion of the fiber structure having a thickness that is smaller than the thickness of the second portion, said thickness decreasing including decreasing a number of layers of warp yarns and increasing a number of warp planes by sharing the warp yarns of at least one warp plane of the second portion between at least two different warp planes of the first portion, said at least two different warp planes lying one behind the other in the weft direction, while conserving the same number of woven warp yarns along the warp direction.
said thickness decreasing including decreasing a number of layers of warp yarns and increasing a number of warp planes by sharing the warp yarns of at least one warp plane of the second portion between at least two different warp planes of the first portion, said at least two different warp planes lying one behind the other in the weft direction, while conserving the same number of woven warp yarns along the warp direction.
A method according to claim 1 or claim 2 , wherein for weaving in the second portion, weft yarns are used, at least some of which present a size and/or a structure that is/are greater than the size and/or structure of the weft yarns used for weaving in the first portion.
A method according to claim 3 , wherein a transition between said two portions of the fiber structure is made by progressively varying the overall size of the weft yarns in successive weft planes.
A method according to claim 1 or claim 2 , wherein a warp plane of the second portion contains all of the warp yarns of two adjacent warp planes of the first portion.
A method according to claim 1 or claim 2 , cent warp planes of the first portion.
A method of making a fiber structure by multilayer three-dimensional weaving, comprising increasing a thickness of the fiber structure in a direction perpendicular to warp and weft directions during a transition in the weft direction from a first portion of the fiber structure to a second portion of the fiber structure having a thickness that is greater than the thickness of the first portion, said thickness increasing including increasing a number of layers of weft yarns and decreasing a number of weft planes by constituting at least one weft plane in the second portion with weft yarns taken from at least two different weft planes in the first portion, said at least two different weft planes lying one behind the other in the warp direction, while conserving the same number of woven weft yarns along the weft direction.
said thickness increasing including increasing a number of layers of weft yarns and decreasing a number of weft planes by constituting at least one weft plane in the second portion with weft yarns taken from at least two different weft planes in the first portion, said at least two different weft planes lying one behind the other in the warp direction, while conserving the same number of woven weft yarns along the weft direction.
A method of making a fiber structure by multilayer three-dimensional weaving, comprising decreasing a thickness of the fiber structure in a direction perpendicular to the warp and weft directions during a transition in the weft direction from a second portion of the fiber structure to a first portion of the fiber structure having a thickness that is smaller than the thickness of the second portion, said thickness decreasing including decreasing a number of layers of weft yarns yarns and increasing a number of weft planes by sharing the weft yarns of at least one weft plane in the second portion between at least two different weft planes of the first portion, said at least two different weft planes lying one behind the other in the warp direction, while conserving the same number of woven weft yarns along the weft direction.
said thickness decreasing including decreasing a number of layers of weft yarns yarns and increasing a number of weft planes by sharing the weft yarns of at least one weft plane in the second portion between at least two different weft planes of the first portion, said at least two different weft planes lying one behind the other in the warp direction, while conserving the same number of woven weft yarns along the weft direction.
A method according to claim 7 or claim 8 , wherein for weaving in the second portion, warp yarns are used, at least some of which present a size and/or a structure that is/are greater than the size and/or structure of the warp yarns used for weaving in the first portion.
A method according to claim 9 , wherein a transition between said two portions of the fiber structure is made by progressively varying the overall size of the warp yarns in successive warp planes.
A method according to claim 7 or claim 8 , wherein a weft plane of the second portion contains all of the weft yarns of two adjacent weft planes of the first portion.
A method according to claim 7 or claim 8 , wherein two adjacent weft planes of the second portion comprise the weft yarns of three adjacent weft planes of the first portion.
Ref US20110277869A1: Claims:
A method of making a fiber structure by multilayer three-dimensional weaving, the fiber structure having a thickness in a direction perpendicular to the warp and weft directions that varies along the warp direction while conserving the same number of warp yarns that are woven at all points of the fiber structure along the warp direction, wherein during a transition in the warp direction from a first portion of the fiber texture to a second portion of the fiber texture having a thickness that is greater than the thickness of the first portion, the number of warp planes is decreased and the number of layers of warp yarns is increased without changing the number of warp yarns, by constituting at least one warp plane in the second portion with warp yarns taken from at least two different warp planes in the first portion.
wherein during a transition in the warp direction from a first portion of the fiber texture to a second portion of the fiber texture having a thickness that is greater than the thickness of the first portion, the number of warp planes is decreased and the number of layers of warp yarns is increased without changing the number of warp yarns, by constituting at least one warp plane in the second portion with warp yarns taken from at least two different warp planes in the first portion.
A method of making a fiber structure by multilayer three-dimensional weaving, the fiber structure having a thickness in a direction perpendicular to the warp and weft directions that varies along the warp direction while conserving the same number of warp yarns that are woven at all points of the fiber structure along the warp direction, wherein during a transition in the warp direction from a second portion of the fiber texture to a first portion of the fiber texture having a thickness that is smaller than the thickness of the second portion, the number of warp planes is increased and the number of layers of warp yarns is decreased without changing the number of warp yarns, by sharing the warp yarns of at least one warp plane of the second portion between different warp planes of the first portion.
wherein during a transition in the warp direction from a second portion of the fiber texture to a first portion of the fiber texture having a thickness that is smaller than the thickness of the second portion, the number of warp planes is increased and the number of layers of warp yarns is decreased without changing the number of warp yarns, by sharing the warp yarns of at least one warp plane of the second portion between different warp planes of the first portion.
A method according to claim 1 or claim 2 , wherein for weaving in the second portion, weft yarns are used, at least some of which present a size and/or a structure that is/are greater than the size and/or structure of the weft yarns used for weaving in the first portion.
A method according to claim 3 , wherein a transition between said two portions of the fiber structure is made by progressively varying the overall size of the weft yarns in successive weft planes.
A method according to claim 1 or claim 2 , wherein a warp plane of the second portion contains all of the warp yarns of two adjacent warp planes of the first portion.
A method according to claim 1 or claim 2 , wherein two adjacent warp planes of the second portion comprise the warp yarns of three adjacent warp planes of the first portion.
A method of making a fiber structure by multilayer three-dimensional weaving, the fiber structure having a thickness in a direction perpendicular to the warp and weft directions that varies along the weft direction while conserving the same number of weft yarns that are woven at all points of the fiber structure along the weft direction, wherein during a transition in the weft direction from a first portion of the fiber texture to a second portion of the fiber texture having a thickness that is greater than the thickness of the first portion, the number of weft planes is decreased and the number of layers of weft yarns is increased without changing the number of weft yarns, by constituting at least one weft plane in the second portion with weft yarns taken from at least two different weft planes in the first portion.
wherein during a transition in the weft direction from a first portion of the fiber texture to a second portion of the fiber texture having a thickness that is greater than the thickness of the first portion, the number of weft planes is decreased and the number of layers of weft yarns is increased without changing the number of weft yarns, by constituting at least one weft plane in the second portion with weft yarns taken from at least two different weft planes in the first portion.
A method of making a fiber structure by multilayer three-dimensional weaving, the fiber structure having a thickness in a direction perpendicular to the warp and weft directions that varies along the weft direction while conserving the same number of weft yarns that are woven at all points of the fiber structure along the weft direction, wherein during a transition in the weft direction from a second portion of the fiber texture to a first portion of the fiber texture having a thickness that is smaller than the thickness of the second portion, the number of weft planes is increased and the number of layers of weft yarns is decreased without changing the number of weft yarns, by sharing the weft yarns of at least one weft plane of the second portion between different weft planes of the first portion.
wherein during a transition in the weft direction from a second portion of the fiber texture to a first portion of the fiber texture having a thickness that is smaller than the thickness of the second portion, the number of weft planes is increased and the number of layers of weft yarns is decreased without changing the number of weft yarns, by sharing the weft yarns of at least one weft plane of the second portion between different weft planes of the first portion.
A method according to claim 7 or claim 8 , wherein for weaving in the second portion, warp yarns are used, at least some of which present a size and/or a structure that is/are greater than the size and/or structure of the warp yarns used for weaving in the first portion.
A method according to claim 9 , wherein a transition between said two portions of the fiber structure is made by progressively varying the overall size of the warp yarns in successive warp planes.
A method according to claim 7 or claim 8 , wherein a weft plane of the second portion contains all of the weft yarns of two adjacent weft planes of the first portion.
A method according to claim 7 or claim 8 , wherein two adjacent weft planes of the second portion comprise the weft yarns of three adjacent weft planes of the first portion.
Ref US20180148381A1: Claims:
A porous body made of a ceramic-matrix composite material for an acoustic attenuation panel, the porous body comprising: a plurality of interwoven ceramic fibers; a metal oxide matrix; and a plurality of channels interwoven with said ceramic fibers, said plurality of channels being interconnected together and defining at least one cavity, wherein at least one channel is wrapped around a ceramic fiber and/or twisted together with at least one ceramic fiber.
a plurality of interwoven ceramic fibers;
a metal oxide matrix; and
a plurality of channels interwoven with said ceramic fibers, said plurality of channels being interconnected together and defining at least one cavity,
wherein at least one channel is wrapped around a ceramic fiber and/or twisted together with at least one ceramic fiber.
The porous body according to claim 1 , wherein the channels are orientated in at least one of a weft direction and a warp direction of the ceramic fibers.
The porous body according to claim 1 , wherein at least one ceramic fiber has a titer between 50 grams/1000 meters and 2500 grams/1000 meters for densities between 2.2 and 4.
The porous body according to claim 1 , wherein at least one channel has an ovoid section having a minor axis between 0.05 mm and 5 mm and a major axis between 0.05 mm and 10 mm.
The porous body according to claim 1 , wherein a volume ratio of the plurality of channels of the porous body is between 2% and 95% of said body.
The porous body according to claim 5 , wherein the volume ratio of the plurality of channels of the porous body is between 50% and 90%.
The porous body according to claim 1 further comprising at least one aero-acoustic surface, wherein the at least one channel interconnects at least one cavity with said at least one aero-acoustic surface.
An acoustic attenuation panel, comprising: an inner layer; an outer layer having an acoustic permeability and in contact with an air flow to be acoustically attenuated; and an intermediate layer between the inner and outer layers, wherein at least one of the intermediate layer and the outer layer comprises a porous body according to claim 1 .
an outer layer having an acoustic permeability and in contact with an air flow to be acoustically attenuated; and
an intermediate layer between the inner and outer layers,
wherein at least one of the intermediate layer and the outer layer comprises a porous body according to claim 1 .
The acoustic attenuation panel according to claim 8 , wherein both the outer and intermediate layers comprise a porous body.
The acoustic attenuation panel according to claim 8 , wherein at least one portion of the ceramic fibers of the outer layer is interwoven with a portion of the ceramic fibers of the intermediate layer.
The acoustic attenuation panel according to claim 8 , wherein the inner layer comprises a porous body and at least one portion of the ceramic fibers of at least one of the inner layer and outer layer is interwoven with a portion of the ceramic fibers of the intermediate layer.
An aircraft propulsion unit comprising at least one acoustic attenuation panel according to claim 8 .
A method for manufacturing a porous body made of a metal-oxide ceramic-matrix composite material, the method comprising: weaving a preform of ceramic fibers and fugitive material fibers such that at least one of at least one ceramic fiber and at least one fugitive material fiber are twisted together, and at least one fugitive material fiber is wrapped around a ceramic fiber; drape-forming the preform on a tooling; and sintering the preform at a temperature to at least partially eliminate the fugitive material fibers and to form a plurality of channels interwoven with the ceramic fibers, wherein the plurality of channels are interconnected together to define at least one cavity.
weaving a preform of ceramic fibers and fugitive material fibers such that at least one of at least one ceramic fiber and at least one fugitive material fiber are twisted together, and at least one fugitive material fiber is wrapped around a ceramic fiber;
drape-forming the preform on a tooling; and
sintering the preform at a temperature to at least partially eliminate the fugitive material fibers and to form a plurality of channels interwoven with the ceramic fibers, wherein the plurality of channels are interconnected together to define at least one cavity.
The manufacturing method according to claim 13 , wherein the preform comprises at least one of: a plurality of warp fibers, wherein at least one of said fibers is a warp ceramic fiber and at least one of said fibers is a fugitive material fiber; and a plurality of weft fibers, wherein at least one of said fibers is a weft ceramic fiber and at least one of said fibers is a fugitive material fiber.
a plurality of warp fibers, wherein at least one of said fibers is a warp ceramic fiber and at least one of said fibers is a fugitive material fiber; and
a plurality of weft fibers, wherein at least one of said fibers is a weft ceramic fiber and at least one of said fibers is a fugitive material fiber.
The manufacturing method according to claim 13 further comprising, after the drape-forming step, the steps of: scattering ceramic powders between the ceramic fibers and the fugitive material fibers, or infiltrating ceramic powders or a preceramic matrix between the ceramic fibers and the fugitive material fibers with a liquid medium; and at least one of drying and polymerizing a set formed by the preform and the ceramic powders or the preceramic matrix.
scattering ceramic powders between the ceramic fibers and the fugitive material fibers, or infiltrating ceramic powders or a preceramic matrix between the ceramic fibers and the fugitive material fibers with a liquid medium; and
at least one of drying and polymerizing a set formed by the preform and the ceramic powders or the preceramic matrix.
The manufacturing method according to claim 13 , wherein the ceramic fibers are impregnated with a ceramic or a preceramic matrix before the step of drape-forming the preform.
The manufacturing method according to claim 13 , wherein the preform is made partially or entirely by depositing ceramic fibers and fugitive material fibers using an automated drape-forming method.
The manufacturing method according to cl
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