Patent ID: 7837914

Claim:
A process of producing a composite component comprising a matrix material reinforced with a three-dimensional preform, the process comprising the steps of: producing a first set of tows in which each tow contains a plurality of substantially parallel filaments, has a predetermined polygonal cross-sectional shape, and is embedded within a temporary matrix formed of a material that is not the matrix material of the composite component or a precursor thereof; producing at least a second set of tows in which each tow contains a plurality of substantially parallel filaments; and then fabricating the three-dimensional preform to comprise the first and second sets of tows, in which the tows of the second set are transverse to the tows of the first set, adjacent tows of the second set are spaced apart to define interstitial regions therebetween having a polygonal cross-sectional shape, and the predetermined polygonal cross-sectional shapes of the tows of the first set are substantially congruent to the polygonal cross-sectional shapes of the interstitial regions so as to substantially fill the interstitial regions.