3-D resin transfer medium and method of use

Abstract

A resin distribution system and method for use in resin transfer molding including a 3-D orthogonal fiber structure having capillary channels therein for permitting a fluid to flow through the structure, wherein the 3-D orthogonal fiber structure further includes X-, Y-, and Z-direction fiber systems, each of having substantially no crimp within a body of the structure, thereby providing a system for distributing the fluid uniformly through the structure.

What is claimed is:  
     
         1 . A resin transfer medium comprising: 
 a three-dimensional engineered fiber structure having an X-direction fiber system, a Y-direction fiber system, and a Z-direction fiber system wherein the X-, Y-, and Z-direction fiber systems are selectively, alternatingly distributed with respect to each other forming three substantially orthogonal fiber systems within the structure, and wherein the X-, Y-, and Z-direction fiber systems form a series of spaced-apart, substantially parallel channels for distributing a fluid through the channels in each of the X-, Y-, and Z-directions, thereby providing a structure for uniform distribution of the fluid through the medium.    
     
     
         2 . The resin transfer medium according to  claim 1 , wherein the X-, Y-, and Z-direction fiber systems are continuous within the structure.  
     
     
         3 . The resin transfer medium according to  claim 1 , wherein the fluid is a resin.  
     
     
         4 . The resin transfer medium according to  claim 1 , wherein the fluid is introduced to the structure by vacuum.  
     
     
         5 . The resin transfer medium according to  claim 1 , wherein the fluid is introduced to the structure using vacuum assisted resin transfer molding processes.  
     
     
         6 . The resin transfer medium according to  claim 1 , wherein the permeability of the structure is at least two times higher than conventional fabrics used for resin transfer molding.  
     
     
         7 . A resin distribution system for use in resin transfer molding comprising a 3-D orthogonal fiber architecture having capillary channels therein for permitting a fluid to flow through the architecture, wherein the 3-D orthogonal fiber architecture further comprises X-, Y-, and Z-direction fiber systems, each of these fiber systems having substantially no crimp therein within a body of the architecture, thereby providing a system for distributing the fluid uniformly through the architecture.  
     
     
         8 . The system according to  claim 7 , wherein the X- and Y-direction fiber systems do not interlace with each other, thereby providing an internal in-plane openness of the architecture in the X- and Y-directions and no crimping of these fiber systems throughout the internal plane of the 3-D fiber architecture.  
     
     
         9 . The system according to  claim 7 , wherein the architecture is does not require any external resin distribution system for introducing the resin into a preform that is to be formed into a composite structure.  
     
     
         10 . A method for resin distribution comprising the steps of: 
 providing a resin transfer medium having three-dimensional engineered fiber structure having an X-direction fiber system, a Y-direction fiber system, and a Z-direction fiber system wherein the X-, Y-, and Z-direction fiber systems are selectively, alternatingly distributed with respect to each other forming three substantially orthogonal fiber systems within the structure, and wherein the X-, Y-, and Z-direction fiber systems form a series of spaced-apart, substantially parallel channels for distributing a fluid through the channels in each of the X-, Y-, and Z-directions;    introducing a fluid into the medium, wherein the fluid is transferred throughout the structure;    thereby providing uniform distribution of the fluid through the medium.    
     
     
         11 . The method according to  claim 10 , further including the step of: 
 providing a vacuum for assisting the fluid flow through the medium.