A woven preform for a reinforces composite material, which may be woven flat and folded into a shape. The preform has a three-dimensional weave architecture with fill fibers woven to provide layer-to-layer interlocking of layers of warp fiber as well as interlocking of fibers within each layer. At l
A woven preform for a reinforces composite material, which may be woven flat and folded into a shape. The preform has a three-dimensional weave architecture with fill fibers woven to provide layer-to-layer interlocking of layers of warp fiber as well as interlocking of fibers within each layer. At least two legs extend from a base, the base and legs each having at least two layers of warp fibers. The legs can be connected at a symmetrical or asymmetrical, distributed-column intersection, with an even or odd number of columns of warp fibers being located between the legs. The outer ends of the base and/or legs preferably have tapers formed from terminating layers of warp fibers in a stepped pattern.
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What is claimed is: 1. A method of forming a woven preform, the method comprising the steps of: (a) providing a plurality of adjacent layers, each layer having a plurality of warp fibers, the warp fibers being generally parallel to each other and forming generally vertical columns; and (b) weaving
What is claimed is: 1. A method of forming a woven preform, the method comprising the steps of: (a) providing a plurality of adjacent layers, each layer having a plurality of warp fibers, the warp fibers being generally parallel to each other and forming generally vertical columns; and (b) weaving a plurality of fill fibers with the layers of warp fibers to form a base and two legs extending from the base, the base and each leg being formed from at least two layers of warp fibers, the base having a first edge and a second edge, each leg having a inner end and an outer end, wherein each fill fiber is woven such that the filler fiber has a beginning at the first edge of the base, then extends across a central section of the base, then exits the layers of the base and extends into the layers of the leg adjacent to the second edge of the base before extending back into and across the central section of the base, and then extends out into the layers of the other of the legs adjacent to the first edge of the base, then exits the layers of the legs and extends back into and across the layers of the central section of the base for extending to the second edge of the base, and wherein the fill fibers interlock the layers of the base, interlock the layers of each leg, and interlock the warp fibers within each layer. 2. The method according to claim 1, wherein the columns of warp fibers include central columns of warp fibers located between the fill fibers connecting one of the legs to the base and the fill fibers connecting the other of the legs to the base, the central columns comprising an odd number of columns and allowing for a substantially mirror-image weave pattern about a central plane of symmetry of the weave architecture. 3. The method according to claim 1, wherein the columns of warp fibers include central columns of warp fibers located between the fill fibers connecting one of the legs to the base and the fill fibers connecting the other of the legs to the base, the central columns comprising an even number of columns and allowing for a substantially asymmetrical weave pattern about a central plane of the weave architecture. 4. The method according to claim 2 or 3, wherein the columns of warp fibers include separator columns of warp fibers adjacent opposite lateral sides of the central columns, each separator column dividing portions of the fill fibers into two groups, one group extending between the base and the leg from between the central set of columns and the adjacent separator column, the other group extending from between the separator column and the columns laterally outward of the separator column. 5. The method according to claim 1, wherein the base has more layers than each of the legs or vice versa. 6. The method according claim 1, wherein the edges of the base and/or the legs are formed tapered. 7. The method according to claim 1, wherein the legs are perpendicular or non-perpendicular or angled to the base. 8. A three-dimensional preform weave architecture comprising: a plurality of adjacent layers, each layer having a plurality of warp fibers, the warp fibers being generally parallel to each other and forming generally vertical columns; and a plurality of fill fibers woven among the layers of warp fibers to form a base and two legs extending from the base, the base and each leg being formed from at least two layers of warp fibers, the base having a first edge and a second edge, each leg having a inner end and an outer end, wherein each fill fiber has a beginning at the first edge of the base, then extends across a central section of the base, then exits the layers of the base and extends into the layers of the leg adjacent to the second edge of the base before extending back into and across the central section of the base, and then extends out into the layers of the other of the legs adjacent to the first edge of the base, then exits the layers of the legs and extends back into and across the layers of the central section of the base for extending to the second edge of the base, and the fill fibers interlocking the layers of the base, interlocking the layers of each leg, and interlocking the warp fibers within each layer. 9. The weave architecture according to claim 8, wherein the columns of warp fibers include central columns of warp fibers located between the fill fibers connecting one of the legs to the base and the fill fibers connecting the other of the legs to the base, the central columns comprising an odd number of columns and allowing for a substantially mirror-image weave pattern about a central plane of symmetry of the weave architecture. 10. The weave architecture according to claim 8, wherein the columns of warp fibers include central columns of warp fibers located between the fill fibers connecting one of the legs to the base and the fill fibers connecting the other of the legs to the base, the central columns comprising an even number of columns and allowing for a substantially asymmetrical weave pattern about a central plane of the weave architecture. 11. The weave architecture according to claim 9 or 10, wherein the columns of warp fibers include separator columns of warp fibers adjacent opposite lateral sides of the central columns, each separator column dividing portions of the fill fibers into two groups, one group extending between the base and the leg from between the central set of columns and the adjacent separator column, the other group extending from between the separator column and the columns laterally outward of the separator column. 12. The weave architecture according to claim 8, wherein the base has more layers than each of the legs or vice versa. 13. The weave architecture according claim 8, wherein the edges of the base and/or the legs are tapered. 14. The weave architecture according to claim 8, wherein the legs are perpendicular or non-perpendicular or angled to the base. 15. A method of forming a woven preform, the method comprising the steps of: (a) providing at least a pair of adjacent base layers of warp fibers for forming a base, the warp fibers being generally parallel to each other and generally arranged in columns; (b) providing at least two layers of adjacent leg layers of warp fibers for forming a pair of legs, the warp fibers being generally parallel to each other and generally arranged in columns; (c) weaving at least one fill fiber among the base layers and leg layers for interlocking the warp fibers of each base layer to each other and interlocking the warp fibers of the leg layers to each other, the legs being connected to the base at intersections by portions of the fill fiber extending between each leg and the base, two groups of fill fiber portions connecting each leg to the base, wherein each fill fiber has a beginning at the first edge of the base, then extends across a central section of the base, then exits the layers of the base and extends into the layers of the leg adjacent to the second edge of the base before extending back into and across the central section of the base, and then extends out into the layers of the other of the legs adjacent to the first edge of the base, then exits the layers of the legs and extends back into and across the layers of the central section of the base for extending to the second edge of the base; (d) weaving an even or odd number of central columns of warp fibers in the base between the intersections of the legs and base; and (e) locating separator columns adjacent the central columns, one of the groups of fill fiber portions for each leg intersecting the base adjacent one side of the corresponding separator column, the other of the groups of fill fiber portions for each leg intersecting the base on the opposite side of the corresponding separator column. 16. The method according to claim 15, wherein the base has more layers of warp fibers than each of the legs or vice versa. 17. The method according to claim 15, wherein the legs are perpendicular or non-perpendicular or angled to the base. 18. A woven preform comprising: a base having a central portion and two lateral edges; at least two legs extending from one surface of the base, wherein the preform is woven with a three-dimensional weave pattern, the base and each leg being formed of at least two layers of warp fibers, the warp fibers being generally arranged in columns, at least one fill fiber being woven among the warp fibers for interlocking the warp fibers of the base to each other and interlocking the warp fibers of the legs to each other, the legs being connected to the base at intersections by portions of the fill fiber extending between each leg and the base, two groups of portions of fill fibers connecting each leg to the base; an even or odd number of central columns of warp fibers in the base, are located between the intersections of the legs and base; and separator columns are located adjacent the central columns, one of the groups of portions for each leg intersecting the base adjacent one side of the corresponding separator column, the other of the groups for each leg intersecting the base on the opposite side of the corresponding separator column, wherein each fill fiber has a beginning at the first edge of the base, then extends across a central section of the base, then exits the layers of the base and extends into the layers of the leg adjacent to the second edge of the base before extending back into and across the central section of the base, and then extends out into the layers of the other of the legs adjacent to the first edge of the base, then exits the layers of the legs and extends back into and across the layers of the central section of the base for extending to the second edge of the base. 19. The woven preform according to claim 18, wherein the base has more layers of warp fibers than each of the legs or vice versa. 20. The woven preform according to claim 18, wherein the legs are perpendicular or non-perpendicular or angled to the base. 21. The method according to claim 1 or 15, wherein the legs are equal or unequal in length. 22. The weave architecture according to claim 8, wherein the legs are equal or unequal in length. 23. The woven preform according to claim 18, wherein the at least two legs are equal or unequal in length.
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