(1) Introduction
(2) Origins

DESCRIPTION

CATIA-V4
3D-CAD
SOLID MODELS
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MANUFACTURE

CONTACT.
INFORMATION.
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The finished billet can be cut into smaller billets and/or slabs,
most efficiently by a CO2-laser.

All (5) constructs are manifestations of
a common "principle of construction",
as described in "Generic Description".
Due to this commonality,
all (5) constructs are described,
in the patent & in this website,
to suit 100% documentation.

The billets are composed as isotropic, 3D-woven constructs;
these constructs are tri-axially ("XYZ")-isotropic.
This isotropy is best seen in the
(5) "'expanded-stacks' representations",
shown in "Colored Illustrations".
Due to this isotropy,
these billets are fully "self-interlocked" at all nodes,
and thus they are fully "self-integral" overall.

(5) "open style" models
&
(5) "compact style" models,
representing each of the
(5) distinct 3D-woven constructs, are
shown in "Photographs Of Models".
Each of these  models
should be seen as
a trivial-sized but illustrative cut-out
excised from
a (much) larger arbitrarily large parent-billet.

Of the (5) distinct 3D-woven constructs:
(3) -the "IIIR"-,"IIIL"- ,"IIO"- types-
can be woven on one weaving-apparatus
&
(2) -the "OOO"-,"OOI"- types-
can be woven on another weaving-apparatus.
With interchangeability among
(2) alternate central modules (plus controls)
&
with a common manner of adjustability among
adjacent, surrounding modules
one weaving-apparatus could be made to weave all (5) constructs.
 
The weaving-apparatus is amenable to
(near) totally-automated operation,
with self-monitoring capabilities & feedback-driven operational-sequencing,
and is capable of continuous operation with
provisions for efficient old-billet removal/new-billet startup.
It is designed with:
1)   space-saving of-spool stock-loading
&
2)   time-saving dual stock-loading.
Explanation for 1):
      Stock emplaced along the length of the billet being woven
is deployed thru the weaving-apparatus as
a square array of elements,
and the number of such elements is "high", after all
given that the billet has ("N")-elements per side,
that array has ("N"-SQ'D.)-elements total.
(For mechanical reasons, "N" has to be a multiple of (4).)
That stock is best stored entirely of-spool, in
"long"-, square-, compact arrays of metal- or plastic tubing,
(1) element per tube, cut free from the spool.
The array in turn can be stored in a covered trench, below floor,
or suspended below ceiling.
Storage in such a "long" array is practical, because of its low usage-rate;
each time the billet is incremented,
the stock-length consumed is equal to only the increment-thickness.
The array can be loaded by (2) persons, (1) person @ each end,
using reusable nylon pull-shuttles and a vacuum-hose.
      Stock also enters the billet being woven
in directions perpendicular to it's length, from (2) sides,
per the following steps.
1) a)  From a "primary"
          single-layer array of ("N")-elements
          all even- OR odd-numbered elements
          are simultaneously pulled
          into the weaving-apparatus.
    b)  At a later time,
          all the remaining elements
          are simultaneously pulled
          into the weaving-apparatus.
2)       From a "secondary"
          single-layer array of ("N")-elements,
          spaced @ 90-degr. from the
          aforementioned primary array,
          all the elements
          are simultaneously pulled
          into the weaving-apparatus.
Each such set of operations contributes to increment the billet once.
Each time the billet is is incremented,
the stock-length consumed is equal to the
length/width of the billet plus req'd. excess.
In this case,
storage in a "long" array is impractical, because of its high usage-rate.
Additionally,
the number of elements involved is "low",
only (2"N") per increment.
Given the above, the side-entry stock may be best handled on-spool,
but with all spooling hardware & -systems
designed "from the ground up" for fully tailored functionality.
Explanation for 2):
      The text above describes the storage-tube array for of-spool storage.
Actually there are (2) such arrays, side by side,
one is loaded with with stock currently being used,
which one could call the "A"-stock,
during which time the other one can be loaded with
what could be called the "B"-stock.
When the "A"-stock is used up,
all its elements simultaneously,  (by design),
the weaving-apparatus can immediately continue with "B"-stock,
switching over automatically.
Stock-loading one array in the manner as described above can be
accomplished during the time it takes for the
stock in the other array to be fully used up,
work can be executed safely & at a comfortable pace.
New stock can be clamped to old stock,
element to element, simultaneously & massively;
the initial string-up of a weaving-apparatus coming on-line can thus
also be its last -until major maintenance anyway-
by using such "follow-on" method.
      The side-entry stock is also provided in duplicate;
the "A"-stock & the "B"-stock both extend
all the way to the weaving-apparatus;
one above the other -when close to the weaving-apparatus- ready for
entry at the (2) entry-sides of the billet being woven.
When the "A"-stock, for both entry-sides, is used up,
all its elements simultaneously, (by design),
the weaving-apparatus can immediately continue with "B"-stock,
switching over automatically.
Again, the new design for on-spool stock handling
referred to above should ensure that
the work to load "B"-stock while "A"-stock is being used up
can be executed safely & at a comfortable pace.

The "operative elements" of the weaving-apparatus are designed as
3D-CAD solid-models with aerospace-grade "CATIA"-software,
showing an illustrative set of sequential machine-configurations
detailing each of (2) successive increments to the billet,
seen frontally & from above,
all stored on an exhaustive duplicate set of discs,
and also documented on mylar & on paper.
The hardware items so documented are not patented
but the documentation is open for inspection in a proper
non-disclosure environment.
An industry wishing to develop the weaving-apparatus for
mass-production of billets may
patent the illustrated hardware &
100%-own these patents.
The industry may additionally 100%-own
the existing patent (#5,263,516) covering the
(5) isotropic, 3D-woven constructs.

The weaving-apparatus is composed of major function-modules and
has a high degree of visibility & accessibility thru out.
The modules are emplaced in- & about a sturdy framework,
thru the use of large locating-surfaces, -pins, -holes, -slots, etc.
They are removable, supplied with lifting-hooks,-eyes etc.
Some are supplied with "V"-notched wheels,
suited to small lengths of construction-angle tracks, per industrial practice.
Some modules are self-standing.
All modules are "shallow" & "transparent",
and free of complex- and/or minutely toleranced parts.
In fact, they have a few simple, distinct parts, repeated over & over again,
located at regular intervals.
Moving-part fits are often very loose indeed, by necessity.
Controls are (generally):
hydraulic (linear) & electric (rotary.)

For contact information, please see: "Information",
on the next page of this site.